Flue Gas System Esps: 1 October 2019 PMI Revision 00 1

Flue Gas System
ESPs
1 October 2019 PMI Revision 00 1

Presentation Plan
• Electrostatic Precipitator-Basics
• Working Principle
• Design and Performance requirements
• Process variables
• Components and functions
• Performance Improvements
• Disposal of Fly ash
• Flue gas conditioning
• Disposal of fly ash system

ELECTROSTATIC PRECIPATATOR
It is a device which captures the dust particles from
the flue gas thereby reducing the chimney
emission.
Precipitators function by electrostatically charging the

dust particles in the gas stream. The charged particles
are then attracted to and deposited on plates or other
collection devices. When enough dust has
accumulated, the collectors are shaken to dislodge the
dust, causing it to fall with the force of gravity to
hoppers below. The dust is then removed by a
conveyor system for disposal or recycling
LOCATION OF ESP
ECO
APH ESP CHIMNEY

TYPICAL SPECIFICATIONS FOR A 200MW
UNITS
NUMBER OF PASS PER BOILER 4
NUMBER OF FIELD IN EACH PASS 6
EFFICIENCY 99.9%
PRESSURE DROP 20
mmWC
GAS FLOW RATE 312.7
Cu.m/sec
INLET TEMPERATURE 136
DEGREE
VELOCITY OF GAS AT ELECTRODE 0.839 m/sec
TOTAL TREATMENT TIME 32.18 SEC
THEORY OF PRECIPITATION
Electrostatic precipitation removes particles
from the exhaust gas stream of Boiler
combustion process. Six activities typically
take place:
Ionization - Charging of particles
Migration - Transporting the charged particles to the collecting
surfaces
Collection - Precipitation of the charged particles onto the
collecting surfaces
Charge Dissipation - Neutralizing the charged particles on the
collecting surfaces
Particle Dislodging - Removing the particles from the
collecting surface to the hopper
Particle Removal - Conveying the particles from the hopper to
a disposal
1 October 2019 point PMI Revision 00 6
ESP
Collector plate Emitter coil
Flue gas
Gas distribution plate

ESP PROCESS
1.Electron emission
STEPS Dust layer
1
2.Dust particle charging Collecting

2
electrode,
grounded
3
3.Migration
5.Rapping
4 5
4.dust collection
Discharge electrode with

Negative high tension (20-60kV) Rapping mechanism
Components of ESP
• Discharge Electrodes • Emitting Electrodes

• Power Components • Collecting Electrodes
• Precipitator Controls • High Voltage Equipment
• Rapping Systems • Rapping Mechanism
• Hoppers
• Purge Air Systems
• Heaters
• Flue Gas Conditioning
• ALI
• Gas Distribution Screen
• Segregating Gates

EMITTING SYSTEM

EMMITING ELECTRODE STRUCTURE

FIXING ARRANGEMENT OF EMITTING
ELECTRODE

EMITTING RAPPING MECHANISM

Rapping Motor &
Mechanism

EMITTING ELECTRODE
TYPE SPIRAL WITH HOOKS

SIZE DIA 2.7 mm
TOTAL NO OF ELECTRODE 29808
PLATE / WIRE SPACING 150mm

COLLECTING PLATE ASSEMBLY
ARRANGEMENT

COLLECTING ELECTRODE
NO. OF ELECTRODE PER FIELD 24

NO. OF PLATES EACH ROW 6
TOTAL COLLECTING PLATE 3456
SP. COLLECTING AREA 214.48 Sq.M/Cu.M/sec

Rapping
Mechanism

Collecting
electrodes
Emitting
electrodes

Rapping
Mechanism

Rectifier
Transformer
Rapping
Motors

ESP HOPPER

Working Principle
Emitting electrode
collecting electrode
Weakest field
Weakest field
Strongest field

Voltage in
KV SPARK
Time in msec

Components and their
function
• Discharge Electrodes: Discharge electrodes emit charging current and
provide voltage that generates an electrical field between the discharge
electrodes and the collecting plates. The electrical field forces dust
particles in the gas stream to migrate toward the collecting plates. The
particles then precipitate onto the collecting plates. They are typically
supported from the upper discharge frame and are held in alignment
between the upper and lower discharge frames. The upper discharge
frame is in turn supported from the roof of the precipitator casing. High-
voltage insulators are incorporated into the support system.
• Collecting Plates :Collecting plates are designed to receive and retain
the precipitated particles until they are intentionally removed into the
hopper. Collecting plates are also part of the electrical power circuit of
the precipitator. These collecting plate functions are incorporated into
the precipitator design. Plate baffles shield the precipitated particles
from the gas flow while smooth surfaces provide for high operating
voltage. Collecting plates are suspended from the precipitator casing
and form the gas passages within the precipitator

function
• Power Supplies and Controls :The power supply system is designed
to provide voltage to the electrical field (or bus section) at the highest
possible level. The voltage must be controlled to avoid causing
sustained arcing or sparking between the electrodes and the collecting
plates. Electrically, a precipitator is divided into a grid, with electrical
fields in series (in the direction of the gas flow) and one or more bus
sections in parallel (cross-wise to the gas flow). When electrical fields
are in series, the power supply for each field can be adjusted to optimize
operation of that field. Likewise, having more than one electrical bus
section in parallel allows adjustments to compensate for their
differences, so that power input can be optimized. The power supply
system has four basic components:
– Automatic voltage control

– Step-up transformer
– High-voltage rectifier
– Sensing device
function
• Gas distribution System: For creating similar gas and dust conditions
Uniformity is desired in the following parameters:
– Gas velocity
– Gas temperature
– Dust loading
Gas distribution devices, which ensure this, consist of turning vanes in the
inlet ductwork, and perforated gas distribution plates in the inlet and/or
outlet fields of the precipitator.
• Rapping Systems : Rappers are time-controlled systems provided for
removing dust from the collecting plates and the discharge electrodes.
Rapping systems are actuated by electrical, or by mechanical means.
Rapping methods include
– Discharge Electrode Rapping : Discharge electrodes should be
kept as free as possible of accumulated particulate
– Collecting Plate Rapping: Remove the bulk of the precipitated dust

function
• Hoppers: Precipitator hoppers are designed to completely
discharge dust load on demand. Typically, precipitator hoppers
are rectangular in cross-section with sides of at least 60-degree
slope. These hoppers are insulated from the neck above the
discharge flange with the insulation covering the entire hopper
area. In addition, the lower 1/4- 1/3 of the hopper wall may be
heated. Discharge diameters are generally 200-300mm. The fly
ash handling system evacuates the fly ash from the hoppers, and
transports the fly ash to reprocessing or to disposal. The ash
handling system are designed and operated to remove the
collected fly ash from the hoppers without causing re-
entrainment into the gas flow through the precipitator. The design
of the ash handling system allow for flexibility of scheduling the
hopper discharges according to the fly ash being collected in
these hoppers.
function
• Ductwork: Ductwork connects the precipitator with

upstream and downstream equipment. The design of
the ductwork takes into consideration the following:
– Low resistance to gas flow
– Gas velocity distribution
– Minimal fallout of fly ash
– Minimal stratification of the fly ash
– Low heat loss
– Structural integrity

Design & Performance
Requirements
Precipitator performance depends on its size and
collecting efficiency. Key design parameters are:
• Collecting area (use of computer models done for
judgment)
• Gas volume.
• Electrical power input (Increasing the power input
improves precipitator collecting efficiency under
normal conditions)
• Dust chemistry.
Process Variables
• Gas flow rate: Decided by coal quality, boiler load, excess
air rate and boiler design. Operates best with a gas velocity
of 1-2 m/sec. At higher velocity, particle re-entrainment
increases rapidly. If velocity is too low, performance may
suffer from poor gas flow distribution or from particle dropout
in the ductwork.
• Particle size and size distribution: Decided by coal quality,
the coal mill settings and burner design. A precipitator
collects particles most easily when the particle size is
coarse. The generation of the charging corona in the inlet
field may be suppressed if the gas stream has too many
small particles (less than 1 µm).
Very small particles (0.2 - 0.4µm) are the most difficult to
collect because the fundamental field-charging mechanism
is overwhelmed by diffusion charging due to random
collisions with free ions.
Process Variables
• Particle resistivity: Influenced by the chemical composition and the gas
temperature. Resistivity is resistance to electrical conduction. The higher
the resistivity, the harder it is for a particle to transfer its electrical charge.
Resistivity is influenced by the chemical composition of the gas stream,
particle temperature and gas temperature. Resistivity should be kept in
the range of 108 - 1010 ohm-cm.
High resistivity can reduce precipitator performance. For example,
burning reduced-sulfur coal increases resistivity and reduces the
collecting efficiency of the precipitator. Sodium and iron oxides in the fly
ash can reduce resistivity and improve performance, especially at higher
operating temperatures.
On the other hand, low resistivity can also be a problem. For example
unburned carbon reduces precipitator performance because it is so
conductive and loses its electrical charge so quickly that it is easily re-
entrained from the collecting plate.
• Gas Temperature:The effect of gas temperature on
precipitator collecting efficiency, given its influence on particle
resistivity, can be significant
Corona Power
The separation of particles from the gas flow in an electrostatic
precipitator depends on the applied corona power. Corona power
is the product of corona current and voltage. Current is needed to
charge the particles. Voltage is needed to support an electrical
field, which in turn transports the particles to the collecting plates.
In the lower range of collecting efficiencies, relatively small
increases in corona power result in substantial increases in
collecting efficiency. On the other hand, in the upper ranges, even
large increases in corona power will result in only small efficiency
increases. Optimum conditions depend upon optimizing the
following:
• Uniformity of Gas velocity
• Fly Ash: Particle size & Resistivity
• Voltage Controls: Spark rate setting, Current & voltage limits
• Plate spacing, Collecting plate & discharge electrode design
• 1Frequency
October 2019 & intensity of Rapping
PMI Revision 00 34
Performance Improvements
Improvement or optimization of precipitator operation can
result in significant savings Combustion process
conditions mainly affect the corona power level. The
primary contributors to combustion process conditions
and their effects include:
• Coal Bituminous coals, sub-bituminous and lignite coals from different
mines are substantially different from each other in the combustion
process. Coal blending is now used for operational and financial
benefits. This results in a wide range of boiler and precipitator operating
conditions.
Precipitating fly ash from difficult coals can be improved with
conditioning systems. However, the furnace and its associated
equipment can still cause problems in the precipitator, particularly coal
mills, burners, and air pre-heaters

• Coal Mills The setting of the coal mills and classifiers defines the
coal particle size which in turn impacts the fly ash particle size.
Larger coal particles are more difficult to combust, but larger fly
ash particles are easier to collect in the precipitator. Furnace
Base-load operation of the boiler is usually better for precipitator
operation than swing-load operation due to more stable operating
conditions
• Furnace : Base-load operation of the boiler is usually better for
precipitator operation than swing-load operation due to more
stable operating conditions. Boiler operation at low loads may be
as problematic for the precipitator as operating the boiler at its
maximum load level, due to fallout of fly ash in the ductwork, low
gas temperatures, and deterioration of the quality of the gas
velocity distribution. If low load operation cannot be avoided, the
installation of additional gas flow control devices in the inlet and
outlet of the precipitator may prove beneficial
• Coal Burner The operation of coal burners, together with
the setting of the coal mills and their classifiers, affects the
percentage of unburned carbon (UBC) in the fly ash. The
use of Lo-NOx burners increases this percentage, and
causes re-entrainment and increased sparking in the
precipitator. Further, the UBC tends to absorb SO3, which in
turn increases the fly ash resistivity. Over-fire air
optimization or coal-reburn systems may reduce UBC in the
fly ash. Air Pre-heater Regenerative air pre-heaters cause
temperature and SO3 stratification in the downstream gas
flow. Flue gas conditioning systems may be used to
equalize the gas flow characteristics.
• Air Pre-heater Regenerative air pre-heaters cause
temperature and SO3 stratification in the downstream gas
flow. Flow mixing devices may be installed in the ductwork
to the precipitator, or flue gas conditioning systems may be
1used to equalize the gas flow
October 2019 characteristics
PMI Revision 00 37
DUST REMOVAL
• Rapping Mechanism
BY Mechanical Impulses OR By vibration of
plates
Periodicity
philosophy

ESP EFFICIENCY
• Deuteche equation
Efficiency=1-(1/ewk* sca)
Efficiency depends upon

a) Gas Flow Rate
b) Migration Velocity

PROCESS PARAMETERS
• Excess Air
• FG Temperature
• Coal Fineness
• ECO/APH Hoppers
• CO Monitors

REGULAR CHECKS
• CRM/ERM checking
• Hopper Heaters
• ALI
• Air Ingress
• Transformer Inspection
• BABCON Tuning
• ALI to CRM trip Protection

Factors affecting ESP
Performance
• Particle Size Distribution
• Gas Speed
• Particle Resistivity (can change with presence of sulfur,
Moisture,temperature)
• ESP Voltage Levels
• Re-entrainment of Fly Ash
– Rapping Frequency
– Fly Ash Properties. (Cohasive Property)
• Sparking, back corona and
• Particle Loading
Skewed Gas Flow
Technology
(SGFT)
•For any dry horizontal flow precipitator
•Reduction in particulate emissions
between 30%
and 60%, average 40%
•Installed by modifying flow control
devices
•Cost effective - Easily installed
•No change in precipitator O & M costs
1 October 2019 43
ELECTROSTATIC PRECIPITATION
TWO COMPONENTS 1
Dust particles carried in suspension are charged electrically
and deposited on a collecting surface
• The first component of collection

takes place on a horizontal plane
• It results in a layer of dust on the collecting surfaces
• Much research has been done on this component
SECOND COMPONENT
The second component of collection

takes place on a vertical plane
Dust agglomerates are

dislodged and fall downwards

TWO COMPONENTS
• While in the treatment zone of a typical precipitator,

most of the dust travels further in the vertical direction
than the horizontal direction
• Vertical movement has a substantial effect on performance

PARTICLES AND AGGLOMERATES
60 60
1 particles
2 agglomerates
2 agglomerates
• Agglomerates fall and disperse to become particles again

• Much of the dust is deposited on collecting surfaces
more than once before it reaches the hopper
• Large agglomerates, which would fall further than small
ones, result in clouds of heavy concentration
• These clouds are difficult to collect, penetrate downstream
fields, and result in rapping puffs
NON UNIFORM DUST DISTRIBUTION
Fine particles (<10 microns)

tend to be the most difficult to
collect due to reintrainment
Reintrainment causes the dust

concentration at the outlet face
to be higher at the bottom than
at the top

Preferred Gas Flow Profile
Skewed Gas Flow optimizes performance by increasing the

treatment time in the lower outlet portion of the Unit
This improves the collection of the reintrained fine particles

thereby reducing emissions and opacity

General Layout
Flow in from Gas Flow

Secondary
Air Heater
Flow to
Chamber 11 ID Fan
(Typical) & Stack
Flow in from Symmetric Around

Primary Boiler Center Line
Air Heater
Flow to
ID Fan
Chamber 12
& Stack
(Typical)
Flow in from
Secondary
Air Heater
Elevation View
Inlet Screens Gas Flow
Outlet Screen
'egg crate' Flow

Straightener
Hopper ID
Baffles Fan

DISPOSAL OF FLY ASH
MHV
SV
DRY
MODE
ASH SLURRY WET

SUMP MODE SILOS

Fly Ash and Flue Gas
Conditioning
• Fly ash resistivity can be modified (generally with the intent
to reduce it) by injecting one or more of the following
upstream of the precipitator:
– Sulfur trioxide (SO3)
– Ammonia (NH3)
– Water
• Sulfur Trioxide and Ammonia Conditioning Systems
In most cases, a sulfur trioxide conditioning system is
sufficient to reduce fly ash resistivity to an acceptable level.
The source of sulfur trioxide can be liquid sulfur dioxide,
molten elemental sulfur, or granulated sulfur. It is also
possible to convert native flue gas SO2 to SO3. The source
of ammonia may be liquid anhydrous or aqueous ammonia,
or solid urea.
SUITABILITY OF AMMONIA DOSING
Ammonia combine with SOX and transforms it to Ammonium
sulphat & Ammonium bisulphate .
Ammonium bisulphate molecules (being adhesive in nature) increases
the adhesion strength of dust collected on electrodes and falls in the
form of lumps while rapping and thus reduces the re-entertainment loss.
Ammonium sulphate is the outcome of neutralization of excess sulpher
present in flue gas.
It is suitable for stations where Sulpher in flue gas is
significant (about 0.4% or more) and re-entertainment loss is

significant.
ADVANTAGES
• Easy layout.
• System can be installed with available resources.
• SPM level can be reduced between 25% ~ 50% in
existing ESP. It mainly depends upon the percentage of
SO2 & SO3 available in flue gas.
• No adverse effect on the health of the equipment.
Ammonia rather neutralizes the acidic gases available in
flue gas.
• Simple to operate.
LAYOUT FOR AMMONIA DOSING IN ESP
DUCT
PASS-A
PASS-D PASS-C PASS-B PASS-A
WATER SPRAY
AMMONIA CYLINDER
ZERO METER

Water Injection
• The injection of water upstream of the precipitator
lowers the gas temperature and adds moisture to
the flue gas. Both are beneficial in cold-side
precipitator applications. However, care must be
taken that all of the water is evaporated and that
the walls in the ductwork or gas distribution devices
do not get wet.

THANK YOU

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Flue Gas System

1 October 2019 PMI Revision 00 1

1 October 2019 PMI Revision 00 2

Precipitators function by electrostatically charging the

APH ESP CHIMNEY

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Collector plate Emitter coil

Gas distribution plate

2.Dust particle charging Collecting

Discharge electrode with

• Discharge Electrodes • Emitting Electrodes

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TYPE SPIRAL WITH HOOKS

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NO. OF ELECTRODE PER FIELD 24

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– Automatic voltage control

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• Ductwork: Ductwork connects the precipitator with

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Efficiency depends upon

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• The first component of collection

The second component of collection

Dust agglomerates are

1 October 2019 PMI Revision 00 45

• While in the treatment zone of a typical precipitator,

1 October 2019 PMI Revision 00 46

• Agglomerates fall and disperse to become particles again

Fine particles (<10 microns)

Reintrainment causes the dust

1 October 2019 PMI Revision 00 48

Skewed Gas Flow optimizes performance by increasing the

This improves the collection of the reintrained fine particles

1 October 2019 PMI Revision 00 49

Flow in from Gas Flow

Flow in from Symmetric Around

Inlet Screens Gas Flow

'egg crate' Flow