ELECTROSTATIC PRECIPITATOR

( ESP )
Basics & Fundamentals
 HISTORY
pioneer
1884 – Sir Oliver Lodge (1851 – 1940)
“Electricity could be used to collect fumes.”

1885 – A. O. Walker & W. O. Hutchings

Full scale precipitator in a lead smelter

1907 – Frederick Gardner Cottrell

Precipitator to collect sulfuric acid mist
 Pioneer Installation
1907 – Chemical Industry
1910 – Non-Ferrous Industry
1910 – Rock Products Industry
1916 – Pulp & paper Industry
1919 – Ferrous Industry
1923 – Power Industry (Detroit Edison)
 Other ESP Application
 Cement Industry (Kiln, Pre-heaters and Mills)
 Smelting Blast Furnace
 Recovery Boiler (Paper-pulp recovery of alkali
salts from waste liquor evaporation gases)
 Gold and silver recovery from electrolytic
copper slimes
 Basic Process of ESP
 Charging fly ash particles
 Transporting to collecting surface
 Holding and discharging on collecting surface
 Moving the fly ash to the hopper
 Moving the ash from the hopper to disposal
Dust Collection Principle

Collecting Plate

Discharge
Electrode
ESP Mechanical Components
 Casing/ Duct/ Hopper/ Manhole
 Collecting plate/ Discharge electrode
 Gas Distribution Plate
 Insulator/ Heating system
 Rapping System
 Anti-sneak age baffle
 Ash handling system
BLCP Power Station MHI ESP
Power Station Sturtevan ESP
Hsinta Power Station Lurgi ESP
Holcim Cement Cooler - FLS ESP
Philippine Sintering Plant – MHI ESP
La Farge Cement Cooler - ELEX ESP
PASAR Smelting Plant – Flakt ESP
SCG Paper Mill - Elwo ESP
Design of Discharge Electrodes & Collecting Plates
Types of insulators
ESP (Control System)
ESP Transformer Rectifier
Primary and Secondary
Transformer leads

Iron Core

Transformer
windings
ESP (T/R High Frequency Unit)
™
PowerPlus Technology
PowerPlusTM is technology breakthrough that uses state-o
f-the-art, three-phase, high-frequency, solid-state switchmod
e technology for collecting the particulate matter in Electrosta
tic Precipitator. PowerPlusTM high-frequency (20 kHz—50
kHz) power conversion technology provides much better, m
ore cost-effective particulate collection, as the effect of pu
re DC voltage. Not only ESPs that emits high emission bec
ause of corona suppression due to high space charge benefit
from pure DC supply but also processes that has low to med
ium resistive dusts will show big improvement. Higher secon
dary kV & current will increase significantly.
 
The PowerPlusTM is a complete all-in-one Power System.
This new technology offers significant advantages over conv
entional Transformer/Rectifier.

• GREATER
• MORE COST EFFECTIVE
• BETTER CONTROL,
• AN INTEGRATED SYSTEM
• FIELD-SERVICEABLE
Horns for acoustic cleaning
ESP (Interlock System)
Typical FLS design for inlet nozzle
Typical FLS design for inlet nozzle
Typical ESP SCR-CLR Electrical System Schematic

SCR
Transformer/Rectifier Set
Current Limiting
Reactor (CLR)
Power Source

Primary Voltage
Meter (AC)
+ –
V

Voltage
Divider
Primary Current
A
Meter (AC)

Secondary Current Secondary Voltage

Firing Automatic Meter (DC)
–
Meter (DC)

Circuit Voltage Control mA KV

– +
Microprocessor
Control Module +

Signal
Precipitator
Resistor

Signal
Resistor
 TYPICAL OPERATING VOLTAGE
LEVELS
ASSUMING GOOD ALIGNMENT
AND NO REVERSE IONIZATION.

COLLECTOR OPERATING
SPACING mm VOLTAGE kV

250 40 – 45
300 48 – 54
400 60 – 70

ACTUAL VALUE DEPENDS ON TYPE OF DISCHARGE ELECTRODE

Basic ESP Performance Factors

PRIOR TO CONSIDERING ANY ENHANCEMENT MEASURE, IT IS

IMPERATIVE THAT THE FOLLOWING ITEMS ARE ADDRESSED.

1. Gas flow and temperature are optimized.

2. Alignment of electrode system is good.
3. Rapping is correct for inlet conditions.
4. Are TRs and AVCs correctly operating?
5. Are TRs operating in reverse ionization mode?
6. Is rapping reentainment a problem?
Basic ESP Performance Factors

 Concentration of Particulate (Spacecharge)

 Particle Size
 Dust Resistivity
 Particle Re-entrainment
 Gas Sneakage
 Uniform Gas Distribution
 Gas Volume
 Collecting Area
 Concentration of Particulate
 High dust loading suppress the spacecharge (ash contain of coal)

 Particle Size
 Submicron particles cause difficult precipitation
 NH3 Injection for dust agglomeration

 Dust Resistivity
 High resistivity (>1012 ohm-cm) cause difficult precipitation
 SO3 Injection for dust particle resistivity reduction at injection rate of 10
to 15 PPM

 Particle Re-entrainment
 Rapping control philosophy – setting study
 Maintenance program on rapping system

 Gas Sneakage
 Maintenance program on anti-sneakage baffle
 Uniform Gas Distribution
 Design Issue – gas distribution test & guiding adjustment
 Maintenance program on distribution plates

 Gas Volume
 Boiler operation process control (air volume / temperature)
 Maintenance program on air leakage

 Collecting Area
 Design Issue
ESP Performance Improvement
 Mechanical Repair
 Rapping Enhancement
 Electrical Energization Approach
 Controller (AVC/Rapping) Upgrade
 Gas Distribution
 SCA Addition
 Flue Gas Conditioning
END OF SESSION