4th generation of Coromax pulse generators for

ESPs
Victor Reyes
FLSmidth Airtech
Denmark
[email protected]

Peter Elholm
FLSmidth Airtech
Denmark
[email protected]

Abstract:

The first plants using the latest generation of Coromax pulse generators for ESPs have been
commissioned. The present paper will present the new features developed as well a comparison with
competing types of power supplies for ESPs. Among the new features, the use of single IGBTs as
main semiconductor switch and extremely narrow pulses can be mentioned. Furthermore the results
obtained after the commissioning of a sinter plant producing 15.000 t/d will be given.

2 Introduction
The tendency in air pollution regulations is a
decrease of the accepted levels for fine
particles. E.g. the EU has imposed lower limit
on ambient concentration of fine particulate
matter (PM2.5). It is well known that pulse
energization is the most effective means in
charging and filtering fine particulate when
using ESPs.
In order to improve the state-of-the-art in pulse
energization, Airtech- Air Pollution Control FLSmidth has developed the 4th generation of its
line of pulse generators. The main goal for the
new system was to increase the rate of rise of
the ESP voltage by a factor of 2 and in this
way to be able to apply higher voltage levels to
the ESP. This was obtained in practice by
decreasing the pulse width correspondingly.
Furthermore, the system is able to apply a
higher pulse voltage compared with previous
generations. Other improvements have been
introduced regarding the manner the high
voltage semiconductor switch handles the
sparks occurring inside the ESP.
Physically the system comprises one control
cabinet and a HV oil tank, like a traditional TR
set, where the oil tank is placed on the ESP
roof, as shown in Fig. 1.

Fig. 1 Coromax HV oil tank

The electrode/collecting system behaves as a
capacitance with losses.The Coromax mrk. IV
is designed for a rated load of 115 nF, but it
can operate with a wide range of ESP
capacitances (40% - 200% of rated value).
The art of pulse energization consists of
narrow HV pulses in the range of tenths of
microseconds, superimposed on a base
voltage, which are applied to an ESP field [1],
[2] generating negative corona.
The principle is illustrated in Fig. 2 showing the
Coromax voltage waveform compared with the
one generated by a traditional single-phase TR
set (DC-energization). Furthermore, the
smooth DC voltage delivered by a SMPS unit
is shown. Some of these units can operate in
the so-called intermittent mode (IE-mode =
intermittent energization) giving a DC voltage
with high ripple and a variety of degrees of
intermittence. But these HV supplies operate in

Fig. 3 Simplified main circuit of a Coromax

pulse system

Fig. 2 Waveform of the output voltage

the millisecond range with modest dv/dt in the
range of few kV/ms.
The present version of the COROMAX system
dealt with in this paper, aims at improving the
performance in fine particulate and high
resistivity dust collection by halving the pulse
width. In this way the dv/dt applied to an ESP
field is doubled (up to 2 kV/s).
To improve the conditions regarding service
and troubleshooting, other requirements were
to avoid series connection of power semiconductors and placement in insulating oil.
Furthermore, because of an eventual higher
sparking level the pulse amplitude has been
increased by 10 kV compared with previous
generations.

Before a pulse is generated, the capacitor CS is

charged to a voltage +UPS through the primary
winding of the pulse transformer. The coupling
capacitor CC is used for avoiding short-circuit
of the DC-power supply and it is charged to the
voltage UDC like the ESP capacitance.
Then a series resonant circuit comprising the
storage capacitance CS, the coupling
capacitance CC, the precipitator capacitance
CF and the leakage inductance of the pulse
transformer (PT) is formed. This circuit is
closed when the IGBT switch is turned on.
When this happens an oscillation is initiated
and a current with the waveform shown in Fig.
4 starts flowing through the IGBT. When the
current through the IGBT reaches its zerocrossing (T/2), it changes direction and
circulates through the reverse diode (D) built in
the IGBT module, until it becomes zero. Then
the period of the oscillation (T) is elapsed and
a HV pulse has been generated.

In order to fulfil these requirements a solution

with pulse transformer with a suitable transformation ratio and a switch made of high power
IGBTs operating at 2.5kV was chosen.
Finally it can be mentioned than considerably
improvements have been introduced in the
automatic control system.

3 Principle of operation of the

COROMAX system
A simplified diagram of the main circuit is
shown in Fig. 3.
The DC base voltage applied to the ESP is
delivered by a controlled HV power supply
(-UDC). The power for pulse generation is
delivered by another controlled HV supply
(+UPS).

Fig. 4. Waveforms during a normal high

voltage pulse

The voltage across the ESP and the current

through the switch has the waveforms shown
in Fig.4. The voltage rating is 60 kVDC and 80
kV pulse, respectively.
The pulse current is a sine wave, where the
positive half-cycle corresponds to the IGBT
conduction interval and the negative to the
reverse diode conduction interval. Its rated
value is 9 kApeak. The rated pulse width is
75s. This can be repeated with a frequency,
variable between 2 and 100 pps. The rated
voltage of the pulse power supply (UPS) is 2.5
kV.
The pulse voltage has a waveform corresponding to a shifted cosine wave. The equations
describing the waveforms can be found in [1].
The block diagram shown in Fig. 5 illustrates
the complete pulse system. In order to cope
with the high pulse current level, especially in
case of sparks in the ESP, the primary circuit is
divided in two equal branches in parallel.
Therefore the pulse transformer comprises 2
primary windings, improving the current distribution between the 2 IGBTs. The DC voltage
supply (UDC) and the pulse supply (UPS) are fed
from the three-phase AC line.

The output of the pulse power supply is filtered

by Lps1, Lps2, Cs1 and Cs2.
The pulse forming network is the same as the
one shown in Fig. 3 with the exception that, in
practice, there are 2 parallel branches in the
primary circuit. Furthermore, in parallel with
each IGBT is connected a clamping network,
consisting of a diode Dcl in series with a large
capacitor Ccl, which function will be discussed
later.

4 Automatic control unit

The firing angle for both power supplies is
determined by the control unit BCU PC. This is
placed
in
the
control
cabinet
and
communicates with control unit BCU LVJB at
the HV tank via a CAN Bus. These units
include
the
control
strategies,
spark
classification, monitoring and alarm processing
system. The operation of the system is
performed from the EPCU (EsP Control Unit),
which also takes care of the rapping control
and heating of insulators and hoppers. EPCU
is common for a number of ESP bus-sections
but typically for one ESP chamber.
The control panel of the EPCU is shown in
Fig.6.

This voltage level is raised by HV transformers

Fig. 5 Block diagram of the COROMAX

and rectified by three-phase bridge rectifiers.
The output voltages (UDC,UPS) are controlled
by three-phase thyristor controllers by varying
the primary voltage of the HV transformer.
Each controller receives the firing pulses from
a firing PC board.
The output of the DC power supply is passed
through a LC filter with capacitive input, whose
main function is to keep the base voltage
smooth, especially after firing a HV pulse.

Fig. 6 Front panel of the control system

When treating medium and high resistivity
dusts, an accurate control of the base voltage
is quite important. The EPCU controls its level
in a way that the generated DC corona
current can be kept at a setpoint of normally a
few milliamps. In this way back corona can be
avoided.

This DC corona current is the current flowing

between two consecutive pulses after the ion
cloud generated by the first one has reached
the collecting plates. This means that this
current has to be measured sampling the
corresponding signals just before the next
pulse is generated. Because a typical
repetition frequency in case of medium dust
resistivity is 50 - 60 pps, the control system
has a time interval of 17 - 20 ms to perform the
measurement. This measurement was not
possible in previous generations and may be
considered as a major improvement in the new
Coromax.

clamping diode is biased in the forward

direction and the current surge pulse charges
the clamping capacitor. If this is sufficient
large, the voltage increase in CCl is limited and
the overvoltage across the IGBTs can be kept
at few hundred volts.
A typical example is seen if Fig. 6, showing
what happens in case of a pulse spark.

5 IGBT switch function

The HV switch is the heart of a pulse system
and the most critical situation for the
semiconductors used, is the occurrence of
sparks.
Normally the sparks occurs around the top of
the pulse, but they can also occur earlier or
later, depending on the mechanical condition
of the ESP and/or the resistivity of the
particulate removed by the ESP. These sparks
are named pulse sparks.

(a)

Occasionally sparks may occur shortly after a

pulse and they are named DC-sparks, as only
the base voltage is applied to the ESP at the
spark instant.
The previous pulse systems used HF thyristors
connected in series as a switch [1,2]. In case
of sparks the switch is exposed to a
considerable overvoltage. To cope with this
situation the switch can be oversized using a
larger number of elements in series, which is
too expensive. The normal solution used is
generation of protection firing pulses. Because
of the connection of many thyristors in series,
this kind of protection is critical, as explained in
[2].
By using an IGBT switch instead, this can be
turned off when a spark is detected. This gives
a much more simple protection principle for the
IGBT switch. When the IGBTs are turned off it
is necessary to have an alternative path for the
energy stored in the system. This function is
performed by the clamping diode Dcl and the
clamping capacitor Ccl. When the IGBTs are
turned off after detection of a pulse spark, the

(b)
Fig. 7 Waveforms in case of pulse spark.
These waveforms are obtained with the
simulation
program
POWERSIM
and
correspond to rated values. Fig. 7.a shows a
pulse spark occurring on top of the pulse just
after the zero-crossing of the IGBT current
(Iigbt). As seen the ESP voltage (Uesp) drops
very fast from 140 kV to 0. The IGBT current

changes direction and begins to increase, but

after a delay of few microseconds the IGBTs
are turned off and the pulse current
commutates to the clamping network. The
current through the clamping capacitor (ICcl) is
shown in Fig.7.b.
Here it is seen that Ccl is charged by this
current and the overvoltage applied to the
IGBTs is limited to about 200 V. Fig. 7 shows
the currents in one parallel branch only. During
a normal pulse the peak current through one
IGBT is 4.2 kA. Fig. 7 also shows that the
IGBTs are not exposed to current surges,
because these are overtaken by the clamping
network made of passive components.
In case of DC-sparks the IGBTs are already
turned off, so the only possible current path for
the surge is the clamping network.
This solution has been patented in a number of
countries, the EU and EEUU among them.
The IGBTs are fired by a commercially
existing IGBT driver, They are physically
placed in a LV junction box (LVJB) attached to
the oil tank as seen in Fig. 8.

Fig. 9 1200A/3300 V IGBT used as switch

As shown, the switch is implemented with
commercially available elements and no series
connection is used. The switch is mounted in
air, so measurements and eventual troubleshooting and replacement is much easier.

6 Practical experiences
After a long test of the prototype in a Danish
power plant a number of units have been sold.
At the moment more than 20 units are in
operation, mainly in sinter strand plants and
also in a power plant.

6.1

Electrical operation

The main waveforms are easy to collect via

existing BNC connectors. The waveforms
corresponding to a normal pulse are shown in
Fig. 10.

Fig. 8 IGBTs mounted in LVJB

The IGBTs are mounted on a heat sink with
cooling fins, which is in contact with the oil
inside the HV tank. Fig. 9 shows one of the
utilized IGBTs together with the corresponding
IGBT driver.

Fig. 10 ESP and IGBT voltage and IGBT

current during a normal pulse.
The voltage across the IGBT is 2.5 kV (rated
value) causing a peak current of about 4.8 kA
flowing through the switch and a total ESP
voltage of 132 kV (UDC = 55 kV). The pulse
width is 78 s.

Fig. 11 illustrates a pulse spark occurring after

the top of the pulse, showing the ESP voltage
and the current through one IGBT. It is seen
that the current through the IGBT is only
flowing during the normal pulse, but when the
sparks occurs the IGBT is turned off. The
surge current is then overtaken by the
clamping network, as illustrated in Fig. 7.

African coal, producing a medium resistivity

flyash.
The ESP is from FLS comprising two
chambers, with 4 bus-sections each, energized
with 8 third generation Coromax systems.
2
Each Coromax energizes 4320 m (400 mm
wide spacing) of collecting area, corresponding
to a capacitive load of 120 nF. The rated mean
current is 600 mA.
The gas flow is 32.000m3/min and the dust
3
load is 18.5 gr/Nm dry @ 6% O2.

Fig. 11 ESP voltage and IGBT current

during a pulse spark.

The new Coromax energizes the 2nd bussection of the West chamber. A switch box was
mounted allowing and easy change-over with
the existing pulse system. The electrical
operation is best illustrated by the CVC shown
in Fig. 13.

During normal (repetitive) operation the waveform of the ESP voltage is shown in Fig. 12.

Fig. 13 Pulse and DC I-V characteristics

Fig. 12 ESP voltage and IGBT voltage at
normal repetitive operation.
Fig. 12 shows also the occurrence of a spark
and the following voltage recovery. It is also
seen the amplitude of the pulses follow the
envelope of the IGBT voltage very close.

6.2

Site experiences

6.2.1 Plant No. 1

The first system (prototype) was installed in a
Danish power plant, the unit #3 at Nordjyllandsvrket. Unit #3 has a nominal load of
350 MW and the boiler is fired with different
coal blends. The load varies typically between
80 and 100% according to the daily demands.
The typical coal blend during the test period
were a mix of Russian, Indonesian and South
African or Russian, Colombian and South

As shown, total voltages (DC+pulse) of 113 kV

are possible (UDC = 50 kV). The increase in the
pulse voltage compared with the old Coromax
is 4-6 kV, but because the prototype only
energizes 1/8 of the ESP, no appreciable
emission reduction was observed. The
3
emission level is below 50 mg/Nm , typically
3
35 mg/Nm .
Moreover, Fig. 13 clearly indicates the
outstanding feature of pulse energization,
where the ESP current can be varied independently of the voltage, just by varying the pulse
repetition frequency.

6.2.2 Plant No. 2

The
first
commercial
units
where
commissioned in 2010 at the waste gas ESP at
sinter plant in South America.
The sinter waste gas is characterized by fine
particulate high resistivity dust and the
Coromax with its individual control of voltage
and current is in particular appropriate for that
process.
A new ESP was delivered comprising two
chambers with 3 sections each. Both inlet
sections are energized with single phase TRs
and the other 4 sections with 4th generation
Coromax systems. See Fig. 1.
2

rated base voltage is 60 kV and the rated

mean ESP current is 600 mA.
The performance test was made with a
production of 5425 t/day, a gas flow rate of
3
19.088 m /min and an inlet temperature about
3
90C. The result was 6 mg/Nm , that is in a
very safe distance to the guaranteed limit. With
operational data close to the design, the much
better results relate solely to the Coromax
features.

7 Conclusions
It has been possible to include improvements
with respect to previous Coromax generations.
Among them, the following can be mentioned:

The plant has sinter strand of 450 m designed

for a production of 15000 t/day. The ESP is
3
designed for a gas flow of 38.868 m /min and
an inlet temperature of 160C. The guaranteed
dust emission is 50 mg/Nm3 (dry).

Almost twice higher dv/dt applied to the ESP

as the pulse width is now only 75 s.

The capacitive load for each Coromax system

is about 145 nF, i.e. 25 % higher than rated
load. The rated pulse voltage is 80 kV, the
rated base voltage is 60 kV and the rated
mean ESP current is 600 mA.

Modern up-to-date HV switch with commercially available IGBTs mounted in air. No

series connected modules are needed, making
possible
an
easy
maintenance
and
troubleshooting.

The performance test was made with a

production of 15800 t/day, a gas flow rate of
29245 m3/min and a temperature about 165C.
3
The result was 5 mg/Nm that was much below
the guarantee limit. Some of the lower value
may relate to the lower gas flow rate. However,
the main part may relate to the unique feature
of the new Coromax.

More simple and efficient way of coping with

sparks, due to the turn-off capabilities of
IGBTs.

6.2.3 Plant No. 3

The second commercial units were also
installed in a sinter plant waste gas ESP in
South America and were commissioned late in
2010. An existing 2 chambers ESP, each with
3 sections, were furnished with new internals
and 6 Coromax systems.
2

The plant has a sinter strand of 146 m

designed for a production of 6100 t/day. The
ESP is designed for a gas flow of 18.350
m3/min and an inlet temperature of 110C. The
guaranteed dust emission is 30 mg/Nm3 (dry).
The capacitive load of each Coromax is about
90 nF. The rated pulse voltage is 80 kV, the

10 kV higher pulse voltage allowing a better

particle charging.

Up-to-date automatic control system, including control of rappers and heaters.

Regarding emission guarantees, these have
been achieved without problems. Further, the
results have been beyond expectation.

8 Litterature
[1] K. Parker. Electrical operation of electrostatic precipitators. IEE Power and Energy
Series. 2003.
[2] V. Reyes Semiconductor switch for HV
pulse generation. 20th Conference on Power
Conversion, Munich, 1990. Germany.