2) ESP Basics

Worldwide Pollution
Control Association
FirstEnergy ESP Seminar
November 27th 28th, 2007
Visit our website at www.wpca.info
ESP Basics
By
Tom Lugar
Buell Division
Fisher-Klosterman, Inc.
Fundamentals
of
Electrostatic Precipitator
(ESP) Operation
The Process in Electrostatic Precipitation

Particle Charging
Particle Collection
Removal of Collected Particulate
Electrostatic Precipitator
A Box with Wires and Plates
ESP Roof Area: H.V. Transformers,

Rappers, Insulator Houses
H.V. Insulator House
Gas Passages 9 Centers
Particle Charging and Collection
ESP Gas Passage Particle Charging & Collection
Emitting Electrodes Corona Emission
Emitting Electrodes Corona Emission
Typical Electromagnetic
Impact Rapper
Typical Rotating Hammer

Rapper Rapping System
Rotating Hammer Rapping System
Automatic Voltage Control (Typical)
Factors Affecting ESP

Sizing and Performance
Precipitator Sizing
Deutsch Equation for ESP Collection Efficiency
= 1 - e -(Aw/Q)
Where:
= Collection Efficiency, fraction

A = Collecting Plate Area, ft2
Q = Flue Gas Volume, ft3/sec (actual)
W = Charged Particle Migration Velocity, ft/sec
The migration velocity of the charged particulate

is roughly proportional the precipitator voltage.
W V2
It is therefore critical that a high voltage level
be maintained in the precipitator for optimal
charging and collection.
Specific Collecting Area - SCA

SCA =
Collecting Plate Area ft2

1000 ft3/min. flue gas treated
Example: 400,000 ft2 plate area

1,000,000 ACFM Gas Flow
SCA = 400
ESP Sizing and Performance

For a given gas volume, precipitator sizing and performance
are dependent on the following specified or assumed
parameters:
Ash Particle Size
Ash Loading
Ash Resistivity
The above parameters vary depending on the type of boiler,
fuel, flue gas temperature and flue gas constituents.
Particle Size Considerations

Very fine particles, less than one micron diameter, provide
small cross sections or targets for capture of negative ions.
Fine particles require more treatment time to capture a
sufficient number of ions to attain an adequate charge.
Charged particles less than 1 micron travel to the grounded

plates in a random motion instead of a more direct path as
taken by larger ash particles.
The particulate removal efficiency of the outlet electrical
fields of an ESP will be less than that of the inlet fields.
ESP Collecting Plate Flyash Layer

Scanning Electron Microscope Image 500X
ESP Collecting Plate Flyash Layer

Scanning Electron Microscope Image -2000X
Ash Loading Considerations

High ash loadings interfere with particle charging
by suppressing the corona from the emitters and
thus the negative ions generated for charging.
The effect of suppression becomes significant if the
higher ash loading has a large population of fines.
Ash Resistivity
Definition: The degree of electrical
conductivity of the ash expressed in ohms-cm.
Typical Range: 1 x 109 - 1 x 1013
The value of resistivity depends on the flue gas
temperature, gas constituents, and chemical
composition of the flyash.
Due to the resistive ash layer on the collecting plate, ionic charge
is stored on the ash layer surface and only a small amount of

current flows through the ash layer to the grounded plate.
Most of the voltage drop is in the ash layer and not in the gap
where particle charging occurs.
Car Battery Analogy
Current flow is reduced due to the resistivity of the corrosive layer

between the battery clamp and terminal.
Effect of Low Ash Resistivity, <1 x 108

Collected ash particles lose their charge quickly
and become re-entrained into the gas steam.
Effect of High Ash Resistivity, 1012 -1013

Low power levels, low voltage sparking,
back corona formation.
Back Corona
If the ash layer voltage drop is very large due to very high resistivity, Back
Corona will form when the ash layer breaks down and the total voltage, Vt,
is not sufficient for sparkover.
With Back Corona, positive corona occurs on the ash layer surface
forming positive ions that are attracted to the negative polarity emitters.
Positive ions encounter negative ions effectively canceling their
contribution to the particle charging process.
Back Corona Glow Regions on Collecting Plate Ash Surfaces

Plan View Looking Down Into a Gas Passage
Effect of High Ash Resistivity on Charged

Particle Migration Velocity
Factors Affecting Flyash Resistivity
Resistivity of Flyash from Low Sulfur Coal @ 300oF
Elemental Analysis of Flyash

Typical Range of Constituents
Component
SiO2
Al2O3
Fe2O3
CaO
MgO
Na2O
K2O
Li2O
TiO2
P2O5
SO3
Maximum %
61.00
31.00
23.70
23.50
5.50
2.66
3.90
0.07
2.30
1.00
1.83
Minimum %
41.20
17.90
3.90
0.30
0.90
0.13
0.28
0.01
0.80
0.16
0.07
The Major Ash Resistivity Effects Due to Mineral

Compounds in the Ash are:
SiO2, Al2O3, CaO, MgO - Increases Ash Resistivity
Na2O, Li2O - Reduces Ash Resistivity
A Most Difficult Combination of Ash and Coal
Constituents For ESP Operation:
SiO2 + Al2O3 > 80%
Fe2O3 < 5%
Na2O < 0.5%
Coal Sulfur Content < 1%
ESP Flue Gas Temperature 330 to 350oF
Deterioration of ESP
Performance Over Time
Ageing of the Box
Excessive Emitter & Plate Ash Buildup
Cracked Support insulator
ESP Rebuild
Restore
Performance
Reduce Maintenance Requirements
Life Extension of the ESP
Precipitator Design Practice - U.S. OEMS

Design Characteristics
Prior
Current
Plate-to-Plate Spacing
8- 9
12 - 16
Precipitator Voltage
45KV
55-75KV
Emitting Electrode
Rapping System
Control System
Wire-Weight
Vibrators/Electromagnetic Impact,
Rotating Hammer
Analog
Rigid
AllElectro-Mag.
Impact, Rotating
Hammer
Microprocessor
based with
Host Computer
Note: Rebuild with Rigid Emitters requires increased plate

spacing, 10-12
Rigid Emitting Electrode Sampling
Rigid Emitting Electrode Example

Pipe & Pin

Mast Type

Pipe and Flared Strip Emitters
Typical Rebuild with Pipe & Pin Emitters
Rebuild With Rigid Emitters will Require Wider

Collecting Plate Spacing in the ESP
Doesnt Less Collecting Plate Area (SCA)

In the Same ESP Box Mean Less Particulate
Collection Efficiency?
Answer: No
Wide Plate Spacing

For a Given Precipitator Casing, Collecting Plate Area
Can be Reduced by Increasing the Plate-To-Plate
Spacing While Maintaining the Collection Efficiency
The Charged Particle Migration Velocity Increases
in Proportion to the Increase in ESP Voltage With
Spacing.
The Increased Voltage Creates an Increased Electric
Field That Further Accelerates the Charged Particles
Attracted to the Grounded Plates.
Wide Plate Spacing

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Worldwide Pollution

Visit our website at www.wpca.info

The Process in Electrostatic Precipitation

ESP Roof Area: H.V. Transformers,

H.V. Insulator House

Gas Passages 9 Centers

Particle Charging and Collection

ESP Gas Passage Particle Charging & Collection

Emitting Electrodes Corona Emission

Emitting Electrodes Corona Emission

Typical Rotating Hammer

Rotating Hammer Rapping System

Automatic Voltage Control (Typical)

Factors Affecting ESP

= Collection Efficiency, fraction

The migration velocity of the charged particulate

Specific Collecting Area - SCA

Collecting Plate Area ft2

Example: 400,000 ft2 plate area

ESP Sizing and Performance

Particle Size Considerations

Charged particles less than 1 micron travel to the grounded

ESP Collecting Plate Flyash Layer

ESP Collecting Plate Flyash Layer

Ash Loading Considerations

is stored on the ash layer surface and only a small amount of

Car Battery Analogy

Current flow is reduced due to the resistivity of the corrosive layer

Effect of Low Ash Resistivity, <1 x 108

Effect of High Ash Resistivity, 1012 -1013

Back Corona Glow Regions on Collecting Plate Ash Surfaces

Effect of High Ash Resistivity on Charged

Factors Affecting Flyash Resistivity

Resistivity of Flyash from Low Sulfur Coal @ 300oF

Elemental Analysis of Flyash

The Major Ash Resistivity Effects Due to Mineral

Excessive Emitter & Plate Ash Buildup

Cracked Support insulator

Precipitator Design Practice - U.S. OEMS

Note: Rebuild with Rigid Emitters requires increased plate

Rigid Emitting Electrode Sampling

Rigid Emitting Electrode Example

Rigid Emitting Electrode Example

Rigid Emitting Electrode Example

Typical Rebuild with Pipe & Pin Emitters

Rebuild With Rigid Emitters will Require Wider

Doesnt Less Collecting Plate Area (SCA)

Wide Plate Spacing

Wide Plate Spacing

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