5TH SEMESTER, INDUSTRIAL TRAINING REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT

FOR THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)

SUBMITTED BY:
LAKSHAY
(8720324)

SIET NILOKHER KARNAL

(HARYANA)

2022-2023

KURUKSHETRA UNIVERSITY
KURUKSHETRA
 LETTER OF UNDERTAKING

I LAKSHAY STUDENT OF SIET NILOKHERI HEREBY CONFIRM THAT

THE REPORT I HAVE PROVIDED IS SOLELY MY OWN EFFORT .I DID
NOT COPY MY REPORT PARTIALLY FROM ANY OTHER STUDENT
OR FROM ANY OTHER SOURCE EITHER AGAINST PAYMENT OR
FEE AND I DID NOT PROVIDE ANY PLAGIARIZED MATERIAL IN
ANY SECTION OF MY REPORT . I FURTHER CONFIRM THAT THE
DOCUMENTS (INTERNSHIP CIRTIFICATE ) THAT I HAVE PROVIDED
IS GENUINE AND HAVE BEEN ISSUED BY THE AUTHORIZED
PERSON IN THE ORGANIZATION .IF I AM FOUND GUILTY OF
MISSTAKING, MISLEADING OR CONCEALING THE FACTS ABOUT
MY ACTIVITE AT ANY STAGE THE UNIVERSTY IS AUTHORIZED TO
TAKE DISCIPLINARY ACTION AGAINST ME ACCORDING TO
UNIVERSTY POLICIES AND REGULATIONS.

LAKSHAY
8720324

2
 ACKNOWLEDGEMENT

I WOULD LIKE TO EXPRESS MY GRATITUDE AND APPRECIATION

TO ALL THOSE WHO GAVE ME THE POSSIBILITY TO COMPLETE
THIS REPORT.SPECIAL THANKS TO MY WHOLE MECHANICAL
ENGINEERING DEPARTMENT STAFF WHOSE HELP, STIMULATING
SUGGESTIONS AND ENCOURAGMENT HELPED ME IN ALL TIME
FABRICATION PROCESS AND IN WRITING THIS REPORT. I ALSO
SINCERLY THANKS FOR THE TIME SPENT PROOFREADING AND
CORRECTING MY MANY MISTAKES.

I WOULD ALSO LIKE TO ACKNOWLEDGE WITH MUCH

APPRECIATION THE CRUCIAL ROLE OF THE MANAGMENT OF ISGEC
WHO GAVE ME A PERMISSION TO USE THE EQUIPMENTS AND ALSO
THE MACHINE AND GIVING A PERMISSION TO USE ALL THE
NECESSARY TOOLS IN THE WORKSHOP.

MANY THANKS GO TO THE SUPERVISORS AND ISTRUCTER

WHO HAVE GIVEN THEIR FULL EFFORT IN GUIDING THE TEAM
IN ACHIVING THE GOAL AS WELL AS THEIR ENCOURAGMENT
TOO MANTAIN OUR PROGRESS IN TRACK.

3
 ABSTRACT
INTERNSHIP IS ONE OF THE BEST METHODS TO MAKE STUDENTS
FAMILIAR WITH THE MODERN TECHNIQUES, LATEST EQUIPMENT
& METHODS USED IN VARIOUS INDUSTRIES. DURING INTERNSHIP,
STUDENTS VISIT VARIOUS COMPANIES AND MAKE THEMSELVES
FAMILIAR WITH THE PRACTICAL ASPECTS OF THE PRODUCTION
METHOD.

THIS REPORT FOCUSES ON THE INTERNSHIP WHICH I HAVE DONE

IN ISGEC YAMUNANAGAR.

THE INTERNSHIP HAS PROVIDED AN UNMATCHED EXPERIENCE

AND OPPORTUNITY TO GAIN PRACTICAL KNOWLEDGE WHICH HAS
INCREASED MY LEVEL OF THINKING AND TAUGHT ME ART OF
DEALING WITH DIFFERENT KINDS OF PEOPLE IN ALL WALKS OF
LIFE. THIS EXPERIENCE HAS IMPROVED MY THEORETICAL AND
PRACTICAL CONCEPTS OF AUTOMOTIVE TECHNOLOGY.

THE WELL PLANNED, PROPERLY EXECUTED AND EVALUATED

INTERNSHIP HELPS A LOT IN INCULCATING GOOD WORK ETHICS.
IT PROVIDES A MEDIUM BETWEEN THE STUDENTS AND THE
INDUSTRY IN ORDER TO DEVELOP THE AWARENESS OF INDUSTRIAL
APPROACH TO PROBLEM SOLVING BASED ON BROAD
UNDERSTANDING OF PLANT.

4
 LIST OF FIGURES
S.No. FIGURE No. DESCRIPTION PAGE No.
1 1 Schematic Diagram of precipitator 16
2 2 Component of electrostatic precipitators 17
3 3 Discharge electrodes 18
4 4 Rapper Coil 19
5 5 Hoppers 19
6 6 Electrostatic basic diagram 20
7 7 Positive and negative plates 20
8 8 Working of electrostatic precipitator 22
9 9 Electrostatic precipitator 24
10 10 Sectional view of ESP 25

5
 CONTENTS
SECTION PAGE NO.

LETTER OF UNDERTAKING............................................................................................2

ACKNOWLEDGEMENT......................................................................................................3

ABSTRACT.............................................................................................................................4

LIST OF FIGURES................................................................................................................5

CHAPTER 1:INDUSTRY
1. ABOUT INDUSTRY.......................................................................................7

2. JOURNEY OF ISGEC AS A CORE MECHANICAL INDUSTRY............8

3. BUSINESS AREA OF ISGEC........................................................................9

4. ISGEC DESIGN OFFICES AND MANUFACTURING LOCATION.......10

5. GLOBAL PRESENCE AND CLIENTS OF ISGEC.....................................11

CHAPTER 2:DETAIL ABOUT INTERNSHIP

1. ABOUT INTERNSHIP.............................................................................12

CHAPTER 3:ABOUT ESP

1. WHAT IS ESP.........................................................................................................13

2. HOW ESP WORKS................................................................................................14

3. DESIGN OF ESP.....................................................................................................16

4. ELECTROSTATIC PRECIPITATOR EFFICIENCY REDUCER..................26

5. APPLICATOPN OF ELECTROSTATIC PRECIPITATOR............................29

6. ADVANTAGE AND DISADVANTAGE OF ESP...............................................30

6
 ABOUT INDUSTRY

ISGEC HEAVY ENGINEERING LTD. IS A DIVERSIFIED HEAVY ENGINEERING

COMPANY HEADQUARTERED IN INDIA. EVOLVING AND ADAPTING ITSELF TO
THE GROWING NEEDS OF THE INTERNATIONAL MARKET, THE COMPANY HAS
BECOME A NAME TO RECKON WITH. WHAT STARTED OFF WITH AN
OFFERING OF SUGAR MACHINERY AND BOILERS HAS, OVER THE YEARS,
DIVERSIFIED AND NOW HAS AN ENVIABLE PORTFOLIO OF BUSINESS
VERTICALS. TODAY, THESE ARE CATEGORISED UNDER THE TWO BROAD
SEGMENTS OF ‘MANUFACTURING’ AND ‘EPC’.

ISGEC MANUFACTURING SEGMENT COVERS PROCESS EQUIPMENT,

MECHANICAL & HYDRAULIC PRESSES, STEEL & IRON CASTINGS, BOILER
PANELS & PIPING, AS WELL AS CONTRACT MANUFACTURING OF INDUSTRIAL
PRODUCTS. OUR EPC PROJECTS SEGMENT UNDERTAKES TURNKEY PROJECTS
FOR SETTING UP INDUSTRIAL & UTILITY BOILERS, SUGAR PLANTS &
DISTILLERIES, POWER PLANTS, AIR POLLUTION CONTROL EQUIPMENT,
INDUSTRIAL WASTEWATER TREATMENT PROJECTS, BULK MATERIAL
HANDLING PROJECTS, AS WELL AS CIVIL CONSTRUCTION, INCLUDING
FACTORIES. WHAT DRIVES THE PEOPLE AT ISGEC IS THE DESIRE TO USE ITS
PROVEN ENGINEERING SKILLS AND VAST CUMULATIVE EXPERIENCE OF
OVER 89 YEARS, TO ACHIEVE EXCELLENCE IN THE PRODUCTS AND PROJECTS
THAT WE EXECUTE. WE BELIEVE IT IS THIS STRIVING THAT WILL HELP ITS
CUSTOMERS ACHIEVE EXCELLENCE IN WHAT THEY DO AND PAVE THE WAY
FOR A FUTURE THAT IS SUSTAINABLE, SUCCESSFUL, AND SECURE.

THE COMPANY’S EXCEPTIONAL ENGINEERING PROWESS HAS CREATED A

LASTING IMPRESSION ACROSS MULTIPLE GEOGRAPHIES COVERING 91
COUNTRIES. IT HAS, AND CONTINUES TO ADDRESS THE DEMANDS OF A WIDE
RANGE OF INDUSTRIES THAT INCLUDE - POWER, DEFENCE, FERTILISER,
SUGAR, OIL & GAS, PETROCHEMICALS, AUTOMOBILE, STEEL, CEMENT,
CHEMICALS, RAILWAYS, SPACE, AND PORTS. KEEPING ABREAST OF THE
LATEST AND MOST RELEVANT TECHNOLOGIES ACROSS OUR PORTFOLIO,
ISGEC HAS STRATEGIC TECHNOLOGY PARTNERSHIPS AND AS WELL AS A
NUMBER OF JOINT VENTURE PARTNERSHIPS WITH LEADING FIRMS FROM
ACROSS THE GLOBE

7
JOURNEY OF ISGEC AS A CORE
MECHANICAL INDUSTRY

8
 BUSINESS AREA OF ISGEC

 PROCESS EQUIPMENT
 BOILERS
 PRESSES
 STEEL CASTING AND IRON CASTING
 AIR POLLUTION CONTROL EQUIPMENT
 CONTRACT MANUFACTURING
 LIQUIFIED GAS CONTAINERS
 POWER, OIL&GAS, FERTILIZERS
 AUTOMOBILES, DEFENCE, SUGAR PLANT
 CHEMICAL, STEEL

9
ISGEC DESIGN OFFICES AND
MANUFACTURING LOCATION

10
GLOBAL PRESENCE AND CLIENTS OF
ISGEC

11
 DETAIL ABOUT INTERNSHIP

I HAD COMPLETED MY INTERNSHIP IN ESP (ELECTROSTATIC

PRECIPITATOR) .WHICH HELPS TO REDUCE AIR POLLUTION WITH
THE HELP OF CORNA EFFECT WHICH HAS BEEN PRODUCED BY
HIGH VOLTAGE TRANSFORMAS.

AN ELECTROSTATIC PRECIPITATOR (ESP) REMOVES PARTICLES

FROM A GAS STREAM BY USING ELECTRICAL ENERGY TO
CHARGE PARTICLES EITHER POSITIVELY OR NEGATIVELY. THE
CHARGED PARTICLES ARE THEN ATTRACTED TO COLLECTOR
PLATES CARRYING THE OPPOSITE CHARGE. THE COLLECTED
PARTICLES MAY BE REMOVED FROM THE COLLECTOR PLATES
AS DRY MATERIAL (DRY ESPS), OR THEY MAY BE WASHED
FROM THE PLATES WITH WATER (WET ESPS). ESPS ARE CAPABLE
OF COLLECTION EFFICIENCIES GREATER THAN 99 PERCENT.

AN ESP IS PRIMARILY MADE UP OF THE FOLLOWING FOUR

COMPONENTS: GAS DISTRIBUTION PLATES, DISCHARGE
ELECTRODES, COLLECTION SURFACES (EITHER PLATES OR
PIPES) AND RAPPERS. THE GAS DISTRIBUTION PLATES CONSIST
OF SEVERAL PERFORATED PLATES WHICH HELP MAINTAIN
PROPER FLOW DISTRIBUTION OF THE ENTERING GAS STREAM.
THE DISCHARGE ELECTRODES ARE DIVIDED INTO FIELDS.
MOST ESPS HAVE THREE OR FOUR FIELDS IN SERIES; HOWEVER,
VERY LARGE UNITS MAY HAVE AS MANY AS FOURTEEN FIELDS
IN SERIES. DISCHARGE ELECTRODES ARE ENERGIZED BY A
SINGLE TRANSFORMER-RECTIFIER (T-R) SET POWER SUPPLY.

12
 WHAT IS ESP
AN ELECTROSTATIC PRECIPITATOR IS A FILTER-LESS DEVICE
THAT IS USED TO CONTROL AIR POLLUTION BY ELIMINATING
POLLUTANTS SUCH AS SOOT AND ASHES AND OTHER HIGH
PARTICULATE MATTER FROM INDUSTRIAL SMOKE STACKS.
ELECTROSTATIC PRECIPITATORS ONLY SPEND ENERGY ON
DISPOSING OF AIR POLLUTANTS. THEREFORE, THESE ARE THE
BEST FOR THE CONSUMPTION OF ENERGY OR ELECTRICITY. IT
WORKS WITH THE USE OF STATIC ELECTRICITY, MOST OF THE
INDUSTRIES USE FOSSIL FUELS FOR ITS MANUFACTURING
PROCESSES AND IN THE RESULT OF THIS THEY EMIT SMOKE IN
THE AIR. THIS SMOKE CONTAINS SOOT, ASHES, AND MUCH OF
THE UNBURNED CO2 IN THE ENVIRONMENT. ELECTROSTATIC
PRECIPITATORS OR (ESP) WILL TAKE THE SOOT, ASHES, AND
UNBURNED CARBON DIOXIDE FROM SMOKE THROUGH AN
ELECTRIC CHARGE AND EMIT CLEAN AIR OR SMOKE INTO THE
ATMOSPHERE. EXTRACTION OF THESE HARMFUL PRODUCTS IS
VERY IMPORTANT AS POLLUTANTS CAN CAUSE SERIOUS
DAMAGE TO BUILDINGS, ENVIRONMENT, AND HUMAN HEALTH.
ELECTROSTATIC PRECIPITATORS ARE USED FOR THE REMOVAL
OF PARTICULATE MATTER FROM THE POLLUTED AIR.
DIFFERENT TYPES OF PARTICULATE MATTER INCLUDE DUST,
SMOKE, SOOT, ASHES, AND FUMES. PRECIPITATORS GIVE A
CONTROL
EFFICIENCY OF 99% FOR PARTICULATE MATTER THAT IS ≥1.0 ΜM
IN DIAMETER. THE SIZE OF PARTICULATE MATTER DOES NOT
AFFECT THE EFFICIENCY OF AN ELECTROSTATIC PRECIPITATOR.
HOWEVER, HIGH OR LOW RESISTIVITY PARTICLES ARE
DIFFICULT TO HANDLE IN THESE DEVICES AND CAN ONLY DEAL
WITH A MODERATE RESISTIVITY OF PARTICULATE MATTER.

13
 HOW ESP WORKS

THE OPERATION OF ELECTROSTATIC PRECIPITATORS IS

FAIRLY SIMPLE. THE DIRTY FLUE GAS ESCAPING
THROUGH THE SMOKESTACK IS PASSED
THROUGH TWO ELECTRODES. THE SHAPE THESE
ELECTRODES TAKE DEPENDS ON THE TYPE OF
ELECTROSTATIC PRECIPITATOR USED, BUT THEY CAN BE
METAL WIRES, BARS, OR PLATES INSIDE A PIPE OR THE
SMOKESTACK ITSELF. ONE OF THE ELECTRODES IS
CHARGED WITH A HIGH NEGATIVE VOLTAGE, AND
THIS PLATE CAUSES PARTICULATES INSIDE THE SMOKE
TO OBTAIN A NEGATIVE CHARGE AS THEY PASS BY THIS
ELECTRODE. FURTHER ALONG THE PIPE, THE SECOND
ELECTRODE CARRIES A SIMILARLY HIGH POSITIVE
VOLTAGE. BASED SOLELY ON THE FACT THAT OPPOSITE
CHARGES ATTRACT, THE NEGATIVELY CHARGED SOOT
PARTICLES ARE PULLED TOWARDS THE POSITIVE
ELECTRODE AND STICK TO IT. OCCASIONALLY THESE
PLATES MUST BE CLEANED TO REMOVE THE
ACCUMULATED SOOT AND DISPOSE OF IT INTO A HOPPER.
THE SOOT AND ASH COLLECTED FROM COAL BURNING
POWER PLANTS IN THIS MANNER IS REFERRED TO AS FLY
ASH.EVEN THOUGH MOST ELECTROSTATIC
PRECIPITATORS WORK IN A SIMILAR WAY, THERE ARE
MANY VARIATIONS AND DIFFERENT TYPES THAT WORK
BETTER FOR DIFFERENT SIZED PARTICLES, DIFFERENT
SMOKE COMPOSITIONS, AND DIFFERENT AMOUNTS OF
POLLUTION. THE NEED FOR A VARIETY OF DESIGNS
COMES PARTLY FROM THE FACT THAT COAL BURNED
AROUND THE WORLD VARIES IN ITS CHEMICAL
COMPOSITION DRASTICALLY. OTHER POWER PLANTS
MAY LOOK TO REMOVE CERTAIN POLLUTANTS - SUCH AS
SULFUR DIOXIDE - OR LOOK TO MINIMIZE THE AMOUNT
OF ASH PRODUCED. ADDITIONALLY, SOME LOW- SULFUR
COALS THAT ARE BURNED HAVE A HIGHER

14
ELECTRICAL RESISTIVITY, WHICH MAKES IT MORE
DIFFICULT TO REMOVE THE ASH PRODUCED BY THIS
COAL USING ELECTROSTATIC
PRECIPITATORS.ELECTROSTATIC PRECIPITATORS ARE
EXTREMELY EFFEVTIVE, AND ARE CAPABLE OF
REMOVING MORE THAN 99% OF PARTICULATE
MATTER. SINCE 1940, EMISSIONS OF PARTICULATE
MATTER SMALLER THAN 10 MICROMETERS HAVE BEEN
REDUCED BY A FACTOR OF 5. HOWEVER, THIS HIGH LEVEL
OF EFFECTIVENESS COMES AT A HIGH COST - ABOUT 2-4%
OF A POWER PLANT'S ELECTRICAL ENERGY OUTPUT GOES
INTO OPERATING ELECTROSTATIC PRECIPITATORS AND
OTHER SYSTEMS USED TO REMOVE PARTICULATE
MATTER.

THE EFFECTIVENESS OF A CERTAIN PRECIPITATOR IS

DETERMINED BY HOW WELL THE SPECIFIC DEVICE DEALS
WITH THE UNIQUE FEATURES AND PROBLEMS OF THE
PLANT IT IS USED AT. ADDITIONALLY, PRECIPITATOR
EFFECTIVENESS IS ALSO DETERMINED BY THE
TEMPERATURE AND MOISTURE CONTENT OF THE FLUE
GAS.

15
 DESIGN OF ESP

MANY INDUSTRIES NEED ELECTROSTATIC

PRECIPITATORS, SINCE THEY WORK WITH FOSSIL FUELS,
WHICH RESULTS IN EMISSION OF HARMFUL CHEMICALS
AND FLUE GASES IN THE ATMOSPHERE. THE
PRECIPITATOR HAS THE FOLLOWING COMPONENTS IN ITS
DESIGN THAT HELPS IT WORK AND FUNCTION PROPERLY.
THESE COMPONENTS ARE:

 ELECTRODES
 440V 50HZ 3 PHASE SUPPLY
 RECTIFIER
 HOOPER
 INSULATOR
THESE ARE THE BASIC COMPONENTS OF A PRECIPITATOR.

FIGURE 1

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THE FIGURE SHOWS THE POSITION AND WORKING OF
EACH COMPONENT IN A PRECIPITATOR. AC SUPPLY IS
GIVEN TO THE CONTROL CABINET WHERE THE VOLTAGE
IS STEPPED UP WITH A HIGH VOLTAGE STEP UP
TRANSFORMER. THEN IT IS RECTIFIED BY THE DIODE
THAT IS PRESENT IN THE RECTIFIER COMPONENT. NEXT
THE AC IS CONVERTED INTO DC, THEN PASSED TO THE
DISCHARGE ELECTRODES. AT THIS STAGE THE FLUE GAS
ENTERS THE DISCHARGE ELECTRODE AND GETS IONIZED.
IONIZED PARTICLES HAVE AN OPPOSITE CHARGE AND
POLARITY TO COLLECTOR ELECTRODES, WHICH MAKES
THESE PARTICLES ATTRACT TO THE COLLECTOR
ELECTRODE. PASSED FROM COLLECTOR ELECTRODES,
THESE PARTICULATE MATTERS ARE THEN PASSED DOWN
INTO HOPPERS AND THE DUST IS DISCHARGED OUT.

FIGURE 2

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 Discharge Electrodes
THE DISCHARGE ELECTRODES THAT ARE PRESENT IN THIS
PRECIPITATOR ARE MADE UP OF TUBES THAT ARE
WELDED AND ANNEALED. THESE ARE COPPER WIRES
THAT ARE SMALLER IN DIAMETER. THE WIRES ARE HUNG
VERTICALLY IN THE SYSTEM AND CAN PRODUCE A VERY
HIGH AMOUNT OF CORONA DISCHARGE. THE MAIN
FUNCTION OF THESE ELECTRODES IS TO CREATE A
STRONG ELECTRIC FIELD THAT SENDS A FLUX TO IONIZE
THE PARTICLES PRESENT IN THE FLUE GAS. THE
COLLECTING ELECTRODES ARE MADE OF STEEL, WHICH
HELPS IN ATTRACTING THE IONIZED PARTICLES.

FIGURE 3
 Rapper Coils
THE RAPPER COILS PRESENT IN THE STRUCTURE ARE FOR
PROVIDING A GOOD AMOUNT OF ENERGY TO THE IONIZED
PARTICLES TO DETACH THEM FROM THE COLLECTING
TUBES. THE ENERGY PRODUCED BY THESE COILS HITS
THE ELECTRODE AT SET TIME INTERVALS. THIS HELPS IN
COLLECTING THE DUST PARTICLES IN THE HOPPER.

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 FIGURE 4

 Transformer Rectifier Unit

THE AC VOLTAGE THAT IS FED TO THE SYSTEM IS
CONVERTED INTO DC VOLTAGE BY USING A
TRANSFORMER RECTIFIER UNIT. THE RECTIFIER PRESENT
HELPS IN RECTIFYING THE AC VOLTAGE INTO DC ONE.

 Hopper Container
THE HOPPER IS A LONG PYRAMIDAL SHAPED CONTAINER
USED FOR COLLECTING PARTICULATE MATTER. THE DUST
IS COLLECTED INTO THE COLLECTING ELECTRODES AND
THEN TRANSFERRED INTO THE HOPPERS. IN HOPPERS THE
RAPPER COILS DETACH THE IONIZED PARTICULATE
MATTERS FROM THE ELECTRODES. WHEN THE HOPPERS
COLLECT ENOUGH DUST PARTICLES, IT IS THEN
EXPELLED FROM THE BOTTOM OF THE DEVICE.
VIBRATORS ARE PRESENT ON THE OUTER WALLS OF THE
DEVICE WHICH HELPS IN RELEASING THE PARTICULATE
MATTERS.

FIGURE 5

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 How Electrostatic Precipitation Works
ELECTROSTATIC PRECIPITATOR IS ALSO CALLED AN
ELECTROSTATIC AIR CLEANER. THIS DEVICE IS USED TO
CLEAN UP THE IMPURE AIR EMITTING FROM INDUSTRIAL
CHIMNEYS. THE FLUE GASES PRODUCED BY INDUSTRIAL
COMBUSTION OF SOLIDS HAVE MANY HARMFUL AND
DANGEROUS POLLUTANTS, WHICH ARE HIGHLY POISONOUS
FOR HUMAN HEALTH AND THE ENVIRONMENT. IT IS
NECESSARY TO ELIMINATE THESE POLLUTANTS FROM AIR
EMITTING FROM THE CHIMNEYS. FOR THIS PURPOSE THERE
IS A DEVICE PLACED IN BETWEEN THE FURNACE TO THE
CHIMNEYS FOR EXTRACTION OF PARTICULATE MATTER
FROM FLUE GAS. THIS DEVICE IS AN ELECTROSTATIC
PRECIPITATOR. FIRST THE FLUE GAS ENTERS INTO THIS
DEVICE WHICH EXTRACTS ALL THE POLLUTANTS FROM THE
GAS AND THEN DISSIPATES LESS HARMFUL GAS INTO THE
ATMOSPHERE.

FIGURE 6

FIGURE 7
20
ELECTROSTATIC PRECIPITATION WORKS BY CREATING
AN ELECTROSTATIC FORCE AND IONIZING THE
PARTICLES. IT ALSO WORKS IN THE PRESENCE OF TWO
ELECTRODES. ONE IS A POSITIVE ELECTRODE AND THE
OTHER IS A NEGATIVE ELECTRODE. THE POSITIVE
ELECTRODE IS IN THE FORM OF PLATES AND THE
NEGATIVE ONE IS IN THE FORM OF MESH WIRE. BOTH ARE
PLACED VERTICALLY AND ALTERNATIVELY TO EACH
OTHER IN THE PRECIPITATOR.

THE NEGATIVE ELECTRODE IS CONNECTED TO THE

NEGATIVE TERMINAL OF THE DC VOLTAGE AND THE
POSITIVE IS CONNECTED TO THE POSITIVE DC VOLTAGE
TERMINAL. TO HAVE STRONGER NEGATIVITY IN THE
NEGATIVE ELECTRODE THE POSITIVE TERMINAL MAY BE
GROUNDED OCCASIONALLY. THE DISTANCE BETWEEN
THE DC VOLTAGE THAT IS SUPPLIED, THE NEGATIVE
ELECTRODE, AND THE POSITIVE PLATE IS ALL WELL
ADJUSTED AND KEEPS THE VOLTAGE GRADIENT HIGH.
THIS IONIZES THE MEDIUM BETWEEN THE NEGATIVE
ELECTRODES AND THE ADJACENT POSITIVE PLATES. THE
MEDIUM THAT IS PRESENT BETWEEN THESE NEGATIVE
ELECTRODES IS AIR. BY THE NEGATIVITY OF THESE
NEGATIVE ELECTRODES THERE WILL BE A DISCHARGE OF
CORONA. THIS CORONA DISCHARGE WILL SURROUND THE
ELECTRODES AND CREATE A NEGATIVELY CHARGED
ENVIRONMENT.

THE AREA OR FIELD BETWEEN THE ELECTRODES IS

COMPLETELY IONIZED WHICH RESULTS IN THE PRESENCE
OF PLENTY OF FREE ELECTRONS AND IONS IN THAT FIELD.
THE WHOLE PROCESS OF ELECTROSTATIC PRECIPITATION
IS DONE WITHIN A METALLIC CONTAINER WITH AN INLET
FOR THE ENTRANCE OF FLUE GAS AND AN OUTLET ON
THE OPPOSITE SIDE FOR MOVING POLLUTANT FREE GAS
INTO THE AIR. WHEN THE FLUE GAS IS PUT INTO THE
PRECIPITATOR THE DUST PARTICLES GET ATTACHED AND
TRAPPED BY THE FREE ELECTRONS AND IONS THAT ARE

21
PRESENT. THESE DUST PARTICLES BECOME NEGATIVELY
CHARGED AND ARE ATTRACTED BY THE ELECTROSTATIC
FORCE OF POSITIVE PLATES.

FIGURE 8
AFTER THE ATTACHMENT OF THESE NEGATIVELY
CHARGED DUST PARTICLES ON POSITIVE PLATES THE
EXTRA FREE ELECTRONS ARE REMOVED FROM THE
PLATES AND THE PARTICLES DROPPED DUE TO
GRAVITATIONAL FORCE. THERE ARE CONTAINERS
CALLED HOPPERS PRESENT IN THE PRECIPITATOR THAT
COLLECT THE DUST PARTICLES FROM THE COLLECTING
PLATES. FROM THE OUTLET, CLEAN AIR IS THEN
DISCHARGED INTO THE AIR. WATER SPRAYS ARE ALSO
INTRODUCED ONTO THE TOP OF THE PRECIPITATOR FOR
QUICK REMOVAL OF DUST PARTICLES FROM THE PLATES.

SOMETIMES THE ELECTROSTATIC PRECIPITATORS ALSO

WORK WITH DENITRIFICATION UNITS WHERE THERE IS A
REMOVAL OF HARMFUL AIR POLLUTANTS NITROGEN

22
DIOXIDE AND SULPHUR DIOXIDE. NOW THESE
PRECIPITATORS ARE USUALLY MARKETED AS AIR
PURIFIERS OR CLEANERS FOR MANY INDUSTRIES AS A
REPLACEMENT FOR FURNACES. THESE PRECIPITATORS DO
NOT ALLOW THE BACTERIA TO BREED, THOUGH THE
PLATES ARE DIFFICULT TO REMOVE AND MAY PRODUCE
OZONE OR NITROGEN OXIDES. SPECIAL FILTERS ARE
APPLIED TO THIS REMOVAL AND ARE SOLD WITH SOAK
OFF CLEANERS THAT CAUSE THE COMPLETE REMOVAL OF
DUST PARTICLES

23
Electrostatic Precipitator

FIGURE 9

24
Electrostatic Precipitator-SECTIONAL VIEW

FIGURE 10

25
Electrostatic Precipitator Efficiency Reducers
THERE ARE 6 FACTORS THAT WILL REDUCE THE
EFFICIENCY OF ELECTROSTATIC PRECIPITATORS. ANY OF
THESE EFFICIENCY REDUCERS WILL CREATE PROBLEMS
IN ELECTROSTATIC PRECIPITATORS. THESE FACTORS ARE:

 Flue Gas Flow Rate

IF THE FLUE GAS IS INTRODUCED INTO THE CHAMBER AT
A VERY EXCESSIVE RATE THEN THE DUST PARTICLES
WILL ACCUMULATE IN THE ELECTRIC FIELD LEADING TO
THE FORMATION OF DUST MASSES. THIS WILL CAUSE AN
INCUBATION OF DUST PARTICLES, MAKING IT DIFFICULT
TO REMOVE THE PARTICULATE MATTER FROM THE GAS.

 Air Flow Distribution

THE DISTRIBUTION OF AIR FLOW ALSO AFFECTS ITS
PERFORMANCE. THE EFFICIENCY OF THE PRECIPITATOR IS
HIGH WHEN THERE IS LOW AIR FLOW. THE REMOVAL OF
DUST HAPPENS MORE QUICKLY AT THE AREA OF LOW AIR
FLOW AND IT IS REDUCED IN AREAS OF HIGH AIR FLOW. IT
IS DUE TO THE EFFECTS CAUSED BY HIGH SPEED SMOKE
OVER THE LOW SPEED SMOKE.

 Dust Specific Resistance

THE EFFICIENCY OF A PRECIPITATOR DEPENDS ON THE
RESISTANCE OF DUST PARTICLES. THE SPECIFIC
RESISTANCE OF PARTICLES SHOULD BE 10,000 TO 10 TIMES
Ω.CM FOR BEST COLLECTION. IF THE SPECIFIC
RESISTANCE IS TOO LOW THE PARTICLES WILL MOVE AND
ESCAPE FROM THE OUTLET BY GAS STREAM, WHICH
DECREASES THE EFFICIENCY OF THE DEVICE. WHEREAS,
IF THE PARTICLES ARE TOO LARGE THEY WON’T ESCAPE.
IT IS NECESSARY TO VIBRATE THE DUST PARTICLES AT
A

26
HIGHER RATE SO THAT THEY CAN VIBRATE TWICE, AND
BE RETAINED BY THE DEVICE FOR PURIFICATION.

 Air Leakage
IN THE OPERATION OF NEGATIVE PRESSURE OF DUST
COLLECTION AIR LEAKAGE WILL BE A CAUSE TO
PRODUCE SECONDARY DUST FLYING. DUE TO AIR
LEAKAGE THE SMOKE SPEED OF THE GAS INCREASES
WHICH RESULTS IN THE SHORT RESIDENCE TIME OF THE
FLUE GAS IN THE DEVICE. AIR LEAKAGE ALSO DECREASES
THE TEMPERATURE OF THE FLUE GAS THAT MAY LEAD TO
CONDENSATION AND EVEN CORROSION.

 Flue Gas Temperature

THE DUST REMOVAL EFFICIENCY INCREASES WHEN THE
TEMPERATURE OF THE FLUE GAS IS BETWEEN 110-130°C.
IF THE TEMPERATURE OF THE FLUE GAS IS TOO HIGH,
SPECIFIC RESISTANCE IS REDUCED, VISCOSITY SHRINKS,
AND THE DRIVE IN SPEED OF THE GAS IS HIGH. THIS WILL
RESULT IN LOW EFFICIENCY OF DUST REMOVAL.
WHEREAS, IF THE TEMPERATURE IS LOW THEN HUMIDITY
INCREASES, IONIZATION WEAKENS, CORONA CLOSURE
HAPPENS, AND THE EFFICIENCY OF DUST REMOVAL ALSO
DECREASES. THE GENERAL SAMPLING OF FLUE GAS RATE
IS 0.8~1.2M/S.

 Soot Concentration
THE SOOT CONCENTRATION WILL INCREASE THE DUST PARTICLES
IN THE ELECTRIC FIELD. IF THE SOOT CONCENTRATION IS TOO
HIGH IT WILL CAUSE THE CORONA CLOSURE. THIS MEANS NO
CURRENT WILL GET PASSED THROUGH THE ELECTRIC FIELD. THIS
NON GENERATION OF CORONA WILL REDUCE THE EFFICIENCY OF
THE PRECIPITATOR. IF THE FLUE GAS HAS A LOT OF SOOT
CONCENTRATION IT SHOULD BE PRETREATED. THE FLUE GAS
CONTENT SHOULD BE KEPT BELOW 5G/M3.

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 Application of Electrostatic Precipitators

 ELECTROSTATIC PRECIPITATORS ARE USED WIDELY IN

INDUSTRIES FOR SMOKE SOOT AND PARTICULATE
MATTER ELIMINATION.
 THE DRY PRECIPITATOR IS USED FOR THE COLLECTION OF
PARTICLES LIKE SOOT, ASH, AND CEMENT.
 THE WET PRECIPITATOR IS USED TO ACCUMULATE
STICKY AND MOIST PARTICLES EFFECTIVELY.
 WET PRECIPITATORS ARE ALSO USED FOR THE CLEANING
OF BLAST FURNACES AND METALLURGICAL HEATING
SYSTEM GASES.
 ELECTROSTATIC PRECIPITATORS ARE ALSO USED IN
MEDICAL FIELDS FOR THE ELIMINATION OF BACTERIA
AND FUNGUS.
 PRECIPITATORS ARE ALSO USED IN AIR CONDITIONING
SYSTEMS FOR PURIFYING AIR.
 PRECIPITATORS ARE USED TO RECOVER SOME
MATERIALS FROM THE FLUE GAS.
 ELECTROSTATIC PRECIPITATORS ARE ALSO USED IN
ZIRCONIUM SANDS FOR THE DETACHMENT OF RUTILE.
 IT IS ALSO USED IN INDUSTRIES FOR COLLECTING
ABRASIVE MATERIALS.
 PRECIPITATORS ARE USED IN FILTERING COOLANT
SMOKE AND MIST FROM THE FINISHING PROCESSES.
 THE PRECIPITATORS ARE ALSO USED FOR FILTERING
EXPLOSIVE DUSTS, MISTS AND MATERIALS FROM THE
FUMES.
 IT IS ALSO CAPABLE OF CAPTURING FINE BLACK CARBON
POWDER OR OXIDES AND MANY MORE FROM THE GAS
FLOW.
 ELECTROSTATIC PRECIPITATORS ARE USED IN PULP
INDUSTRIES AND IN POWER PLANTS.

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 Advantages and Disadvantages of Electrostatic
Precipitators

Electrostatic Precipitator Advantages

 INITIAL COST IS LESS
 EFFICIENCY UP TO 99%
 LOW MAINTENANCE IS REQUIRED
 HELPS TO PROTECT THE ENVIRONMENT
 HIGHLY EFFICIENT WORKING OTHER THAN ANY
SEPARATORS
 RELIABLE AND EASY TO OPERATE
 HELPS IN CLEANING THE ENVIRONMENT
Disadvantages of Electrostatic Precipitators
 SOME PRECIPITATORS ARE EXPENSIVE TO USE
 SOME OF THEM REQUIRE HIGH MAINTENANCE AND
INSTALLATION
 ALSO REQUIRE LARGE SPACES TO OPERATE

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 Conclusion

 INDUSTRIAL SMOKE AND FUMES IS THE BIGGEST CAUSE

OF AIR POLLUTION.
 THESE POLLUTANTS ARE THE CAUSE OF MANY
ENVIRONMENTAL AND HUMAN HEALTH ISSUES.
 ELECTROSTATIC PRECIPITATORS ARE INSTALLED IN THE
WAY OF FURNACES AND CHIMNEYS OF INDUSTRIES.
 ELECTROSTATIC PRECIPITATORS ARE USED TO PURIFY
THE FLUE GAS EMITTING FROM THE INDUSTRIES.
 THESE PRECIPITATORS WORK ON THE PRINCIPLE OF
ELECTROSTATIC FORCE AND CHARGE THE PARTICLES.
 SPECIALLY DESIGNED FOR CAPTURING THE PARTICULATE
MATTERS FROM THE FLUE GASES.
 THE NEGATIVELY CHARGED PARTICLES GET ATTACHED
TO THE POSITIVE PLATES AND THEN COLLECTED IN THE
HOPPERS.
 THESE PRECIPITATORS HAVE AN EFFICIENCY OF 99% IN
PURIFYING THE CONTAMINATED GAS.
 CERTAIN FACTORS ARE INVOLVED IN AFFECTING THE
EFFICIENCY OF THE PRECIPITATORS SUCH AS
TEMPERATURE, AIR FLOW AND SPECIFIC RESISTANCE.
 THERE ARE MANY DIFFERENT TYPES OF ELECTROSTATIC
PRECIPITATORS DESIGNED ACCORDING TO ITS FUNCTION.
 COMMONLY USED ELECTROSTATIC PRECIPITATOR IS
PLATE WIRE ONE.
 ALMOST ALL OF THESE WORK WITH PARALLEL
CONFIGURATION BUT TWO STAGE PRECIPITATORS WORK
ON SERIES CONFIGURATION.

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