Principles of Design on Electrostatic Precipitators

K.Suresh Kumar ESP Consultant

 Bachelors Degree in Electrical & Electronics Engineering from Guindy Engineering College (Presently- Anna University), Madras University, Chennai, Tamilnadu, South India. Obtained the degree in June 1975

K.Suresh Kumar ESP Consultant

 From 1976 to 2003 with BHEL ESP Group From 2003 to date continue to be in the same field Expertise in Sizing & Selection of ESP for a whole range of applications, bagasse, coal, biomass, steel, cement, paper, soda ash etc. Expertise in gas distribution and model studies and CFD analysis

K.Suresh Kumar ESP Consultant

K.Suresh Kumar ESP Consultant

Electrostatic Precipitator (ESP) is an emission-control unit designed to trap and remove dust particles from exhaust gas stream of an industrial process. For example

K.Suresh Kumar ESP Consultant

K.Suresh Kumar ESP Consultant

K.Suresh Kumar ESP Consultant

K.Suresh Kumar ESP Consultant

K.Suresh Kumar ESP Consultant

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Selection & Design

WE ARE AWARE THAT ESP PERFORMANCE IS DEFINED BY THE EQUATION:

Efficiency = 1- e -W . A/Q WHERE : Efficiency = (dust inlet dust outlet)/ Dust inlet

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Selection & Design

W in the above equation is the migration velocity A is the Collecting area required for the given efficiency Q- is the gas volume that is to be handled by the ESP

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 So to design an ESP we need to have the following minimum data: W - Migration velocity / the type of dust that is to be collected Inlet dust loading Outlet dust emission Gas Volume Knowing which we can calculate the Collecting area to be provided in the ESP

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This is where the core of the design is It is dependent on: Dust chemistry Particle size ditribution Electric field strength Gas viscosity

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 This migration velocity may be determined by the equation w = qEp / 6r Where q = particle charge Ep = Field strength = 3.14 = gas viscosity r = radius of particle
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 That is theoritical. In practice the migration velocity for various dust is determined in the laboratory on a pilot ESP. Much work has gone in this for many decades. Migration velocities for various dusts have been determined. This again depends on the process and also on the chemistry of dust.

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Chemical composition
Austrailia n ash S 18 0.7 Canadia n 14 0.25 Australia n2 12 0.4 USA 10 1.1 Polish 13.5 0.9 lignite 10.42 1.81 lignite 10 3 Imported 6.21 0.39 Indian 45 1 Indian 2 50 0.38

p2o5 Sio2 Fe2o3 Al2o3 Tio2 Cao Mgo So3 K2o Na2o Lio2

+ + + + + + +

0.1 67 0.75 26 1 0.3 0.2 0.02 2.5 0.12 0.01

0.4 56 3 29 1.4 3.4 1.6 3 1.2 0.3 0.02

0.05 63 4 27 0.8 0.5 0.8 0.02 1.5 0.6 0.02

0.7 53 6 31 1.6 1.5 1.1 1.2 2.9 0.4 0.05

0.3 48 7.5 26 1.1 5.5 3.5 5.5 2.5 0.8 0.01

traces 35 18.5 19.5 <1 10.5 0.1 ..08 0.13 2.5 -

traces 36 27 22 <1 11.5 0.2 0.12 0.19 2.7 -

0.1 35 15 25 0.9 10 4 8 1 1 -

0 60.5 5.19 29.21 1.7 0.22 1.13 0 0 2.05 3.24 3.24 73.84 13.68 9.19 0.05 3.24 0.05

wk

10.2

20

30

37.7

51

35

35

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 The design of ESP is basically determining what is the collection area that is to be provided. For this we have to know what is the efficiency required This is determined from the inlet dust and the emission required by the equation Efficiency = (dust inlet dust outlet)/ Dust inlet

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 The efficiency is known. Then from the eqn. Efficiency = 1- e -W . A/Q We can calculate the Area A if we know the gas volume Q and the migration velocity w. The gas volume is provided by the process designer / owner. Migration velocity is known by the ESP designer.

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 From experience it is seen that the manner in which this collection area is physically arranged in an ESP has an effect in its performance. The collecting area can be increased by increasing the height of collecting plate, increasing the width of ESP, - increasing the length of the collecting system increasing the number of rows of collecting plates the width of esp. . along

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 WHILE PHYSICALLY ARRANGING THE REQUIRED COLLECTING AREA THE FOLLOWING ARE TO KEPT IN MIND: - ASPECT RATIO - GAS VELOCITY - TREATMENT TIME - ELECTRODE SPACING - FIELD SIZE
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 This is the ratio of effective height of collecting electrode vs the effective length of collecting system. As the height increases AR reduces for a given Collecting area.

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 GAS VELOCITY IS AN IMPORTANT PARAMATER. FOR EACH TYPE OF DUST THERE IS A VELOCITY BEYOND WHICH REINTRAINMENT OF COLLECTED DUST TAKES PLACE. FOR BAGASSE / COAL THE VELOCITY SHOULD BE LESS THAN 1M/S A GOOD DESIGN PRACTICE WOULD BE TO KEEP IT BELOW 0.8 TO 0.9 M/S SITE STUDIES HAVE SHOWN THAT IT IS NOT POSSIBLE TO OBTAIN EMISSION LEVELS LESS THAN 100MG/Nm3 IF GAS VELOCITY IN ESP EXCEEDS 1 M/S

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 Treatment time. This the the total period of time in seconds that the gas is under the effect of active fields. For coal fired boilers the treatment time around 15 to >30 seconds would be required for an emission less than 50mg/Nm3 This depends on the efficiency requirement.

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 THE COLLECTING ELECTRODE SPACING IS AN IMPORTANT FEATURE. THE COLLECTING AREA REQUIRED FOR A GIVEN PERFORMANCE WITH A HIGHER SPACING IS LESS THAN THAT REQUIRED WITH A LOWER SPACING IF THE COLLECTING AREA REQUIRED WOULD BE 100 SQ.M FOR 400MM SPACING THEN IT WOULD BE 133 SQ.M FOR A 300MM SPACING .
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 Field size is limited from electrical design aspect. Very large fields could mean large disturbances during sparking etc. This would be bad both from performance point of view and also from life of electrical components.
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ESP EFF 100.5 100 99.5 99 98.5 98 97.5 0 50 100 150 200 250 ESP EFF

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Company 1 2 3 Gas flow m /s 103 Inlet Dust gms/Nm3 6 Number of fields 4 Length of field 3.4 Height of field 11 Width of field 8.4 Spacing between Electrode rows 400 SCA (area provided per unit gas volume) 60 Treatment time 12 Aspect Ratio 1.30 Gas velocity m/s 1.19 Emission mg / Nm3 100

103 6 4 3.4 11 8.4 300 80 Higher for 300 12 1.30 1.19 100

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julie flora Gas Flow 28.02

Coal 16.34

70% Groun Cotto 70% GNS+ d nut n CS+30 30% shell stalk % JF JF. 31.34 34.8 36 30.44

50% 70% JF+50 JF+30 % CS % L. 31.43 22.93

gastemp
Inlet dust Emission Efficiency SCA Coll area

160
5.68 0.075 98.67 48.17 1350

160
16 0.075 99.53 103.2 1687.

160
3.54

160
2.11

160
3.34 0.075 97.75 37.91 1365

160
4.08 0.075 98.16 44.34 1350

160
2.98 0.075 97.48 40.08 1260

160
2.11 0.075 96.44 37.67 864
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0.075 0.075 97.88 96.44 43.07 38.62 1350 1344

K.Suresh Kumar ESP Consultant

Specification
Specifying an ESP requirement: 1. Gas Volume m3/s or Nm3/s 2. Inlet dust loading gms / Nm3 3. Outlet emission mg/Nm3 4. Efficiency % 5 Spacing mm 6 SCA m2/m3/s 7 Gas velocity m/s 8 Type of dust Coal ash, Biomass ash, cement, steel Sponge iron, soda ash, etc

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Sizing
Knowing the parameters and dust to be handled you work out the collecting area Then decide the cross-section required to get desired velocity in chamber Then decide number of fields to accommodate the collecting area.

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How to get the best? ---1

Give the parameters viz gas volume, gas temp., inlet dust loading, outlet emission required to various ESP vendors. Make a thorough analysis before arriving at these parameters. Verify how the different coals (diffrenet Carolific values and ash content) will effect boiler operation and resulting gas volumes and inlet dust to ESP. The worst conditions volume and inlet dust contents should be considered as inputs for ESP selection.

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How to get the best? ---2

Obtain technical offers from the vendors. Compare the technical offers for 1. Gas Volume, inlet dust loading, outlet emission, efficiency 2. SCA, Collecting area,electrode spacing, gas velocity, no.of fields, aspect ratio etc. 3. Identify the best technical offer (1.highest SCA with a given electrode spacing, 2. higher no. of fields, good gas velocity etc) 4. Now ask all vendors to give their priced offer for the selected technical particulars. 5. Now you can get the best price for the best technical equipment.

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