BASICS OF ELECTROSTATIC PRECIPITATOR

and
SIZING OF PRECIPITATORS
D.VISUVASAM

Deputy General Manager/AQCS, BHEL, Ranipet e.mail: dvisuvasam@bhelrpt.co.in

VENUE

BHEL Ranipet , Tamilnadu 12-11 -2008

ATMOSPHERE

This figure is now closer to 0.038%

Important!

AIR POLLUTION

ELECTROSTATIC STATIC PRECIPITATORS

Designed, manufactured, supplied, installed & commissioned precipitators for green field applications for utility boilers up to 800 MW as well as for Industrial applications like steel, Cement, paper, Glass and Biomass.
Up-gradation of older precipitators to present emission. Capability exists for 1000 MW boiler ESPs.

ADVANTAGES OF ELECTROSTATIC PRECIPITATORS

VERY HIGH COLLECTION EFFICIENCY

LOW PRESSURE DROP CAPACITY TO COLLECT SUB-MICRON PARTICLES ROBUST CONSTRUCTION - LONGER LIFE LESS MAINTENANCE ADAPTABILITY

ELECTROSTATIC PRECIPITATOR WORKING PRINICIPLE

ELECTROSTATIC PRECIPITATOR WORKING PRINCIPLE

THE PRECIPITATION PROCESS INVOLVES 4 MAIN STEPS. CORONA GENERATION PARTICLE CHARGING PARTICLE COLLECTION REMOVAL OF PARTICLES

PRINCIPLE

CORONA DISCHARGE IN SPIRAL ELECTRODE

ELECTROSTATIC PRECIPITATOR SIZING

PRECIPITATOR DESIGN DATA

COLLECTION EFFICIENCY
INLET DUST LOADING. OUTLET DUST LOADING.

SPECIFIC COLLECTION AREA

GAS FLOW.

MIGRATION VELOCITY APPLICATION GAS TEMPERATURE

ASH CHEMISTRY. GAS ANALYSIS. DUST PARTICLE SIZE DISTRIBUTION. GAS MOISTURE. PARTICLE SHAPE. ASH RESISTIVITY. COAL SULFUR. VOLTAGE WAVE FORM .

ADDITIONAL DATA CONSIDERED FOR ESP SELECTION

NO. OF ESPS PER BOILER. MINIMUM NUMBER OF FIELDS REQUIRED. MINIMUM SPECIFIC COLLECTING AREA. MAXIMUM GAS VELOCITY. MINIMUM ASPECT RATIO. MAXIMUM AREA CONNECTED TO ONE TR SET. COLLECTING ELECTRODE SPACING.

COMPARISON OF COAL ANALYSIS- TYPICAL

Sl. No 1 2 3 4 5 6

Description Fixed carbon Volatile matter Moisture Ash High Heat Value Hard grove Index

Unit % % % % Kcal/ kg

1970 36.5 25.5 10.0 28.0 4750 50

1980 32.4 21.6 16.0 30.0 4050 50

1990 25.0 18.0 12.0 45.0 3000 50

COAL REQUIREMENT FOR BOILERS TYPICAL

Coal with ash content 45 % and HHV 3000 Kcal / Kg 110 MW Coal required in tph Ash generated tph 95 42.75 210 MW 185 83.25 500 MW 420 189

Ash entering ESP tph

34.2

66.6

151.2

POLLUTION CONTROL LEGISLATION IN INDIA

AS PER CPCBS SPM EMISSION REGULATION JULY 1984 - GUIDELINES : BOILER SIZE PROTECTED AREA OTHER AREA NEW (AFTER 1979) 350 mg/Nm3 150 mg/Nm3

OLD (BEFORE 1979) < 210 MW > 210 MW 150 mg/Nm3 150 mg/Nm3 600 mg/Nm3 ---

AS PER NOTIFICATION Dt 19 05 1993, BY MINISTRY OF ENVIRONMENT AND FOREST : SPM EMISSION : 150 mg/NM3

AS PER NOTIFICATION Dt 28 03 2003, BY MINISTRY OF ENVIRONMENT AND FOREST : SPM EMISSION : 100 mg/NM3

20 to 50 mg/NM3 IS BEING FOLLOWED FOR MOST OF THE NEW PROJECTS.

ESP SIZING THEORY

COLLECTION EFFICIENCY

= (Inlet dust outlet dust)/Inlet dust =(60-0.1)/60 X100 %

= 99.83 %

ESP SIZE Vs EFFICIENCY

ESP COLLECTION EFFICIENCY Vs SIZE 2.0 1.9

COMPARITIVE ESP SIZE

1.8 1.7 1.6 1.5 1.4 1.3 1.2 1.1 1.0 99.00 99.10 99.20 99.30 99.40 99.50 99.60 99.70 99.80 99.90 100.00

COLLECTION EFFICIENCY %

ESP SIZING THEORY

DEUTSCH - ANDERSON EQUATION Collection Efficiency = 1 - e - w. SCA where, w = Migration velocity SCA = Specific Collecting Area

Migration Velocity
The velocity with which the dust particle travel towards the collecting electrode under the influence of electric field.

Specific collecting area

Amount of collecting area required per m3/s. gas flow.

DEFINITIONS

Flue gas velocity, m/s

Flue gas flow in m3 ESP effective cross section m2

Treatment time, sec

Effective length of ESP in m Flue gas velocity in m/s

Aspect ratio

Effective length of ESP Collecting electrode height

EFFECT OF GAS VELOCITY

Gas velocity
VELOCITY IS DECIDED BY THE GAS FLOW AND COLLECTION EFFICIENCY REQUIRED

HIGHER THE GAS VELOCITY, HIGHER THE CARRYOVER OF DUST PARTICLES WITHOUT COLLECTION - RE-ENTERTAINMENT VERY POOR VELOCITY ALTERS THE FLOW DISTRIBUTION AND EFFECTS SETTLING OF DUST PARTICLES OPTIMUM VELOCITY DEPENDS UPON THE APPLICATION -WILL IMPROVE THE PERFORMANCE.

EFFECT OF TREATMRNT TIME

TREATMENT TIME

TIME AVAILABLE FOR CAPTURING THE DUST PARTICLE. MORE TREATMENT TIME AT REASONABLE VELOCITY IMPROVES THE COLLECTION EFFICIENCY. PROBABILITY OF CAPTURING THE RE-ENTRAINED PARTICLES IMPROVES WITH TIME.

EFFECT OF ASPECT RATIO

ASPECT RATIO

DURING THE RAPPING, THE FALLING OF DUST PARTICLE TAKE A TRAJECTORY FORM. LOWER THE ASPECT RATIO, THE TRAJECTORY DUST TRAVEL ALONG WITH GAS FLOW WITHOUT FALLING IN TO HOPPERS - LEADS TO RE-ENTRAINMENT LOSS. HIGHER THE RATIO, PERFORMANCE WILL BE GOOD. OPTIMUM ASPECT RATIO DEPENDS ON ALLOWABLE VELOCITY, REQUIRED COLLECTION EFFICIENCY AND AVAILABLE SPACE.

EFFECT OF HIGH ASH COAL IN ESP

INCREASED INLET DUST CONCENTRATION. HIGHER GAS FLOW. HIGHER EMISSION FOR A GIVEN DESIGN PARAMETERS. REQUIRES MORE NUMBER OF FIELDS. EROSION OF INTERNALS. ASH HANDLING SYSTEM PROBLEMS.

PARAMETER VARIATION EFFECT ON ESP PERFORMANCE

Parameters Gas velocity Aspect ratio Treatment time Moisture in gas Gas sneakage Gas distribution Reentrainment Variation Performa nce Remarks

ASH COLLECTION AND STAGE EFFICIENCY IN ESP

MERITS OF BHEL ESPS

RIGID CASING WHICH CAN TAKE UP EXTERNAL AND INTERNAL LOADS WITHOUT DEFORMATION. INLET AND OUTLET SCREENS WHICH GIVE UNIFORM FLOW DISTRIBUTION INSIDE ESP BAFFLE ARRANGEMENT TO PREVENT SNEAKAGE OPTIMUM FLOW DISTRIBUTION ACHIEVED THROUGH FLOW MODEL TEST AT LABORATORY. WIDER ACCESS SPACE BETWEEN THE FIELDS ENABLING EASY ACCESS AND MAINTENANCE WIDE EXPERIENCE AND HENCE BETTER KNOWLEDGE OF INDIAN FLY ASH CONDITIONS HIGH AVAILABILITY PROMPT AFTER SALES SERVICE

MERITS OF CONTROL SYSTEM FOR ESPs

IMPROVED MICROPROCESSOR BASED CONTROLLERS WITH INTERMITTENT CHARGING AND BASE CHARGING REDUCED CORONA POWER CONSUMPTION IMPROVED PERFORMANCE WITH HIGH RESISTIVE DUST NT BASED INTEGRATED OPERATING SYSTEM (IOS) SUPERVISING AND CONTROLLING ESP FROM PLANT

CONTROL ROOM
DATA LOGGING

NEED FOR RETROFITTING

POLLUTION NORMS CHANGED FROM

600 100

mg/Nm3.

CHANGE IN COAL PROPERTIES 4750 -3000 Kcal/Kg.

CHANGE IN BOILER BEHAVIOUR.

CHANGE IN PRECIPITATOR CONDITIONS ( OLD/IN-EFFECTIVE INTERNALS). INTRODUCING THECHNOLOGICAL ADVANCEMENTS.

VARIOUS OPTIONS
REHABILITATION OF MECHANICAL AND ELECTRICAL SYSTEM. SUPPLEMENTING SPECIFIC COLLECTION AREA

- Adding additional fields.

- Increasing the height of the collecting electrode. - Adding series ESPs. - Adding parallel ESPs. REBUILDING PRECIPITATORS. CONVERSION OF PRECIPITATOR INTO BAG FILTER. FLUE GAS CONDITIONING. BLENDING OF COAL. - SHORT TERM SOLUTION.

BASIC PRINCIPLE OF OPERATION OF BAG FILTER

BAG ON TUBE SHEET

PULSING IN ACTION

GENERAL

DATA

PHYSICAL FLOW MODELLING

CFD MODELING

FLOW DISTRIBUTION BETWEEN INLET AND OUTLET

BHEL/ RANIPET POLLUTION CONTROL PRODUCTS and SERVICES

HIGH EFFICIENCY PRECIPITATORS. FABRIC FILTERS.

ASH HANDLING SYSTEM.

FLUE GAS CONDITIONING SYSTEM. FLUE GAS DESULPHURIZATION SYSTEM.

COMPLETE RETROFITTING OF PRECIPITATORS.

CONDUCTING RLA AND PERFORMANCE EVALUATION TEST. POLLUTION CONTROL CONSULTANCY. FLOW MODELING AND CFD MODELING.

APPLICATION:

ESP - BHEL EXPERIENCE

CAPABILITY:
- GAS FLOW UP TO 4,36,7016 M 3 / HOUR

- POWER STATIONS UP TO 660 MW - CEMENT, STEEL & FERTILISER INDUSTRIES

- PULP & PAPER & SUGAR PLANTS

- CHEMICAL RECOVERY BOILERS - BIO MASS APPLICATIONS - GLASS INDUSTRY

- EMISSION LEVEL AS LOW AS ~20 mg / NM 3

AND COLLECTION EFFICIENCY AS HIGH AS 99.97% AND ABOVE

COMPLETE TURNKEY SYSTEM:

- DUCT WORK AND DAMPERS - SUPPORT STEEL STRUCTURES - THERMAL INSULATION

FUEL RANGE:
- INDIGENOUS / IMPORTED COAL - LIGNITE

- PITH
- BAGASSE - RICE HUSK / RICE STRAW - BARK & ALL LOW GRADE FUELS

- COMPUTERISED MANAGEMENT SYSTEM

Thank You