ESP , WORKING & ITS

PERFORMANCE
EVONIK NOIDA

EMISSIONS FOSSIL FUELED

PLANT
Fossil-fueled electric-generating plants
emit combustion gases to the
atmosphere that may contain
pollutants in the Gas phase or as
suspended solid or liquid particulates.
Environmental laws and regulations
define and restrict the amounts of the
gas, solid, or liquid pollutants that can
be emitted to the atmosphere.

POLLUTANT EMISSION
Potential air pollutant gas emissions can be
controlled prior to combustion by switching,
blending, or co firing with low sulfur fuels.
In addition, cleaning coal by beneficiation
can reduce pollutants in the fuel.
Pollutants can also be reduced by energy
conservation measures or by increasing plant
thermal efficiency.
The atmospheric emissions control design
should be integrated into the power plant
design so that regulatory requirements are
reliably achieved at the lowest overall cost.

PARTICULATE CONTROL
After combustion, most fossil fuels, excluding natural
gas or liquified petroleum gas, yield residual particulate.
The primary particulate constituents are ash and
unburned carbon.
The ash consists of silica, alumina, and other
noncombustible compounds. The amount of ash varies
widely, sometimes exceeding 50 wt %.
These particulates leave the boiler as bottom ash,
economizer ash, or fly ash.
Bottom ash falls to the bottom of the boiler and is
removed periodically.
Economizer ash generally has larger particle size,
separates from the flue gas, and drops into hoppers for
removal in the economizer area.
Fly ash is relatively small and leaves the boiler
entrained with the flue gas

Typical ash distributions for a

variety of boiler types:

Pulverized coal
Stoker
Cyclone
Circulating fluidized bed

NATURE OF ASH
PARTICULATES
The ash split is a function of the fuel particle size;
boiler temperatures; ash fusion and deformation
temperatures; ash particle sizes, densities, and
shapes; and boiler flue gas velocities.
Stoker-fired units produce the largest particles.
Wall- and corner-fired pulverized coal (PC) fueled
boilers produce smaller, spherical shaped particles.
Particles from cyclone-fired units are also mostly
spherical and are smaller than ash from PC boilers.
Fluidized bed units produce a wide range of particles
that are asymmetrical, non spherical, and shaped
more like crystals

 Knowledge of the boiler type, fuel characteristics,

the resultant fly ash mineral analysis, particle
loading, and particle sizes is essential in the
selection and design of an appropriate particulate
removal control technology.
Electrostatic precipitators and fabric filters are the
most prevalent choices.
The final selection is generally based on economics
and compatibility with the design fuel, operating
conditions, regulatory requirements, and other
pollution control technologies required for the unit.
Guaranteed outlet emissions of particulates in the
range of 50 to 100mgms/ NM3.

PARTICULATE MEASUREMENT
TECHNIQUES
US EPA provides reference test methods Method 5
and 17 that are adequate for determining emission
rates down to 0.001 grains per dry standard cubic
foot (gr/dscf).
These test methods are accurate to very low levels if
the test equipment operator uses the equipment
properly and for a sufficient amount of sampling time.
However, longer tests (required by very low emission
limits) also make maintaining steady-state conditions
more difficult.
Test methods to determine very low emission rates
require continued attention and should be
appropriately planned and configured to furnish
accurate and repeatable data.

ESP; DRY-HORIZONTAL
PLATE TYPE

Bag collector type: long pulsing external filtration type dust collection.
3.2.2 Each boiler is equipped with 2.
3.2.3 Gas rate at collector inlet (per boiler) Design coal 1007m3/s 1280C
worst coal
1015.7m3/s 1250C
3.2.4 Maximum dust content at collector inlet design coal 70.2g/Nm3
worst coal 80.2g/Nm3
3.2.5 When a field is put out, collector outlet maximum dust concentricity
should be no more than 50mg/Nm 3.
3.2.6 Collector inlet gas T: 126
3.2.7 Guaranteed dust collection efficiency 99.95%
3.2.8 Proper resistance electricity bag collector1200Pa under design
conditions
3.2.9 Proper air leakage rate 2%
3.2.10 Field number of each collector: electric collector (2) bag collector (24
sub-sectional houses).
3.2.11 Inlet & outlet number of each collector 2 inlets and outlets
respectively
Inlet & outlet wind direction Inlet & outlet horizontally
3.2.12 It is required by bag collector that when starting boiler and oil is used,
gas would flow through gas duct bypass;

Electrostatic Precipitators

Electrostatic precipitators (ESP) sized for the efficiency

required to meet current particulate emission limits
operate on the full range of utility power plant.
ESPs are the most widely installed utility particulate
removal technology.
ESPs use transformer-rectifiers (T-Rs) to energize
discharge electrodes and produce a high-voltage direct
current(dc) electrical field between the discharge
electrodes and grounded collecting plates.
Particulate matter entering the electrical field acquires a
negative charge and migrates to the grounded
collecting plates.
This migration can be expressed in engineering terms as
an empirically determined effective migration velocity,
but takes place in the turbulent flow regimen with the
particulate entrained within the turbulent gas patterns.

Electrostatic Precipitators

Thus, the charged particles are actually captured when

the combined effect of electrical attraction and gas flow
patterns moves the particulate matter close enough so
that it can attach to the collecting surfaces.
A layer of collected particles forms on the collecting
plates and is removed periodically by mechanically
rapping the plates.
The collected particulate drops into hoppers below the
precipitator and is removed by the ash handling system.
Some particulate is also re entrained and either collected
in subsequent electrical fields or emitted from the
precipitator.
The physical size of an ESP is determined by the required
particulate removal efficiency, the expected electrical
resistivity of the fly ash to be collected, and the expected
electrical characteristics of the energization system.

Specific Collection Area

The ESP size is often measured in terms of
specific collection area.
The specific collection area (SCA) of a
precipitator has units of square feet per
1,000 actual cubic feet per minute (acfm)
of flue gas flow.
The SCA for the required performance can
be determined by using the DeutschAnderson equation, which relates the
collection efficiency (E) to the unit gas flow
rate, the particulate's effective migration
velocity and the collection surface area .

Treatment Time
The treatment time is the amount of time
that the flue gas is within the electric and
collection fields of the ESP.
High efficiency ESPs typically have
treatment times between 7 and 20 seconds.
Shorter times apply to high-sulfur fuels with
higher permissble emissions.
Longer times are required for low-sulfur
fuels with low sodium oxide fly ash contents
or lower permissble emissions.

Flue Gas Velocity

The speed with which the flue gas moves through the ESP is
important in the design and sizing of the ESP.
Higher design velocities result in smaller ESP cross-sectional area
inlets but could result in an undersized ESP with high ash re
entrainment losses and low treatment time.
The most practical design gas velocity with coal fuel fly ash is
around 4 ft/s.
ESPs on oil fueled boilers generally have velocities in the 3 to 4
ft/s range.
Some instances exist where a higher velocity may be appropriate
but typically, higher velocities raise concern about reentrainment
of the collected ash.
Lower velocities are suggested for ash with a high potential for
reentrainment, such as particulate with a high carbon content.
However, the effects of too low a velocity as would be experienced
during low boiler load operation must also be considered.
Too low a velocity in the ESP could result in the flue gas
meandering and possibly allowing ionization of the gas, which
leads to sparkover and performance degradation.

Aspect Ratio
Another way to combat re entrainment difficulties is to
install an ESP with a higher aspect ratio.
The aspect ratio is the ratio of the treatment length
(effective ESP length excluding walkways) to the
collection plate height.
Higher aspect ratios allow the particulate collected at
the top of the inlet collecting plates to reach the
hoppers before exiting the ESP.
Many existing ESPs have aspect ratios of around 0.8 to
1.2. These low aspect ratios may be appropriate for
applications where a problem with re entrainment is not
expected or where regulatory requirements are not
severe.
However, meeting contemporary particulate emission
limits generally necessitates aspect ratios in the range
of 1.2 to 2.0.

Gas Distribution

Optimum particulate removal requires uniform gas velocity

throughout the entire precipitator treatment volume with minimal
gas bypass or "sneakage around the discharge electrodes or
collection plates.
If the flue gas distribution is not even, the particulate removal will
decrease and re entrainment losses will increase in high velocity
areas.
This will reduce overall collection efficiency.
The International Conference of Clean Air Companies (ICAC,
formerly IGCI) developed standards and test methods to define
the minimum acceptable gas flow distribution within an ESP.
These standards are described in IGCI Publication EP-7.
It may be appropriate to require that in addition to meeting IGCI
EP-7 requirements, the flue gas exhibit a root mean square (RMS)
velocity deviation of <15%.
Physical scale models with gas flow measurement studies are
necessary to locate and design flow correction devices that will
permit meeting these standards. The correct fabrication and
installation of these devices within the ESP is also critical.

Electrostatic Precipitator
Control
The objective of the ESP control system is to create
and maintain an electrical field so that the desired
collection of fly ash occurs.
An additional control objective is to minimize power
consumption consistent with performance.
This is accomplished by T-Rs, current-limiting
reactors, and a supervisory control system.
The T-Rs step up the voltage from 480 V to between
25 kV and 125 kV, depending on plate spacing and
particulate electrical resistivity, and convert
alternating current (ac) to direct current (dc). A
An ESP with wide plate spacing requires T-Rs with a
higher voltage rating and more current capability
than an ESP with narrow spacing.

Rapping Systems.
Collecting and discharge electrodes retain
particulate on their surface. If this
material gets too thick, the electrical
characteristics become unstable (spark or
arc over, back-corona, or decrease in
corona generation)and collection
decreases.
Periodic rapping cleans the collecting and
discharge electrodes to ensure the proper
functioning of the ESP.

 During rapping, groups of these electrodes receive short

and generally intense intermittent energy inputs via
rotating hammers, vibrators, or dropped weights.
The resultant shearing acceleration forces cause large
sheets of fly ash to fall from the collecting electrodes into
the hoppers.
If the acceleration forces perpendicular to the plate
surfaces are too large,the fly ash is excessively
reentrained into the gas stream.
The rapping energy is imparted to either the top, bottom,
or side (edge) of the collection plates and discharge
electrodes.
All three locations are successful.

 The online capability to adjust the rapping frequency,

sequence, intensity, or combinations of these parameters to
match changes in load or fly ash properties, may improve
overall collection or electrical efficiency.
This capability is helpful in increasing fuel or operating
flexibility. However, many ESPs with internal and un
adjustable online rapping intensity or sequence designs
operate successfully.
Advances in rapper control technology may increase ESP
efficiency by enhancing the plate and discharge electrode
cleaning to match the rate at which particulate is collecting
in any given mechanical section.
The rapper control system customizes the rapper
sequence, frequency, and intensity by comprehensive
measurements of ESP operating parameters.

Ash Resistivity.
Resistivity is a measure of how easily the ash or particulate acquires an
electric charge. Typical values for resistivity range from 1 x 108 ohm-cm
to 1 x 1014 ohm-cm.
High-resistivity particulate is difficult to remove because it does not
accept a charge easily. Conversely, with very low resistivity particulate,
the collected particles can rapidly lose their charge and become re
entrained.
High resistivity particles require a larger ESP than those with a lower
resistivity.
The effective migration velocity, w, is lower for high resistivity. The ideal
resistivity range for electrostatic precipitation is 5 x 109 to 5 x 1010
ohm-cm. Operating resistivity varies with the flue gas moisture and S03
content, ash chemical composition, and temperature.
The S03 content is the largest single factor affecting the operating
resistivity. The amount of S03 condensed on the fly ash is a function of
the sulfur content of the coal, the amount of oxidation of S02 to S03.
The operating temperature of the ESP. For medium- and high-sulfur
fuels, the particulate's surface S03 resistivity controls precipitation.
For low-sulfur fuels, the volume resistivity, as determined by fly ash
chemical composition, controls precipitation. For these, sodium oxide
above 0.5 wt % has the biggest influence.

ESP CHRACTERISTICS
ESP suppliers have specific major component design features.T hese
include discharge and collection electrodes; gas flow distribution
devices; casing and structural framework; electrical power supply
including controls, high voltage dc distribution, and insulators; and
rapper cleaning systems and controls.
The ESP internal components are top supported to facilitate thermal
expansion.
The major design types are generally characterized by the discharge
electrode and support design.
The early ESP discharge electrodes were wires up to 30 ft long, with
alignment
weights on the bottom end and the top end suspended from horizontal
frames.
These early day US ESP designs, built through the 1970s, became
labeled the "American" or "weighted wire" type. The wires eventually
exhibited breakage due to electrical erosion or fatigue.
A single broken wire can ground a bus section, significantly affecting the
performance and ultimately the precipitator's reliability.

 The wire breakage problem was addressed using relatively short (15 ft
or less) discharge electrode strips (or wires) stretched within vertically
oriented structural support frames.
These designs were labeled "pipe frame," "bed spring," or "mast"
types and were characterized as the "rigid frame" or "European" type.
The Babcock & Wilcox/Rothemule rigid frame precipitator is typical of
this design.
The reliability advantage of the "rigid frame" with no marked wire
breakage versus the lower cost of the "weighted wire" led to the rigid
discharge electrode design.
The rigid discharge electrodes replaced the "weighted wires" in the
"American" design. They are pipes or other light structural members
with points, scallops, or other sharp edges for corona generation.
This design permitted taller and less expensive precipitators with
collection plate heights and discharge electrode lengths up to 50 ft.
The Enelco precipitator with Rigitrode discharge electrodes shown in
Fig. 14-2 is typical of the current American type design.