PRESENTATION

ON
ELECTROSTATIC PRECIPITATOR
FOR 660 MW UNITS
AT
APML , TIRORA
Date: 20/08/2012
* Principle: It consists of four complicated and interrelated
physical processes :

* Gas ionization.
* Charging suspended dust particles.
* Charged dust particles drift toward electrodes.
* Charged dust particles collection.
* Corona effects  Ionization  Separation of ash and
flue gas
 TECHNICAL SPECIFICATION OF ESP at TIRORA
Specification & Type 2 BE 7240 / 4-10 / 30 / 400 / 15 / 9 x 2 x 5 + 2 + 4-G

Working Pressure ± 9800 Pa

Equipment resistance < 235 Pa

Leakage Rate < 1 % (the guaranteed value of design & manufacture)

Number of Column/ Pass 2 units

Number of Chamber per Pass 2 units

Number of Rows per pass 8

Number of Field per pass 40 units

Effective Length of ESP 46.55 m

Effective Cross- sectional Area 720 m2

Flue Gas Temperature 146° C

Flue Gas Velocity 0.79 m / s

Flue Gas Treating Time 58.92 s

Inlet Concentration 71.3 g /N m3

Collecting Efficiency 99.93%

Total Collecting Area 335160 m2
 TECHNICAL SPECIFICATION OF ESP at TIRORA

SCA 296.3 m2 / m3 /s

Number of Hopper 160 units

Hopper Heating Mode Plate Type Electric Heating

Hopper Heating Load 1600 KW

Type of C.E. Plate BE Type

Type of D.E. Wire CS20A needle barbed wire for field no.1 & 2

Type of Insulation : Mineral Fiber Block Insulation in accordance with ASTM C612, Class 3,
and have a density of 144 to 200 kg/m3.
PARAMETER DESIGNED COAL BEST COAL WORST COAL
H2O ( % ) 10 12 11.90
Ash ( % ) 37 28.45 41.5
Fixed Carbon ( % ) 25.4 28.05 23.6
Volatile ( % ) 27.6 31.5 23.5
Carbon ( % ) 41.6 47.8 35.60
Hydrogen ( % ) 2.6 2.95 2.23
Sulphur ( % ) 0.25 0.3 0.45
Nitrogen ( % ) 1.025 1.20 1.22
Oxygen ( % ) 7.2 7.3 7.6
Carbonate ( % ) 0.3 -- --
Phosphorous( % ) 0.025 -- --
Gross Calorific Value ( kcal / 3927 4527 3331
kg )
Grindibility Index 50 53 50

Ref.: ESP O&M manual

 PARAMETER DESIGNED BEST COAL WORST COAL
COAL
Silicon Dioxide (% ) 54.16 51.008 55.72
Aluminium Oxide (% ) 27.62 25.852 26.48
Ferricoxide (% ) 8.04 8.08 7.37
Titanium Oxide(% ) 1.7 1.82 1.80
MAPO(% ) 0.16 0.356 0.26
Calcium Oxide(% ) 3.4 4.176 3.45
Magnesium Oxide(% ) 2.34 2.756 2.25
Sulpher Trioxide(% ) 1.28 2.764 1.35
Distortion Temperature 1140 º C 1136 º C 1180 º C
Hemisphere Temperature 1340 º C 1240 º C 1300 º C
Flow Temperature 1400 º C 1350 º C 1400 º C

Ref.: ESP O&M manual

* Total 320 DE rappers are installed in single pass.
* Negative voltage is provided to DE which ionises the flue
gases.
* Total 912 CE rappers are
installed in single pass.
* Collecting plates are connected
to earth.
* Hopper Heater:
* Designed to maintain the hopper wall above the acid dew point
(normally 120-150 °C) during normal operation.
* Total no. of hopper heaters are 1600.
* Capacity : 0.5 KW
* Resistance :350 Ω

* Insulator Heater:
* Use to remove moisture around support insulators.
* The set value of the thermostat for insulator heating is normally
15-25℃ above the gas dew point.
* Total no. of insulator heater 640.
* Each heater is of 1.0 KW and having resistance 160Ω.
* Advantages:
* It is applied for dust removal from
D.E and C.E.
* Ableto provide even acceleration
with reasonable distribution.
* Adjustable rapping strength,
without lateral shear force, few
internal faults and long service
life.
* All
rapping devices are set up on
the top of ESP and are isolated
from flue gas.
* Working:

*When DC current passes through the coil of rapper,

magnetic force is generated to lift the rapper rod to a
certain height, and then cut off power to disable the
magnetic force so that the rapping rod falls down and
hit C.E plate or D.E frame, which results in rapping
force.
*The strength of rapping force depends on the rapping
height which can be adjusted by changing the intensity
of current passing through the coil and the current
intensity of coil can be adjusted by phase control of
silicon control rectifier.
* Total No. of HV Silicon Rectifying Transformers: 80
* 1.3A/60 KV, 72 Sets
* 1.0A/60 KV, 8 Sets
S.No Parameter Field 10 Field 1 to 9

1 Input Voltage (AC) 415 V / 50 Hz 415 V / 50 Hz

2 Input Current (AC) 208 A 270 A

3 Input Power (AC) 86 KVA 112 KVA

4 Output Voltage (DC) 60 KV 60 KV

5 Output Current (DC) 1A 1.3 A

6 Output Power ( DC) 60 KW 78 KW

 160 numbers of ESP hoppers are distributed in 4
chambers, through A & B flue gas passes.
There are 160 nos. of hoppers placed under the HV field to
contain the ash particles.

Equipments in hoppers:
*Hopper heaters
*Emergency ash discharge valve
*RTD
*Ash level indicator
*Fluidising Pad
 Air
Heater
12 KW
ESP FLUIDISING BLOWER
2 Nos.( 1 W+ 1 S) for one unit
To ESP Fluidising Pads
Capacity- 350 m3/Hr. @ 6 MWC
Air
Heater
12 KW

TEMP: 80-125°C
 APH ESP Hoppers – 160 Nos.
Hoppers
8 Nos.

Wetting Head
Cap. -62 TPH
Water press.-3.5 kg

Collector Tank
Collecting Channel
Seal Box Ash Slurry Sump
Cap. -105 m3 / compartment Drain Sump
for
Ash Slurry
Three Cell P.H.Drain
Collector A.H. Pump House
Ash Slurry Pumps-4 series
In plant
Surge Hopper
Vac. Pump ASH
SILOS , Cap. -1700 MT
Disposal
D-Pump
1 2 3 4 POND
* Here at Tirora, the Fly Ash Handling system is equiped with two types of
evacuation system.

* 1) Dry Fly Ash Collection & Disposal System:

* The function of Dry Fly Ash Handling System is to collect, transport and
store fly ash from outlet of ESP & APH hoppers to Fly ash SILO. The ash
from fly ash silo will be transported away by trucks & wagons.

ESP Hopper ( 160 nos.) & APH Hoppers ( 8nos,) are connected to
the Three Cell Collector Tank
 Vacuum line from vacuum pumps are connected to the Three Cell
Collector.
 Vacuum is created at the three cell collector tank .
 The ash by vacuum action is evacuated from the hoppers .
 The ash goes to the Three Cell Collector - In Plant Surge Hopper
 D-Pump.
 Conveying Air Compressor line is connected to the D-Pump.
 The conveying air acts as force and transports the ash from D-pumps
to the Fly Ash Silos.
 The ash from Silos are loaded to the trucks / wagons with the help
of Rotary Vane Feeder installed below each silo.
* 2) Wet Fly Ash Collection & Disposal System:

* In this system ash from ESP & APH hoppers gets mixed with water , forms slurry
and is transported to ash slurry sump and then to ash pond by means of ash slurry
pumps.

ESP Hopper ( 160 nos.) & APH Hoppers ( 8nos,) are also
connected to Wetting Head at the tower near ESP.
High pressure water line from FA H.P. water pump is connected
the wetting head .
Vacuum line from vacuum pumps are connected to the Collector Tank and ash by
vacuum action is evacuated from the ESP & APH hoppers .
At wetting head by nozzle action vacuum is created which helps in evacuation of
ash from ESP & APH hoppers .
Ash gets mixed with water , converts into slurry and goes to the
collector tank  Seal Box  Ash Slurry Sump.
The slurry from the slurry sump is pumped out to the Ash Pond by
Ash Slurry Pumps ( 2 in series)
* Reference for specifications of pumps and line diagram:

1. APML Drg. No. : TIR1-EPC-AHP-DM-F-001

2. APML Drg. No. : TIR1-EPC-AHP-DM-F-002
ANY QUESTION OR DOUBTS?