ELECTROSTATIC PRECIPITATORS

1.O NECESSITY OF PRECIPITATION

There are two fundamental reasons which necessitate precipitation of solid parties of solid
partcies from the flue gas emitted out of a chimney stack.

1.1 Emission OF Grit And Dust Depending upon the process, the solid particles may
have various mechanical and chemical characteristics and may crate hazards to health,
corrosion etc. various statutes try to guard against this hazard. The generally accepted
maximum limits for the dust emitted are 0.2 grains/cft for normal grit from boiler b (0.05)
grains/cft for red oxide emission from steel-making process C) 0.01 grains/cft for
poisonous fumes like lead or arsenic.

The quantum of deposition depends up on a no. of factors including a (height of stack, b)

velocity of wind, c) difference between flue gas and ambient temperature, d) density of
ambient air, e) particle size etc.

If the height of the chimney is more, dispersion is more and therefore accumulation of dust
is distributed over a larger area. Similarly large steam velocity, and larger difference in
temp. and density also result in larger dispersion of dust partides.

As regards partied size, smaller the partied, larger is the free falling velocity of partied as
would be evident from the following table.

Partide size in 1000 U 100 10 1 Less than 0.1

Free falling velocity in 10 1 0.05 0.002 Brownian motion partides do
A/Sec. not settle.

This dust deposition per unit area can be reduced, if the particle size emitted out could be
reduced.

1.2 Visual Appearance of plume: Although visual appearance does not cause any hazard to
plant and property, it is objectionable from tow view-points.

a) Aest etics. B) visibility is the surrounding area which may effect movement of vehicular and
air traffic especially when it crates foggy conditions.

For the same concentration of dust obstruction to light is more, if the particle size is smaller as
would be evident from the following table.

Particle size in 8 2.5 1.5 0.15

% light obstructed 5 16 25 95

Specific gravity of ash 4 gm/cm3, concentration rate 0.05 gm/ft3

2.0 Methods of Dust Extraction: Various methods have been adopted to achieve the
objective of separating the dust particles from flue gas which are briefly described as under.

2.1 Cyclonic Separators: The method depends upon the principle of mechanics viz, the fact
that a change of direction in any particulate motion results in imparting of centrifugal force
which has a tendency to move the particle further apart. Heavier the particle, more is the force.
The steam of gas is made to pass through a vessel in a circul fashion. The change in direction of
flow, imparts centrifugal force to solid dust particles, these particles separate out from the flue
gas path and by suitable configuration of venal (called cyclonic operator) are removed.

These separators are very simple in construction requiring very small capital expenditure
compared to other methods. However there is a limit to which the particles can be removed.
Below the particle size of 10 M the method is not very much effective. Another disadvantage of
the method is that pressure doop is considerable on account of vortex flow. On an average, there
is a draft loss of 2.5 to 3 W.C. Thus fan power requirement increases to a considerable extent.
Third disadvantage of this method is that erosion problems are severe, as rejection of dust
particles by centrifugal force inherently results in heavy impingement of dust particles on the
wall of cynonic separator.

It is therefore, justified for small power plants with stoker firing system. Where percentage of
fly ash is less.

2.2 Gravity Settling Chambers : In this method the dust laden gas is permitted to pass
through a large chamber at a very low velocity. Under the action of gravity, the dust particles fall
out of the gas stream. Very low gas velocity helps this process. The method is the simplest of all.
However space required is prohibitive. Moreover very small particles below 100 M cannot be
removed by this method.

2.3 Bag Filter: In this method, the gasses are passed through bags of woven fabric. Silicon
treated glass fiber is the most ideal material on account of maximum operating temp. of the
material. Efficiency of bag filter is very high as it can remove very small particles even upto the
size of 1 M. However its efficiency deteriorates very fast, if blinding (i.e. blocking of porous
portion) occur. Depending upon temp. of gasses and chemical properties of fly ash or smoke, the
acidic corression is also quite prominent. These factors necessitate frequent cleaning, repairs and
replacement. On the other hand development of holes in the filter vitiate its performance
drastically as the hole provides a bye pass.

The greatest drawback of bag filters is its fairly high cost as also the excessive pressure drop
across it (which can be as high as 4-5 inches of W.C.) the later results into large operating cost in
the form of increased fan power requirement and consequent energy consumption.

2.4 Scrubbers And Wet Washer :- In this method, the gasses are passed through a shower of
highly disintegrated water particles. Efficiency o f duct collection is very high and chances of re-
entrainment are very remote. Basic capital cost is also quite low compared to other methods.
The scheme is fundamentally very simple to operate also. Draft loss in the flue gas path is also
fairly low.
However the scheme requires a large quantity of water which has to be at a high pressure to
effect good disintegration. This undoubtedly means large energy consumption for pumping
water. The water gets polluted also and unless it can be safely discharged as an effluent, causes
water treatment problems requiring large scale sedimentation and chemical dosing. The capital
cost of all this plant may far outweigh the basic low cost of the scrubbing plant alone.

Another problem which arises is cooling of gas, resulting in condensation of acidic components
of the gas. This gives rise to acidic corrosion on the downstream side unit of the scrubber. The
resultant lowering of gas temp. results in a highly visible plume. The deposition of dust
particles in the surrounding area also becomes severe on account of poor spreading.

The scrubber has therefore very limited scope of application where water disposal is not a
problem. It is also a highly desirable process where dust in flue gas is valuable and recovery is
economically viable.

2.5 Electrostatic Precipitation :- this method, the flue gas is passes through a highly stressed.
The process of ionization is further accelerated on account of corona discharge. The dust
particles collect charge and get conglomerated to ionized particles. They are therefore attracted
to the electrode system, impinge there and lose their velocity. The factors affecting this process
of precipitation are many and the basic process and its control are quite complex. However, it
has been found that for must of the applications, this is a highly economical system. Draft loss is
minimum (as low as 0.25 of water column). The efficiency of precipitation is very high and
particles as small as 0.1/u can be removed by this process. The technique is quite complex and
calls for a very careful selection of electrode centrifugation spacing, field strength, control
devices etc. design is also not based on any mathematical mode, but on empirical formulae and
tests on proto types.

3.0 Principle Of Electrostatic Precipitation : A system of discharge or emitting electrodes

charged to a very high, negative potential with respect to earth, colliding electrodes are suspend
in the center of the collecting electrode plates. The resulting electrostatic field creates stress in
the media, separating the two sets of electrodes, giving rise to a regulated corona discharge.
When the stream of dust laden gasses is permitted to pass through this highly stressed field, the
dust particles get ionized at negative potential and are attracted towards the earthed electrode.
They loose their charge on these electrodes and in turn, lose their velocity. The configuration of
collecting electrodes is such as to aid the collection of these particles. Some of the particles also
get positively charged, and in turn are attracted to the emitting electrode.

At frequent interwals the electrode system is rapped, by means of a rapping mechanism which
discharges the collected particles into the dust hoppers at the bottom of the precipitator.

4.0 Historical Background : First attempt for electrostatic precipitation was made at a lead
works in North wales by Dr. H.O. walker and Prof. Oliver Lodge at the end of the last century. A
whimshurst machine consisting of 5ft dia plates was used, driven by a 1HP steam engine. The
effect was not very much successful as the equipment did not have much current carrying
capacity. The process is not truly electrostatics on account of the fact that a continuous drift of
changed particles (gaseous/dust ions) exists and gives rise to flow of current.

Moeller in Germany and Conttrell in America did lot of pioneering work in the field. First
commercial operation was commissioned in California is 1910. Many plants utilized the
principle thereafter, for dust collection or recovery processes. The method is adopted for power
stations cement works and for processes where either liquid or solid recovered from gas is
valuable or gas is required in a clean state for use as a fuel

Although there has been enormous developments in this field, precise mechanism of electrostatic
precipitation is far from being fully understood.

5.0 Design Criteria

5.1 Method of Precipitation : In D.C. energized precipitation process, which happens to be the
only currently used method, the material is deposited on either of the electrode systems by
corona discharge. There are two ways in which this discharge is classified.

1. Negative corona wherin discharge electrode is charged to negative polarity.

2. Positive Corona-wherin discharge electrode is charged to positive polarity.

The former is preferred in most of the applications, as negative ions are very much lighter
in weight than positive ions and are subjected to greater acceleration. Hence, they can
carry alongwith them larger proportion of dust particles to collecting electrodes.
Removal of dust is more efficient there and re-entrainment is minimum.

The process used in ESP is called single stage precipitation as ionizing and collection of
dust particles occurs in the some place. Discharge or emitting electrode, therefore, has the
dual function of maintaining a controlled corona condition as also to provide electrical
field necessary to accelerate charged particles towards electrode system. This
complicates the design because these two requirements are contradictory to each other. A
good corona discharge requires non-uniform field, which only can provide the necessary
local concentration of electrostatic field. However high velocity of charged particles in a
direction perpendicular to gas flow is possible only if the field is uniform, failing which
there would be vortices. A balance has therefore to be struck between these two.

Another important aspect of electrostatic precipitation is that, unfiltered, single phase

D.C. supply is preferred over pure and filtered D.C. supply. This is on account of the fact
that occurrence of voltage zero enables any arc to be extinguished quickly. Therefore, in a
modern ESP, single phase, full-wave rectifier is preferred to three phase full-wave
rectifier.

5.2 Classical Theory Of Precipitation : - Although the theories propounded and

equations put forward do not explain fully the complex phenomenon occurring is an ESP,
and cannot be used for design purposes, they give an idea about the mechanism of
precipitation process.

There are basically two mechanism for ionization.

1. creation of charged particles by bombardment of ions, moving under the influence of

electric field.
2. attachment of ions to particles by ion diffusion for particle sizes above 2/u,
bombardment charging predominates. For particles below 0.2/u, bombardment
charging predominates. For particles below 0.2/u diffusion charging is more
 important. According to theoretical calculations 80% of the limiting charge is
obtained by bombardment charging within 1/100 second. This is more than adequate
looking to the contact time of gas in the precipitation zone. This also specifics
maximum limit for gas velocity.

Migration Velocity : - This is defined as the velocity of particles toward the collecting
electrodes. This is directly related to corona and field strength, diamotor of particle and fluid
viscosity. However, in practice, it has been found that particle size, has very little effect on
precipitation efficiency.

Re-Entertainment : This is factor which poses serious limitation to application of classical

theory. The dust particle is likely to rejoin the stream of gas after discharging. This puts a limit
to the efficiency of the precipitation. Although corrections are evolved to cater for re-
entrainment, the entrainment phenomenon is highly probabilistic and depends to a great extant
on configuration of collecting electrodes.

1) Deutsch Formula : -n = 1-e s/dv OR n = 1-e sa/v

2) Rose and wood Fomula : n=1 =e-kx

Where,
S= Effective migration velocity.
1= Field length of precipitator
d= spacing between discharge electrode and collecting electrode.
V= Gas velocity.
A= Total collecting electrode erea.
V= Gas volume/passing thro precipitator per second.

The effective migration velocity is calculated from efficiency of an existing plant and this then is
used to determine other factors in the equation when designing precipitator for similar process.
However this formula can be used only for gas velocity in the neighborhood of the value used for
the test plant. Effort is however made to maintain velocity in this region by suitably sizing the
gas flow path.

If large deviations for gas velocity are contemplate, a prototype, is normally reliable than direct
application of Deutsch formula.

5.3 Type of ESP

1. Dry Mist Type used for non-stocking particles

2. irrigated type flow of liquid (mostly water) in the from of thin field along the collecting
electrode used for sticky particles.

6.0 Requirements:

6.1 Gas velocity : A flue gas velocity of 4 to 5 cft/sec is ideal on the basis of practical
experience. A higher velocity results in re-entrainment while a lower velocity would naturally
call for much bigger installation and hence larger capital outlay.
6.2 Dust Resistivity : Very high dust resistiving results in deterioration in performance of ESP
(more than 2X1010 ohm/cm) due to very low conductivity.

On the other hand, if the resistivity is very low (lower than 10 7 ohm/cm) resulting in high
conductivity, the dust particles deposited on collecting electrodes have an increased tendency for
re-entrainment due to easy ionization.