INCREASING THE EFFICIENCY OF

Upgrades for Tumbling-Hammer ESPs YOUR EUROPEAN-DESIGNED

PRECIPITATOR

CLASSIC EUROPEAN DESIGN...IMPROVED BY BHA

EUROPEANS HAVE A FLAIR FOR DESIGN. Some of the world’s finest products are
produced there. European designed precipitators are no exception - almost all
are exceedingly rugged and efficient. But as they age, or as the demands placed
on them are increased, weaknesses in the European design emerge. There’s a lot
of wasted space inside that could be used for collection. The internal rapping
systems (known as “tumbling hammers”) wear out and become ineffective.
Tumbling-hammer precipitators usually have very large electrical sections. When
sparking occurs in these large sections, emissions increase. And, as the discharge
electrodes become corroded or eroded from sparking, failures occur - and they’re
very hard to locate, reach, and remove. Worn tumbling hammer precipitators are
notoriously difficult to repair, due to the lack of access between the collecting
plates. Keeping these precipitators functional can become a real maintenance
nightmare, especially after they’ve been in service for several years.

BHA HAS A FLAIR FOR DESIGN, TOO. Some of the world’s finest precipitator
products are designed and manufactured by BHA. We have the solutions to the
common problems encountered with tumbling hammer precipitators.

BHA OFFERS YOU THE SOLUTION TO COMMON TUMBLING HAMMER DESIGN PROBLEMS
FOUR-POINT SUSPENSION requires significant space inside and outside the precipitator.
The discharge electrode frames are suspended from support insulators at the four corners of
each field. The frames usually carry the discharge electrode hammer systems, as well. The
entire assembly uses valuable space between fields that could be used for gas treatment.

TUMBLING-HAMMER MECHANISMS also waste space within the treatment zone. Up

to 30% of the area in the casing of a tumbling-hammer precipitator is taken up by the
internal DE frames and the tumbling hammer systems. The BHA solution utilizes
this wasted space, and provides easily adjustable custom rapping for each section of
the precipitator. Tumbling hammer systems often become damaged or misaligned.

ACCESS TO INTERNAL COMPONENTS is very limited. In most designs, it is nearly

impossible to climb over the tops of the collecting plates, which are mounted to supports
under the roof of the precipitator. This makes reaching the center of the fields very
difficult. It is hard to even see the interior of the fields, and routine inspections and
repairs can become arduous tasks.
The BHA Solution Areas shown in red are part of
the solution supplied by BHA
2

This sketch shows BHA’s approach to 1

upgrading tumbling hammer ESPs. One
1 3
field of this four-field precipitator was
3
converted by BHA into an externally-
rapped design. The conversion provides an
extra electrical field, more collection surface,
more reliable rapping, durable rigid discharge
electrodes, and greater ease of maintenance.
1
Some highlights of the improved design are
listed below:
Four-point suspension is replaced using support insulators
positioned over the center of the electrical fields. This yields
1 more space at the leading and trailing edges of the fields that is 2 4
used to increase collecting surface area.

Tumbling-hammer configuration is removed and replaced by

2 externally-mounted rappers on the roof. These rappers require no
space between fields for installation within the precipitator.

In the BHA design, collecting plates are suspended from replacement roof beams, providing space to access the center of the fields from the top. It is much
less difficult to reach the middle of the collecting fields to remove failed discharge electrodes or perform other maintenance. Plus, the new electrical
3 fields are much smaller. When sparking occurs, it shuts down only a small percentage of the precipitator while the spark is being quenched. This means
the precipitator operates more efficiently under all conditions, and can be kept working well through easy, routine maintenance.

The new rapping systems have no moving parts inside the precipitator, so dust-laden gas will not affect operation or cause abrasion. There are no
4 bearing surfaces to wear, and no hammers to flatten and become misaligned. Rapping impact force and frequency can easily be changed by adjusting the
rapping programs through software. The external rapping system can be maintained and adjusted without shutting down the precipitator.

EXTERNAL ELECTROMAGNETIC RAPPERS

External rappers can be serviced and inspected while the
unit is in operation. Rapping problems can be pinpointed by
checking rapper control and voltage control readings.
Individual rappers are linked through a rapper control
computer, and can be programmed to strike with greater or
lesser intensity and frequency, as needed.

CENTRALLY LOCATED SUPPORT INSULATORS

The insulators that support the discharge electrode (DE)
frames are located directly over the center of the frames.
There are two advantages to this design: first, it is easy to
create two (or more) high-voltage bus sections for each
mechanical field; second, the mechanical fields can be
installed very close together to utilize all the available space
within the precipitator casing. This means greater efficiency.

RUGGED RIGID DISCHARGE ELECTRODES

BHA supplies a variety of DE styles suited to any type of precipitator in any application. Rigid discharge electrodes have
emitter pins welded to a strong mast. The emitters can be custom positioned to create ideal electrical characteristics.
Different pin spacing can be used for different fields, reflecting the varying dust concentration from inlet to outlet. Not
only is performance maximized, but the rigid DEs are far more rugged, and will not quickly wear or break like wire
electrodes can.
 The BHA Solution
Use of insulator compartments and smaller, individual
electrical frames allows the creation of responsive electrical
sections that are much less affected by sparking. Sections
can be removed from service to correct problems without
impacting the rest of the precipitator.

Access doors in roof allow maintenance personnel to enter

the de-energized precipitator to perform maintenance, even
at the center of the mechanical fields. Tasks that would be
impossible in the original tumbling hammer design become
easy and fast.

Roof mounted electromagnetic rappers have no moving

parts inside the precipitator. Rappers can be maintained
without taking the precipitator off-line, and the impact
strength and frequency can be individually adjusted for
precision cleaning and maximum precipitator efficiency.

Top-end frames are assembled on the ground to form a perfect

match to the existing precipitator casing. The new upper
frames provide a solid structural support for the new inter-
nal components and roof-mounted equipment, and provide
extra room to increase total collection surface area.

New collecting plates and rigid discharge electrodes are

custom-made in our factory to fit the new top-end frames.
Field installation is rapid, accurate, and trouble-free.
Collecting electrodes from BHA are the strongest and most
reliable designs available, and will fit any ESP shell.

The footprint of the original precipitator casing remains the

same, while the collecting area inside the shell increases up to
35%. Collection efficiency can be increased significantly, at
much lower cost than building a new precipitator or baghouse
(or adding a new field).

Customers around the world have restored their precipitators’

optimal performance by choosing the BHA top-rapping
conversion. Call BHA for a reference list of satisfied customers.
How a Typical BHA Top-Rap Conversion is Done

STEP 1 STEP 2 STEP 3

The insulator compartments and roof are removed Wall extension frames are assembled on the ground Once the sidewall extensions are installed, new
from the existing precipitator, and the internal for fast and easy installation. The frames are collecting plates are bolted into the pre-hung
components are lifted away. Here, a tumbling lifted onto the existing precipitator, ready for support channels. When collecting plate alignment
hammer frame is being removed. collecting plate installation. Note anvil beams. is completed, the plates are welded in place.

STEP 4 STEP 5 STEP 6

In this view, two precipitators are receiving new Discharge electrode support frames can be pre- The discharge electrode frames rest above the
sidewall extension frames and collecting plates. assembled on the ground, and hoisted at once. collecting plates until the support insulators are
Once the plates are installed, the discharge The discharge electrodes are carefully guided installed. Then they are lifted and aligned in
electrodes can be hoisted and installed. into position between the collecting plates. their final position.

STEP 7 STEP 8 STEP 9

The new insulated roof panels and the support The support insulator compartments are welded The externally-mounted rappers are then
insulator compartments are installed next. Note out, and the roof walking surface is installed. installed. The project is almost complete.
the pre-welded roof penetrations for the rappers. Each new support insulator is housed separately
for easy maintenance.

STEP 10 STEP 11 STEP 12

This shows the interior of a new, completed cell. Viewing a completed gas passage from the top, The top-rap conversion is complete. This Bulgarian
The discharge electrode frames are now supported showing rugged ESP-3 collecting plates and precipitator is equipped with penthouse style
in final position. There is ample room above the DE RDE-1 rigid discharge electrodes. insulator compartments rather than individual
frames and plates for inspection & maintenance. compartments. Both styles are available.
 Top-Rap Conversion Case Histories
Pulp and Paper Mill, Puerto Esperanza, Argentina
Parameter Original Upgraded
Gas Volume 478,000 m3/hr 478,000 m3/hr
Inlet Dust Loading 28 g/Nm3 28 g/Nm3
No. Mechanical Fields 3 3
No. Electrical Fields 3 each 6 each
Total Collecting Plate Area 5,780 m3 7,705 m3
Aspect Ratio 1.58 1.30
SCA, m3/(m3/sec) @300 mm 87.1 116.0
Gas Velocity 0.73 0.70
New top-end frames being hoisted onto paper
Treatment Zone Length 26.7 27.9
mill precipitator during rebuild in Argentina.
Treatment Time, sec. 18.3 19.9

This customer has two ABB precipitators serving the Recovery Boiler. Before the BHA upgrade, there were serious mainte-
nance problems with the tumbling hammer systems, and emissions were too high. One of the units was badly damaged by a
fire, and the remaining unit could operate only at reduced inlet gas flow rates. BHA engineered a top-rap conversion to allow
the customer to increase boiler capacity and reduce outlet emissions. BHA increased collecting plate area 33% and doubled
the number of electrical sections. BHA rebuilt the fire-damaged unit first, and isokinetic testing of the combined gas stream
showed emissions less than 35 mg/Nm3. Performance was so good, the customer chose to rebuild only one field of the
remaining unit, rather than all three. Rapper maintenance requirements have been virtually eliminated.

Cement Kiln Precipitator, Arkansas, United States

Parameter Original Upgraded
Gas Volume, ACFM 260,000 260,000
Inlet Dust Loading 17,500 lbs/hr 17,500 lbs/hr
No. Mechanical Fields 2 4
No. Electrical Fields 2 each 8 each
Total Collecting Plate Area 132,935 sq. ft. 150,650 sq. ft.
Aspect Ratio .86 1.01
SCA, ft 2/1000 acfm @11” 465 579
Gas Velocity 2.35 ft/sec 2.3 ft/sec
Installing new RDE-1 Rigid Discharge Electrodes
Treatment Zone Length 31.44’ 36.33’
during kiln precipitator rebuild in USA.
Treatment Time, sec. 13.4 15.7

Alternate fuels were being burned in this customer’s wet-process cement kiln. Methods for reducing emissions while burning
these fuels were required. BHA converted the tumbling hammer Lurgi precipitator to top-rapping. The upgrade doubled the
number of mechanical and electrical fields, while increasing treatment length and collecting plate surface area about 25%
within the existing casing. The new design offers rapid recovery from sparking due to the smaller electrical sections. The
external top-mount rappers clean small sections, greatly reducing reentrainment and opacity spikes. Emissions tests showed
that even when burning alternate fuels, outlet emissions were less than 0.005 gr./dscf.

Copper Smelting Facility, Leyte, Philippines

Parameter Original Upgraded
Gas Volume 82,220 m3/hr 82,220 m3/hr
Inlet Dust Loading 56 g/Nm3 56 g/Nm3
No. Mechanical Fields 3 3
No. Electrical Fields 3 each 6 each
Total Collecting Plate Area 2,095 m3 2,280 m3
Aspect Ratio 1.32 1.30
SCA, m3/(m3/sec) @300 mm 91.82 99.94
Gas Velocity, m/sec 0.57 0.54
Treatment Zone Length 7.94 m 8.19 m Roof of rebuilt smelter precipitator in foreground
with original units shown in background.
Treatment Time, sec. 14.0 15.23

The smelting process requires maximum performance, reliability, and availability. BHA engineered this top rap conversion that
contains double the electrical sections found in the original design. This customer had serious problems with dust buildups
that decreased performance to the point that the acid plant was affected by excess particulate. Production had to be halted
periodically to clean the precipitator. With the top-rap conversion, these buildup problems have been virtually eliminated.
Plus, the increase in collecting plate area provides a much more efficient, trouble-free ESP.
 BHA’s Top-Rap Design Gives You:
◆ More available collecting surface for increased collection efficiency
- up to 35% more area utilized inside precipitator casing, without
enlarging the overall size of the precipitator
◆ More reliable discharge electrodes
◆ Greatly improved access for maintenance
◆ Ability to maintain rapping system with unit on-line
◆ Enhanced control over rapping to match process
conditions
◆ Site-specific increases in collection efficiency, particle migration
velocity, and ESP power utilization
◆ Better-than-new performance for relatively low cost compared
with a new precipitator or baghouse, or new field addition
◆ Additional electrical fields can be configured for much better response Two tumbling hammer precipitators being converted to
to sparking and dramatic increases in precipitator efficiency BHA’s top-rapping design. These upgrades have been
successfully completed in plants around the world.
◆ Reduced reentrainment of dust due to improved rapping control BHA has more experience with this conversion than
any other precipitator company in the world.

PROVEN RESULTS–INCREASED PERFORMANCE, RELIABILITY, AND EFFICIENCY

Discharge electrodes can be assembled in Closer look at the collecting plate hanger beams Installing roof-mounted rappers near the end
frames on the ground, along with bundles of in the pre-assembled top-end frame. Rapper of a successful top-rap conversion in South
collecting plates, for a minimum of hoisting shaft connection sockets are also shown. America.
and rapid field installation.

BHA’s precipitator field crews consistently achieve the highest EMR safety ratings in the industry.
For additional information, call your BHA account representative at our toll free number, 800-821-2222.

Brazil Tel 55 (011) 7924 3656 Fax +55 (011) 7924 0168
China Tel +86-21-6357-7100 Fax +86-21-6357-5727
Germany Tel +49-2528-300 Fax +49-2528-30100
India Tel +91-20-56-78 500 Fax +91-20-56-78 505
Japan Tel +81 3-5363-6324 Fax +81 3-5363-6325
Philippines Tel +63-2-753-3555 Fax +63-2-753-3565 8800 East 63rd Street • Kansas City, Missouri USA 64133
Spain Tel +34-93-720.7676 Fax +34-93-712.0577 800-821-2222 • +1-816-356-8400 • Fax +1-816-353-1873
www.bha.com • info@bha.com
Switzerland Tel +41-62-386-7777 Fax +41-62-386-7766
United Kingdom Tel 0800 964 984 Fax 0800 731 4461

Bogotá • Mexico City • Monterrey • Sao Paulo • Sydney • Valencia

WORLD LEADER IN INNOVATIVE FILTRATION TECHNOLOGY

P6MK192 Lit. No. 1125 7-29-99