Flue Gas System ESPs

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Presentation Plan
Electrostatic Precipitator-Basics Working Principle Design and Performance requirements Process variables Components and functions Performance Improvements Disposal of Fly ash Flue gas conditioning Disposal of fly ash system

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ELECTROSTATIC PRECIPATATOR
It is a device which captures the dust particles from the flue gas thereby reducing the chimney emission.
Precipitators function by electrostatically charging the dust particles in the gas stream. The charged particles are then attracted to and deposited on plates or other collection devices. When enough dust has accumulated, the collectors are shaken to dislodge the dust, causing it to fall with the force of gravity to hoppers below. The dust is then removed by a conveyor system for disposal or recycling
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LOCATION OF ESP

ECO

APH
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ESP

CHIMNEY
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TYPICAL SPECIFICATIONS FOR A 200MW UNITS

NUMBER OF PASS PER BOILER NUMBER OF FIELD IN EACH PASS 4 6

EFFICIENCY
PRESSURE DROP mmWC

99.9%
20

GAS FLOW RATE Cu.m/sec

INLET TEMPERATURE DEGREE VELOCITY OF GAS AT ELECTRODE
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312.7
136 0.839 m/sec 32.18 SEC
5

TOTAL TREATMENT TIME

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THEORY OF PRECIPITATION
Electrostatic precipitation removes particles from the exhaust gas stream of Boiler combustion process. Six activities typically take place:

Ionization - Charging of particles Migration - Transporting the charged particles to the collecting surfaces Collection - Precipitation of the charged particles onto the collecting surfaces Charge Dissipation - Neutralizing the charged particles on the collecting surfaces Particle Dislodging - Removing the particles from the collecting surface to the hopper Particle Removal - Conveying the particles from the hopper to a disposal point 24 May 2012 PMI Revision 00 6

ESP
Collector plate Emitter coil

Flue gas

Gas distribution plate

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1.Electron emission
1

ESP PROCESS STEPS Dust layer

2.Dust particle charging
2 3

Collecting electrode, grounded

3.Migration
5.Rapping 4 4.dust collection 5

Discharge electrode with Negative high tension (20-60kV)

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Rapping mechanism
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Components of ESP
Discharge Electrodes Power Components Precipitator Controls Rapping Systems Purge Air Systems Flue Gas Conditioning Emitting Electrodes Collecting Electrodes High Voltage Equipment Rapping Mechanism Hoppers Heaters ALI Gas Distribution Screen Segregating Gates

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EMITTING SYSTEM

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EMMITING ELECTRODE STRUCTURE

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FIXING ARRANGEMENT OF EMITTING ELECTRODE

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EMITTING RAPPING MECHANISM

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Rapping Motor & Mechanism

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EMITTING ELECTRODE
TYPE SIZE TOTAL NO OF ELECTRODE PLATE / WIRE SPACING SPIRAL WITH HOOKS DIA 2.7 mm 29808 150mm

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COLLECTING PLATE ASSEMBLY

ARRANGEMENT

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COLLECTING ELECTRODE

NO. OF ELECTRODE PER FIELD

24

NO. OF PLATES EACH ROW

TOTAL COLLECTING PLATE SP. COLLECTING AREA

6
3456 214.48 Sq.M/Cu.M/sec

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Rapping Mechanism

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Collecting electrodes

Emitting electrodes

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Rapping Mechanism

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Rectifier Transformer

Rapping Motors

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ESP HOPPER

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Working Principle
Emitting electrode
collecting electrode

Weakest field
Weakest field

Strongest field

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Voltage in KV

SPARK

Time in msec

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Components and their function

Discharge Electrodes: Discharge electrodes emit charging current and provide voltage that generates an electrical field between the discharge electrodes and the collecting plates. The electrical field forces dust particles in the gas stream to migrate toward the collecting plates. The particles then precipitate onto the collecting plates. They are typically supported from the upper discharge frame and are held in alignment between the upper and lower discharge frames. The upper discharge frame is in turn supported from the roof of the precipitator casing. Highvoltage insulators are incorporated into the support system. Collecting Plates :Collecting plates are designed to receive and retain the precipitated particles until they are intentionally removed into the hopper. Collecting plates are also part of the electrical power circuit of the precipitator. These collecting plate functions are incorporated into the precipitator design. Plate baffles shield the precipitated particles from the gas flow while smooth surfaces provide for high operating voltage. Collecting plates are suspended from the precipitator casing and form the gas passages within the precipitator
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Components and their function

Power Supplies and Controls :The power supply system is designed to provide voltage to the electrical field (or bus section) at the highest possible level. The voltage must be controlled to avoid causing sustained arcing or sparking between the electrodes and the collecting plates. Electrically, a precipitator is divided into a grid, with electrical fields in series (in the direction of the gas flow) and one or more bus sections in parallel (cross-wise to the gas flow). When electrical fields are in series, the power supply for each field can be adjusted to optimize operation of that field. Likewise, having more than one electrical bus section in parallel allows adjustments to compensate for their differences, so that power input can be optimized. The power supply system has four basic components:

Automatic voltage control Step-up transformer High-voltage rectifier Sensing device

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Components and their function

Gas distribution System: For creating similar gas and dust conditions Uniformity is desired in the following parameters: Gas velocity Gas temperature Dust loading Gas distribution devices, which ensure this, consist of turning vanes in the inlet ductwork, and perforated gas distribution plates in the inlet and/or outlet fields of the precipitator. Rapping Systems : Rappers are time-controlled systems provided for removing dust from the collecting plates and the discharge electrodes. Rapping systems are actuated by electrical, or by mechanical means. Rapping methods include Discharge Electrode Rapping : Discharge electrodes should be kept as free as possible of accumulated particulate Collecting Plate Rapping: Remove the bulk of the precipitated dust
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Components and their function

Hoppers: Precipitator hoppers are designed to completely discharge dust load on demand. Typically, precipitator hoppers are rectangular in cross-section with sides of at least 60-degree slope. These hoppers are insulated from the neck above the discharge flange with the insulation covering the entire hopper area. In addition, the lower 1/4- 1/3 of the hopper wall may be heated. Discharge diameters are generally 200-300mm. The fly ash handling system evacuates the fly ash from the hoppers, and transports the fly ash to reprocessing or to disposal. The ash handling system are designed and operated to remove the collected fly ash from the hoppers without causing reentrainment into the gas flow through the precipitator. The design of the ash handling system allow for flexibility of scheduling the hopper discharges according to the fly ash being collected in these hoppers.
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Components and their function

Ductwork: Ductwork connects the precipitator with upstream and downstream equipment. The design of the ductwork takes into consideration the following: Low resistance to gas flow Gas velocity distribution Minimal fallout of fly ash Minimal stratification of the fly ash Low heat loss Structural integrity
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Design & Performance Requirements

Precipitator performance depends on its size and collecting efficiency. Key design parameters are: Collecting area (use of computer models done for judgment) Gas volume. Electrical power input (Increasing the power input improves precipitator collecting efficiency under normal conditions) Dust chemistry.
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Process Variables
Gas flow rate: Decided by coal quality, boiler load, excess air rate and boiler design. Operates best with a gas velocity of 1-2 m/sec. At higher velocity, particle re-entrainment increases rapidly. If velocity is too low, performance may suffer from poor gas flow distribution or from particle dropout in the ductwork. Particle size and size distribution: Decided by coal quality, the coal mill settings and burner design. A precipitator collects particles most easily when the particle size is coarse. The generation of the charging corona in the inlet field may be suppressed if the gas stream has too many small particles (less than 1 m). Very small particles (0.2 - 0.4m) are the most difficult to collect because the fundamental field-charging mechanism is overwhelmed by diffusion charging due to random collisions with free ions.
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Process Variables
Particle resistivity: Influenced by the chemical composition and the gas temperature. Resistivity is resistance to electrical conduction. The higher the resistivity, the harder it is for a particle to transfer its electrical charge. Resistivity is influenced by the chemical composition of the gas stream, particle temperature and gas temperature. Resistivity should be kept in the range of 108 1010 ohm-cm. High resistivity can reduce precipitator performance. For example, burning reduced-sulfur coal increases resistivity and reduces the collecting efficiency of the precipitator. Sodium and iron oxides in the fly ash can reduce resistivity and improve performance, especially at higher operating temperatures. On the other hand, low resistivity can also be a problem. For example unburned carbon reduces precipitator performance because it is so conductive and loses its electrical charge so quickly that it is easily reentrained from the collecting plate.

Gas Temperature:The effect of gas temperature on precipitator collecting efficiency, given its influence on particle resistivity, can be significant
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Corona Power
The separation of particles from the gas flow in an electrostatic precipitator depends on the applied corona power. Corona power is the product of corona current and voltage. Current is needed to charge the particles. Voltage is needed to support an electrical field, which in turn transports the particles to the collecting plates. In the lower range of collecting efficiencies, relatively small increases in corona power result in substantial increases in collecting efficiency. On the other hand, in the upper ranges, even large increases in corona power will result in only small efficiency increases. Optimum conditions depend upon optimizing the following: Uniformity of Gas velocity Fly Ash: Particle size & Resistivity Voltage Controls: Spark rate setting, Current & voltage limits Plate spacing, Collecting plate & discharge electrode design 24 May 2012 Frequency & intensity of Rapping PMI Revision 00

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Performance Improvements
Improvement or optimization of precipitator operation can result in significant savings Combustion process conditions mainly affect the corona power level. The primary contributors to combustion process conditions and their effects include:

Coal Bituminous coals, sub-bituminous and lignite coals from different

mines are substantially different from each other in the combustion process. Coal blending is now used for operational and financial benefits. This results in a wide range of boiler and precipitator operating conditions. Precipitating fly ash from difficult coals can be improved with conditioning systems. However, the furnace and its associated equipment can still cause problems in the precipitator, particularly coal mills, burners, and air pre-heaters

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Performance Improvements
Coal Mills The setting of the coal mills and classifiers defines the coal particle size which in turn impacts the fly ash particle size. Larger coal particles are more difficult to combust, but larger fly ash particles are easier to collect in the precipitator. Furnace Base-load operation of the boiler is usually better for precipitator operation than swing-load operation due to more stable operating conditions Furnace : Base-load operation of the boiler is usually better for precipitator operation than swing-load operation due to more stable operating conditions. Boiler operation at low loads may be as problematic for the precipitator as operating the boiler at its maximum load level, due to fallout of fly ash in the ductwork, low gas temperatures, and deterioration of the quality of the gas velocity distribution. If low load operation cannot be avoided, the installation of additional gas flow control devices in the inlet and outlet of the precipitator may prove beneficial
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Performance Improvements
Coal Burner The operation of coal burners, together with the setting of the coal mills and their classifiers, affects the percentage of unburned carbon (UBC) in the fly ash. The use of Lo-NOx burners increases this percentage, and causes re-entrainment and increased sparking in the precipitator. Further, the UBC tends to absorb SO3, which in turn increases the fly ash resistivity. Over-fire air optimization or coal-reburn systems may reduce UBC in the fly ash. Air Pre-heater Regenerative air pre-heaters cause temperature and SO3 stratification in the downstream gas flow. Flue gas conditioning systems may be used to equalize the gas flow characteristics. Air Pre-heater Regenerative air pre-heaters cause temperature and SO3 stratification in the downstream gas flow. Flow mixing devices may be installed in the ductwork to the precipitator, or flue gas conditioning systems may be 24 May 2012 PMI characteristics 38 used to equalize the gas flow Revision 00

DUST REMOVAL
Rapping Mechanism BY Mechanical Impulses OR By vibration of plates Periodicity philosophy

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ESP EFFICIENCY
DEUTSCH - ANDERSON EQUATION
Collection Efficiency = 1 - e - w. SCA
where, w = SCA =

Migration velocity Specific Collecting Area

Migration Velocity
The velocity which the dust particle travel towards the collecting electrode under the influence of electric field. Specific collecting area Amount of collecting area required to be provided to collect dust in gas flow rate of 1 m3/s.
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 IMPORTANT DEFINITIONS:-

Flue gas velocity, m/s =

Flue gas flow in M3per sec ESP effective c/s area m2

Effective length of ESP Collecting electrode height

Aspect ratio

Treatment time, sec = Effective length of ESP in m Flue gas velocity in m/s

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PROCESS PARAMETERS
Excess Air FG Temperature Coal Fineness ECO/APH Hoppers CO Monitors

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REGULAR CHECKS
CRM/ERM checking Hopper Heaters ALI Air Ingress Transformer Inspection BABCON Tuning ALI to CRM trip Protection

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Factors affecting ESP Performance

Particle Size Distribution Gas Speed Particle Resistivity (can change with presence of sulfur, Moisture,temperature) ESP Voltage Levels Re-entrainment of Fly Ash Rapping Frequency Fly Ash Properties. (Cohasive Property) Sparking, back corona and Particle Loading
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Skewed Gas Flow Technology (SGFT)

For any dry horizontal flow precipitator Reduction in particulate emissions between 30% and 60%, average 40% Installed by modifying flow control devices Cost effective - Easily installed No change in precipitator O & M costs
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ELECTROSTATIC PRECIPITATION TWO COMPONENTS

Dust particles carried in suspension are charged electrically and deposited on a collecting surface

The first component of collection takes place on a horizontal plane It results in a layer of dust on the collecting surfaces Much research has been done on this component
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SECOND COMPONENT

The second component of collection takes place on a vertical plane

Dust agglomerates are dislodged and fall downwards

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TWO COMPONENTS
1 2

While in the treatment zone of a typical precipitator, most of the dust travels further in the vertical direction than the horizontal direction Vertical movement has a substantial effect on performance
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PARTICLES AND AGGLOMERATES

60 1 particles 60

2 agglomerates 2 agglomerates

Agglomerates fall and disperse to become particles again Much of the dust is deposited on collecting surfaces more than once before it reaches the hopper Large agglomerates, which would fall further than small ones, result in clouds of heavy concentration These clouds are difficult to collect, penetrate downstream fields, and result in rapping puffs
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NON UNIFORM DUST DISTRIBUTION

Fine particles (<10 microns) tend to be the most difficult to collect due to reintrainment Reintrainment causes the dust concentration at the outlet face to be higher at the bottom than at the top

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Preferred Gas Flow Profile

Skewed Gas Flow optimizes performance by increasing the treatment time in the lower outlet portion of the Unit This improves the collection of the reintrained fine particles thereby reducing emissions and opacity
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General Layout

Flow in from Secondary Air Heater

Gas Flow

Chamber 11 (Typical)

Flow to ID Fan & Stack

Flow in from Primary Air Heater

Symmetric Around Boiler Center Line Flow to ID Fan & Stack

Chamber 12 (Typical)
Flow in from Secondary Air Heater

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Elevation View

Inlet Screens

Gas Flow Outlet Screen

'egg crate' Flow Straightener Hopper Baffles ID Fan

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DISPOSAL OF FLY ASH

MHV

SV

DRY MODE ASH SLURRY SUMP

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WET MODE
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SILOS
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Fly Ash and Flue Gas Conditioning

Fly ash resistivity can be modified (generally with the intent to reduce it) by injecting one or more of the following upstream of the precipitator: Sulfur trioxide (SO3) Ammonia (NH3) Water Sulfur Trioxide and Ammonia Conditioning Systems In most cases, a sulfur trioxide conditioning system is sufficient to reduce fly ash resistivity to an acceptable level. The source of sulfur trioxide can be liquid sulfur dioxide, molten elemental sulfur, or granulated sulfur. It is also possible to convert native flue gas SO2 to SO3. The source of ammonia may be liquid anhydrous or aqueous ammonia, 24 May 2012 PMI Revision 00 57 or solid urea.

SUITABILITY OF AMMONIA DOSING

Ammonia combine with SOX and transforms it to Ammonium sulphat & Ammonium bisulphate .
Ammonium bisulphate molecules (being adhesive in nature) increases
the adhesion strength of dust collected on electrodes and falls in the form of lumps while rapping and thus reduces the re-entertainment loss. Ammonium sulphate is the outcome of neutralization of excess sulpher present in flue gas.

It is suitable for stations where Sulpher in flue gas is

significant (about 0.4% or more) and re-entertainment loss is
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significant.

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ADVANTAGES
Easy layout. System can be installed with available resources. SPM level can be reduced between 25% ~ 50% in existing ESP. It mainly depends upon the percentage of

SO2 & SO3 available in flue gas.

No adverse effect on the health of the equipment. Ammonia rather neutralizes the acidic gases available in flue gas.
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Simple to operate.
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LAYOUT FOR AMMONIA DOSING IN ESP

DUCT PASS-A

PASS-D

PASS-C

PASS-B

PASS-A

WATER SPRAY

AMMONIA CYLINDER
ZERO METER

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Water Injection
The injection of water upstream of the precipitator lowers the gas temperature and adds moisture to the flue gas. Both are beneficial in cold-side precipitator applications. However, care must be taken that all of the water is evaporated and that the walls in the ductwork or gas distribution devices do not get wet.

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THANK YOU

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