Advancements in ESP
Yatindra Nadkarni, CEO Ionisation Filtration Industries Pvt Ltd, Pune, India.
Chemical Industry Copper Lead & Zinc Smelters Cement Industry De-tarring of Fuel Gases Paper Mills Steel Industry Electric Power Industry Carbon Black Aluminum Smelters
Since inv enti on, ov er last more tha n 100 years, lots of i mprov eme nts / a dv anceme nts did take pl ace in ESP comp one nts & o perati ng practices. Some of these a dv anceme nts are c ov ered here.
Advancements in ESP
Hybrid ESP + Bag filter : For ESPs which are giving too high
a emission due to plant capacity enhancement/ tighter emission norm/ changes in design paramet er s/ inadequate ESP sizing etc.
Av oids exte nsiv e, repetitiv e Trial -&-Error (T&E ) met hod on fiel d erecte d ESP, for e nsuri ng uni form gas v elocity inside ESP
Mi nimises l oss of time ass ocia ted with repe titiv e T&E tes ts, site m odificati ons e tc. whic h prov es crucial in a n ESP up grada tio n j ob.
For a ne w ESP, C FD e nsures prop er orientati on of inlet / ou tlet nozzles, GD screens For a fie ld erec ted ESP, C FD eli mina tes costlier site m odi ficati ons / al terati ons of nozzles, GD scree ns & v anes a fter ev ery T&E tes t.
Facilita tes be tter plan ning o f Plan t Sh ut-do wns for ESP up grada tio ns with No la st min ute s urprises, No sh ut-d own ext ensi ons, No a ddition al loss of prod ucti on
Has lo wer cos t (~ on e-four th of Model s tu d y) Better s peed of res ults (2 to 3 mo nth s)
No Mo del s tud y set -u p Flexi-glass m odel No elab orate floor spac e requireme nt for la b set -u p (CF D require s onl y a Workstati on & So ftware)
MODEL STU DY OF A N ESP
CFD Res ult Hi ghl ights : Flue gas havi ng h igh er veloc ity regi on (re d) on left flank of ESP Unev en g as flow, thus low erin g ESP efficie ncy
No Fiel d GD te st a t site No ESP sh utd o wn (~ 10-12 da ys ) for GD tes ts No likel y ex tensi on of s hu td own peri od res ulti ng i n extended l oss o f pr od ucti on & rev enue
Emitting Electrode s
Badl y a ffec ts emis siv ity Suppress es Secondar y Curren t Field opera tes at muc h lower e fficie nc y
Every spark & arc results in etching of metal from surface of emitting electrodes Etching results in :
Reduc tion in ra dius of c urv ature More coro na genera tion Possible next s park/arc at same l ocati on
Anneal ed c op per coa ted nails en sure sharp c orona poi nts ov er a lon g ti me. Zero pr oba bility of S nap ping Lo wer 'coro na onset v oltage Higher e fficie nc y of ESP for same process parame ter Simplici ty o f ins tallati on Adap tabili ty to all desig ns Lo wer d own ti me for retro fits
Lo wer coro na onse t v oltage e nsures begi nning o f pr ocess of i onizati on well in a dv ance o f back coro na regi on During back c oro na, e mitti ng electro des get coate d wi th dus t Pipe prov ides s urface for s uch c oati ng Nails still re main free fr om dus t genera te cor ona ESP conti nues to receiv e p ower with d ust -coa ted ele ctro des to ev en
Can easil y be retr ofi tte d on an y exis ting Emi tti ng electro de fra me/ mas t de sign
An innovative way to increase collecting plate area as well as improve rapper impact. The space between two consecutive fields can be utilised for installing additional collecting plates. This design modification is applicable only to certain types of ESPs. However the increase in collection area that this modification can fetch is up to 33%
Adv antages
No cha nge in foo tpri nt Inlet, outlet duc t work & n ozzles remai n same Fan a nd s tack loc ati on ke pt unc han ged No m ov ing par ts with in pre cipitator c asin g Virtual elim ina tion of mai nte nance Mov ing par ts bei ng ou tside gas stre am, the y ca n be main tain ed onli ne
Adv antages
Improv ed relia bility i n rappin g mec hanis ms Rappi ng se qu ence, freq uenc y & intensi ty can readil y be c han ged thr ou gh micro -co ntroller. This mini mises p ossi bility of pu ffin g. Higher treatmen t len gth red uce re-e ntrai nme nt of dust Supp ort i nsula tors pertai ning to an i ndiv idual field are hou sed i n separa te comp artme nts.
TR Controller
TR Controller
TR Controller
TR Controller
DL DT : Revolutionary Technology
What is DLDT ?
Lowers outlet emission by 25 to 50 % at about one tenth cost of conventional methods Saves electrical power by 10 to 15 % Lowest down time required for implementation No recurring costs
Modify gas flow pattern inside ESP deflect it from inlet bottom to outlet top to achieve uniform dust load from top to bottom of ESP
with turnin g v anes with bl ockin g o f per forated p lates with ad diti onal gas dis tributi on dev ices at outle t o f ESP
What is Im portant ?
Aspects Overlooked
At low gas velocity dust settles down due to gravity Re-entrainment of dust during rapping of plates Acute gradient in voltage & current levels affect migration velocity
80%
16%
4%
Gas Flow
kV mAmps
Lo w Co nce ntrati on
Gas Flow
Practical Observations
Upper portion is under-utilized Lower portion is over-loaded High current drain in low resistance area Voltage drops due to loading of T/R set No corona in lower portion
Lo w Resis tance
Gas Flow kV mAmps
Practical Observations
Practical Problems
Drop in voltage reduces migration velocity Increased gas volume increases re-entrainment of dust Fine & light dust that is more susceptible, increases emission Puffing is more visible & adds to average emission
Underlining Theory
Dust Load Distribution is More Important
DL DT Methodology
Identify ideal angle for gas flow to overcome gravitational effect Create a DEAD POCKET at outlet bottom of ESP Computer flow modeling to arrive at new gas distribution devices Verification of computer modeling in field after implementation
than
Gas Distribution
Methodology
Advantages - Electrical
Entire ESP from top to bottom is uniformly loaded Reduction of current drain saves electrical energy Higher kV results in higher migration velocity - crucial for collection of fine particles
kV mAmps
Reduced Em ission
Technological Advantages
Dust falls in dead pockets at lower end of outlet field during rapping Reduced re-entrainment of dust during ESP operation Puffing is eliminated
All ESPs are sized as per Deutsch Anderson Equation DLDT is based on parameters over & above those in Deutsch Anderson Equation As a result, with DLDT, Performance improvement is assured in all ESPs
Conclusion
Dust Load Distribution is
Emissio n fro m ESP for : Ash with 20-25% w/w mois ture, ~ 100 m g/ N m3 Ash with 8-10% w/w mois ture, > 1000 m g/ N m3
PrecipFilter installed in last ESP field (field emptied of its internals) ESP housing 3 Fields (Prior to Retrofit ) (Hazy environment due to dusty stack) ESP now housing 2 Fie lds Plus PrecipFilter (Clean Environment)
Fly-ash Dry er ESP at J RP Ce ment Plant, Rewa, MP running over last 3 yea rs with Zero maintenance
Handles The
servic es cov er Application Engg, Design, CFD, Supply, and Supervision of E&C & Maintenance contra cts for Air Pollution Control (APC) equipment.
Conducts
Inspection/Comprehensive Audits of old ESP/Baghouses & proposes Short /Long term Corre ctive m ea sure s with a special focus on minimum cost, least downtime & least loss of production
IFI
also offers quality replacem ent parts of air pollution control equipment.
Now
an established name as original eqpt manufacturer (OEM) & project engineering company for ESPs, Bag Filters, Emission monitors, amongst others.
Thanks.