ELECTROSTATIC PRECIPITATOR

ESP
Construction
By
Sunil Ranalkar
Assistant Engineer
Nasik Training Engineer
 Ash produced in power plants:

 30% of total quantity of coal

 Fly ash =85%
 Bottom ash =15%
ESP construction details & maintenance

Sunil V Ranalkar
AE
Nashik Training center
PRESENTATION
 INTRODUCTION
 METHODS FOR REMOVAL OF FLY ASH PARTICLES
FROM FLUE GAS
 ELECTROSTATIC PRECIPITATOR
 CONSTRUCTIONAL FEATURES OF ESP
 PRINCIPLE OF OPERATION OF ESP
 WHAT IS CORONA?
 FACTORS AFFECTING ON ESP PERFORMANCE
 ADVANTAGES & DISAVANTAGES OF ESP
INTRODUCTION
PRECIPITATOR
Is a Device / Apparatus Which Removes DUST PARTICLES From
GAS/ AIR by PRECIPITATION
It is designed to trap and remove dust particles from the exhaust
gas stream of an industrial process.
Precipitators are used in
• Thermal Power Plants
• Cement Industry
• Chemical Industry
• Metals Industry
• Paper Industry
 In Thermal Power Plant, flue gases are formed as a product of
combustion. Some minute ash particles are also carried out the flue gases.
These ash particles are referred as Fly Ash. Steam generators burning
pulverized coal with furnace. Fly ash remains in fine suspension
approximately 85 % of the ash contained in coal burnt are carried along
with flue gases. This fly ash particles if, emitted to atmosphere pollutes the
environment. They may cause lung, skin diseases. Besides that fly ash
particles have harmful effects such as,
• They may cause poor visibility.
• They may reduce intensity of duration of daylight.
• They may settle down & get precipitated on earth’s surface.
• They may get deposited on fields causing harm to vegetables & buildings.
METHODS FOR REMOVAL OF FLY ASH
PARTICLES FROM FLUE GAS:
 Gravity setting
 Internal apposition
 Diffusion
 Electrostatic Precipitator
 Internal Precipitation
ELECTROSTATIC PRECIPITATOR
An electrostatic precipitator is a large, industrial emission-control
unit. In this type of arrangement, force acting on dust particles is of
electrical ionization. ESP is situated in the path of flue gases in between Air
Heaters & ID Fans.
It is designed to trap and remove dust particles from the exhaust
gas stream of an industrial process.
The Central Pollution Control Board recommended a limiting value
of suspended particles in Air. For the sensitive Area it should not be ≥
100µg/Nm3
CONSTRUCTIONAL FEATURES OF ESP
The ESP may be divided into two major groups,
Electrical Parts
• High voltage rectifier
• Main & auxiliary control
• Switches
• Heaters
• Interlocks.
Mechanical Parts
• Casing
• Internals of the precipitator -
- Gas distribution screen,
- Emitting electrode system,
- Collecting electrode system,
- Rappers for discharge electrodes,
- Rappers for Collecting electrodes ,
- Interlocks.
 No. of passes :4
 No. of fields per pass :5
 Temperature : 145OC
 Gas velocity : 1m/s
 Size of collecting plate : 9m X 0.4m
 Plate/wire spacing : 125 mm
 Collection efficiency : 98.5%
EMITTING ELECTRODE

►SPECIFICATIONS:

 Electrodes per row =36

 No of rows per field =38
 No of electrodes in =1368
each field
 Plate / Wire spacing =125m.m.
 COLLECTING PLATE

► Materiel : Steel sheet:

► Total no of collecting plates =9 plates/row
► Total no. of rows =39
 Total collecting electrodes =39X9 =351
► Nominal Height of = 9 Meters
collecting plate
► Nominal width of = 400 M.
collecting plate
 Rapper Mechanism:

 Rolling hammers

 Made up of cast iron

 Rapping freq. =6 raps/hr

(collecting plates)

 Rapping freq. =10raps/hr

(emitting wires)
TECHNICAL DATA OF ESP
 Flue Gas with dust particles

Clean Air
CORONA

Collecting Plates +ve

DE Electrode -ve
WHAT IS CORONA?
CORONA is an electric discharge phenomenon in which gas
molecules are ionized by the collision of electron in the region of high
strength electric field.

CORONA
FORMATION
Conductor caring
HIGH VOLTAGE
POWER SUPPLY SYSTEM
ESP HOPPERS
ESP

Advantages:
• Less power requirement
• Economical & easy to operate
• Nearly 99% efficiency obtainable
• Very small particles can be collected.

Disadvantages:
• High initial cost
• Large space requirement
ELECTROSTATIC PRECIPITATOR
FOR 210 MW UNIT BOILER
 Design Conditions:-
 Gas Flow rate : 1565280 M3/hr
 Temperature : 139.5C
 Dust concentration : 25.4 gms/m3
 Pressure at the inlet of precipitator : 200 mmwc
 Type of precipitator :2 FAA(36) 436 – 9590- 2
 Number of precipitators pass/boiler :2
 Number of parallel pass/boiler :4
 Guaranteed collection efficiency for design condition :98.50%
 Pressure drop across the precipitator for design conditions : 15
mmwc
 Velocity of gas at electrode zone on total area :
1.271 m/sec
 Collecting Electrodes:-
 a) No. of rows of collecting electrode per field : 39
 b) No. of collecting electrode plates per field (Nine plates are arranged in
each row) : 351
 c) Total No. of collecting plates per boiler : 5616
 d) Nominal height of collecting plate : 9 mtrs.
 e) Nominal length of collecting plate : 400 mm.
 Emitting Electrodes :-
 a) Type :Spiral with conical ends.
 b) Size : 2.5 mm
 c) No. of electrodes in the frame forming one row : 36
 d) No. of electrodes in each field : 1368
 e) Total length of electrodes/Boiler : 21888 mm
 f) Total length of electrodes/field : 7679 mm
 g) Plate/Wire spacing : 125 mm
 Rappers for Collecting Electrodes:-
 a) No. & type of rappers
:One drop hammer/row of collecting electrodes, collecting surface of 64.8 m2.
 b) Rapper size :4.9 kgs.
 c) Frequency of rap :Varying from 6 raps/hr. at the inlet field to 1 rap/hr. at the exit
field.
 d) Drive : Geared electric motor controlled by synchronous programmer.
 Rappers for Emitting Electrodes:-
 a) No. and type of rappers : Approximately one drop hammer for two rows of
electrodes.
 b) Frquency of rap : 10 raps/hr.
 c) Drive : Geared electric motor controlled synchronous
programmer.
 Hoppers:-
 a) Type : Pyramidal
 b) No. of hoppers : 40 ( 2 per field)
 c) Capacity : 8 hours storage
 d) Heating :Electrical heating provided for the bottom of hoppers.
 Electrical items:-
 Rectifier :-
 a) Number : 20 Numbers
 b) Rating : 60 KV(Peak)/8 MV
 c) Type : Silicon diode full wave bridge
connection
 d) Location : Mounted on the top of
precipitator
 ii) Motor for rapping of Emitting Electrodes:-
 a) Quantity :20 Nos.
 b) Rating :Geared motor, 0.6 HP/1.1 rpm at 3
phases, 415 V, 50 cycles.
 c) Location :On the side panels of casing.
 iii) Motor for rapping of Collecting Electrodes:-
 a) Quantity :20 Nos.
 b) Rating :Geared motor, 0.5 HP/1.1 rpm at 3 phase, 415 V, 50
cycles.
 c) Location :On the side panels of casing.
PRECHECKS:-
 Ensure that relevant Electrical / Mechanical permits are cancelled by
authorised person.
 Ensure that Earthing Connections are removed.
 Ensure that all ESP manhole doors are closed properly.
 Ensure that 415 V, ESP LT Board is charged.
 Ensure that ESP control panel and auxillary panel supply is normalised.
 Ensure that rectifier transformers local isolator are made ‘ON’.
 Ensure that all ESP fields megger values are OK(i.e. 7200 mega ohms).
Ensure that all intelligent controller of ESP (ICE-C) Voltmeters, ammeters of
the control panel are available, duly attended and calibrated.
 Intelligent Controller of Electro Static Precipitator- ICE-C:-
 Following observations and operations can be done by ICE-C during the
individual field charging.
 Intelligent Controller of Electro Static Precipitator- ICE-C:-
 Following observations and operations can be done by ICE-C during the
individual field charging.
 Check the status of each field from digital display and following values can
be observed by it.
 – Precipitator current.
 E - Precipitator voltage
 H - Spark per minute
 O – lm limit
 1 – ls limit
 2 – S control
 3 – T control
 4 – Slope after spark.
 5 - Under-voltage limit.
 6 – Charge ratio.
 7 – Pulse current limit.
 8 – Load gain.
 9 – Address.
 Following indications / tripping provided on ICE-C:-
 TX temperature high (indication)
 Buch. Top float (indication)
 Buch. Bottom float(tripping)
 Under Voltage (indication)
 Theramal O/L / TX temperature V/H (tripping)
 V= Peak Reached (Indication)
 Adjust the current by current limit switch (current protection meter) during
normal course of field working.
 I.e. increase the current till the normal spark rate (about 5 sparks per
minute) observed.
 Decrease the current, as the higher spark rate observed i. e more than 5
sparks per minute. Higher spark rate indicates either the hopper is full or
obstacles in between the electrodes i.e. the effective distance between
electrodes is decreased.
 If the field is in the charge ratio mode, keep the is setting at maximum (i.e.
till the spark occurred).
 Values on Intelligent controller on digital
display shows in % and its conservation is
72KV = 100% in case of each Ist field ( i.e.
A1, B1, C1 and D1, B2 to B5, C2 to C5 and
D2 to D5). It is 60KV = 100 %.
 Refer following table for the values of voltage
for the fields