5.

2 EQUIPMENT DESCRIPTION
System of Power Plant is provided with a horizontal, dry type Electrostatic Precipitator having one
steel casing. Gases from the system are directed into the ESP through inlet funnels and the cleaned
gases at the ESP exit are directed to the ID fans and stack through outlet funnels. Each ESP is
equipped with 7 electrical fields lengthwise (effective length and height of each field is 3.75m and
12.5 m respectively) and electrical Bus section widthwise thus providing 7 electrically separated Bus
Sections each served by 1 HV Transformer Rectifier Set. Each ESP is provided with 2 Dust
Collecting hoppers per field. A system of platforms and stairs are provided for easy access to all
parts of the ESP.
Collection plates and discharge electrodes are normally attached to the frame at the top so that the
elements hang vertically due to gravity. This allows the elements to expand or contract with temperature
changes without binding or distorting. Shells, hoppers, and connecting flues should be covered with
insulation to conserve heat, and to prevent corrosion resulting from water vapor and acid condensation on
internal precipitator components. If the ESP is installed on a coal-fired boiler, the flue gas temperature
should be kept above 120C (250F) at all times to prevent any acid mists in the flue gas from
condensing on ESP internal components. Insulation will also help minimize temperature-differential
stresses, especially on hot-side precipitators. Ash hoppers should be insulated and heated because cold fly
ash has a tendency to cake, making it extremely difficult to remove. Insulation material is usually 10 to
15 cm (4 to 6 in.) thick. To stop gas for bypassing the effective electrical field elaborate covers / baffle

plates are arranged on either side of the field with casing wall as well in hopper at the bottom of the
field.

Precipitator Components
All electrostatic precipitators, regardless of their particular designs, contain the following essential
components:
Discharge electrodes
Collection electrodes
High voltage electrical systems
Rappers
Hoppers
Shell

MECHANICAL SYSTEM:
1. Casing or Shell
The shell structure encloses the electrodes and supports the precipitator components in a rigid frame to
maintain proper electrode alignment and configuration. The Casing support allows for free thermal

expansion of the casing during operation especially for hot-side precipitators because precipitator

components can expand and contract when the temperature differences between the ESP (400C or
752F) and the ambient atmosphere (20C or 68F) are large. Excessive temperature stresses can literally
tear the shell and hopper joints and welds apart. The outer sheet or casing wall is usually made of lowcarbon or mild-grade steel that is 0.5 to 0.6 cm (3/16 to 1/4 in.) thick.

The casing is an all-welded steel construction, assembled from pre-fabricated waif and roof panels.

The casing is provided with access doors with gas tight seal construction at all strategic locations
(suitably protected with a key interlock system) so that all internal parts can be approached for
inspection and maintenance. The roof carries the precipitation internals, insulation housing

transformer etc. The precipitator casing is designed for horizontal gas flow.

Figure 5.1: The Electrostatic Precipitator Design with support structure

2. Hoppers

When the electrodes are rapped, the dust falls into hoppers and is stored temporarily before it is
disposed in a landfill or reused in the process. Hoppers are located at the bottom of the
precipitator. The hoppers are adequately sized to hold the ash. The hoppers shall have minimum
plate thickness of 6mm. Typically, precipitator hoppers are rectangular in cross-section with
sides of 50 to 70 (60 is common) slope to allow dust to flow freely from the top of the hopper
to the bottom discharge opening. 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 8" - 12".

Figure 5.3: Hoppers

Baffles are provided in each hopper to avoid gas leakage. Hopper being a vast empty area, the
possibility of gas leakage through the underside of the field is maximum. To stop the leakage double
layer of gas screen plates are provided at the bottom of each field. The upper portion of two adjacent
hoppers is suitably reinforced to support adjacent hoppers across the precipitator width. The lower
portion of the hoppers are provided with electrical heating system with thermostatic control to
prevent bridge formation in the inside face of the hopper plate and to ensure free flow of ash.
Suitable jacketing end insulation is provided to prevent loss of heat in the hoppers. Each dust hopper
is provided with high dust level monitoring system operating on Radio frequency principle. The
level monitoring system includes its normal accessories like level switch, local & remote signaling
lamps. Precipitator hoppers are designed to completely discharge dust load on demand. Dust

should be removed as soon as possible to avoid packing, which would make removal very
difficult.
3. Gas distribution system
Improving gas velocity distribution in the precipitator reduces particle re-entrainment and boosts
precipitator efficiency. Typically, a uniform gas velocity is desired, but there are site-specific
exceptions. The gas velocity inside the ESP is much less than that in the ducting before the
precipitator. It is therefore essential that special arrangement be made to get a uniform velocity
distribution over the entire cross section of ESP. Gas velocity distribution can be most effectively

influenced by the use of gas distribution devices. In general, gas distribution devices consist of

turning vanes in the inlet ductwork, and perforated gas distribution plates in the inlet and/or
outlet fields of the precipitator. A good distribution cannot be obtained solely through the design of
the inlet funnel.

Figure 5.4 : Gas distribution screen

A special gas distribution device is therefore located at the inlet of the precipitator. This device
consists of three rows of perforated modular designed screen plates hung within a framework in the
casing inlet. The gas flow pattern within the ESP is checked prior to the commissioning and
additional deflector added on the screens if required. It may be necessary, depending on the type of
dust, to install rapping mechanism for keeping the gas distribution clean.

4. Emitting & Collecting System Suspension Arrangement

The Emitting and Collecting Electrode System are suspended from roof beams connected to roof
panels. A robust suspension system ensures close tolerance to be maintained in the electrode spacing.

5. Emitting electrode
Discharge or emitting electrodes create a strong electrical field that ionizes flue gas, and this
ionization charges particles in the gas. Discharge electrodes are either small-diameter metal
wires that hang vertically (in the electrostatic precipitator), a number of wires attached together
in rigid frames, or a rigid electrode made from a single piece of fabricated metal.
The most essential part of precipitator is supported by high-voltage insulators. The frames are
welded to form a rigid box like structure for holding the emitting electrodes are located centrally
between collecting electrodes curtains. The emitting electrodes are kept taut between the frames.
The frame is assembled, adjusted and welded to its final position inside the casing, which makes it
possible to obtain and maintain highly accurate electrode spacing. The framework has a four point
suspension effectively taking care of the expansion due to exposure to hot gases inside the ESP. All
sharp edges and ends of frame parts are rounded to maintain electrical clearance.

Figure 5.6: Emitting system

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.
6. Collecting electrode system
Collection electrodes collect charged particles. Collection electrodes are either flat plates or
tubes with a charge opposite that of the discharge electrodes. Most precipitators use plate
collection electrodes because these units treat large gas volumes and are designed to achieve
high collection efficiency. The plates are generally made of carbon steel. However, plates are
occasionally made of stainless steel or alloy steel for special flue-gas stream conditions where
corrosion of carbon steel plates would occur.
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.
The plates range from 0.05 to 0.2 cm (0.02 to 0.08 in.) in thickness. For ESPs with wire
discharge electrodes, plates are spaced from 15 to 30 cm apart (6 to 12 in.). Plates are usually
between 6 and 12 m (20 to 40 ft) high. The collecting plates are made of 1.5mm cold rolled mild
steel plate and shaped in one piece by roll forming. Plate baffles shield the precipitated particles
from re-entrainment while smooth surfaces provide for high operating voltage. Top, center, or
bottom spacer bars may be used to maintain collecting plate alignment and sustain electrical
clearances to the discharge system. The collecting plates are provided with hooks to their top
edge for suspension. The hooks are hung from support angles welded to the roof structure. The

collecting plates form a row or curtain for each field. All the collecting plates in a row are held in

position by a shock bar at the bottom. The shock bars are spaced by guides.

Figure 5.8: Collecting plates

7. Rapping system:
Rappers impart a vibration, or shock, to the electrodes, removing the collected dust. Rappers remove dust
that has accumulated on both collection electrodes and discharge electrodes. These rappers are driven

by geared motors. The rapping system employs tumbling hammers which are mounted on a
horizontal shaft. As the shaft rotates slowly the hammers tumble on top the shock bar/shock
beam which transmits the blow to the electrodes. The rapping shaft of emitting electrode of
electrically isolated from the geared motor drive by a shaft insulator. The space around the shaft
insulator is continuously heated to avoid condensation.
A rapping system is designed so that rapping intensity and frequency can be adjusted for varying
operational conditions. Once the operating conditions are set, the system must be capable of maintaining
uniform rapping for a long time. Collection electrodes are rapped by hammer/anvil or magnetic
impulse systems. Rigid frame discharge electrodes are rapped by tumbling hammers and wires are
rapped by vibrators. Liquid sprays are also used (instead of rapping) to remove collected particles form
both tubes and plates.

Emitting Rapping System

Fig 5.7 Emitting rapping system

During electrostatic precipitation, a fraction of the dust will be collected on the emitting electrodes
and the corona will gradually be suppressed as the dust layer grows. The emitting system consisting
of tumbling hammers. The hammers hit specially designed shock beams and the vibrations generated
are transmitted to the emitting electrodes. One rapping system is provided per electrical bus section.

Collecting Plate Rapping

The rapping energy is efficiently distributed to each electrode via the shock bar. The stiffness and the
design of the shock bar guarantee that the rapping energy introduced to each electrode row is given
the best distribution and without concentration in one singular point. Rapping results into
acceleration rather than deflection and therefore the dust cake is not broken, only dislodged and the
dust re-entrainment is kept low. The rapping frequency should be kept as low as possible in order to
minimize the losses from rapping. When judging the effectiveness of the collecting system it is also
essential to keep in mind the total collecting area being rapped at any one time. The higher the
percentage of the total collecting area being rapped at any time, the greater the re-entrainment of dust
into the gas.

8. Insulator housing :
Each electric bus section is supported from insulators located in insulated compartments. The

support insulators, supporting the emitting electrode system are housed in insulator housings.
The HV dc connection is taken through a bushing insulator mounted on the insulator mounted on
the insulator housing wall. Each bus section is equipped with four Support Insulators each provided
with a 1 KW tubular coil type heating elements controlled by thermostat. Each heater wraps each
insulator to provide uniform heating within the chamber. These heaters heat the air space inside the
insulator compartment and in turn prevent condensation and deposition of moisture on the insulator.
The compartments are provided with top opening covers for easy access to the insulators for
inspection and service. A special tooling arrangement for each insulator compartment makes it

possible to suspend the emitting system from a temporary jacking hook if the insulator must be
changed. A screen tube is installed immediately below and in connection with the support insulator,
which prevents fouling of the insulator by dust.

Figure 5.5: Insulator housing

ELECTRICAL SYSTEM
High voltage equipment provides the electric field between the discharge and collection electrodes used
to charge particles in the ESP.

9. High voltage transformer rectifier (HVR) with electronic controller (EC) :

High-voltage equipment determines and controls the strength of the electric field generated
between the discharge and collection electrodes. This is accomplished by using power supply
sets consisting of three components: a step-up transformer, a high-voltage rectifier, and control
metering and protection circuitry (automatic circuitry). The transformer rectifier supplies the
power for particulate charging and collection.
The basic function of EC is to feed the precipitator with maximum power input under constant
current regulation. Automatic voltage control varies the power to the transformer-rectifier in
response to signals received from sensors in the precipitator and the transformer-rectifier itself.
Whenever there is a flash between emitting and collecting electrodes, the EC will sense the flash
over and quickly react by bringing the input voltage to zero an blocking it for a specific period.
It thus protects the internal components from arc-over damages, and protects the transformerrectifier and other components in the primary circuit. After the ionized gases are cleared and the

dielectric strength restored, the controller will quickly restore the power to a preset value and
raise it to the original non sparking level. The ideal automatic voltage control would produce the
maximum collecting efficiency by holding the operating voltage of the precipitator at a level just
below the spark-over voltage. However, this level cannot be achieved given that conditions
change from moment to moment. Instead, the automatic voltage control increases output from
the transformer-rectifier until a spark occurs. Then the control resets to a lower power level, and
the power increases again until the next spark occurs. The EC ensures adequate power input to
the precipitator while reckoning the electrical disturbances within the precipitator. Regulated ac
power from EC is fed to the primary of the transformer precipitator, which is stepped up and
rectified to give a full wave power output. The transformer-rectifier is mounted on roof of the
precipitator which the EC is located in an air conditioned control room.
A reliable power supply to precipitator is a must for the precipitator to perform at its highest
level without causing excess sparkover between the discharge electrode and collection plate.
This is accomplished through a device called Transformer Rectifier (T / R) unit. The equipment
basically consists of a single-phase thyristor AC regulator that controls the primary voltage. The
primary low-tension voltage is fed to a high voltage step up single-phase transformer. The
secondary AC high voltage of the transformer is rectified by a rectifier to achieve a high voltage
DC output. In a T-R set, the transformer steps up the voltage from 400 volts to approximately
50,000 volts. This high voltage ionizes gas molecules that charge particles in the flue gas. The
rectifier converts alternating current to direct current. Direct (or unidirectional current) is
required for electrical precipitation. T / R unit is sized to get the required current density to
create corona discharge.
The transformer-rectifier set is connected to the discharge electrodes by a bus line. A bus line is
electric cable that carries high voltage from the transformer-rectifier to the discharge electrodes.
The bus line is encased in a pipe, or bus duct, to protect the high-voltage line from the
environment and to prevent the line from becoming a potential hazard to humans. The highvoltage bus lines are separated, or isolated, from the ESP frame and shells by insulators. The
insulators are made of non-conducting plastic or ceramic material.
10. Auxiliary control panel(ACP)
The ACP houses the power and control circuits required for energizing rapping motors and
heating elements of the precipitator. Each gas path is controlled by one ACP. The complete ACP
is of modular type with individual modules for each feeder. Each module houses the power and
control circuits with meters, push buttons, switches, and indicating lamps mounted on the door

of the compartments. Following are the modules for the outgoing feeders:

Hopper heaters for each field

Support insulator heaters
Shaft insulator heaters
Collecting electrode rapping for each field.
Emitting electrode rapping motor for each field.
11. Safety interlock
A interlock system is incorporated to prevent accidental contact with live parts of the precipitator
and to enable energisation only when the EP is boxed up.
12. Disconnecting switch

Each field is provided with one disconnecting switch for isolation of emitting system from the
associated transformer. In the ON position the emitting system is connected to transformer and
in OFF position the emitting system is grounded.

Electrostatic precipitator power supply circuit.

Sectionalization
The discharge electrodes are arranged in fields, frequently referred to as high tension bus
sections, each powered by its own T-R set. This electrical partitioning, also known as
sectionalization, is used primarily because power input requirements differ at various locations
within a precipitator. To adequately charge the incoming particles, more power is needed at the
inlet sections (where high dust concentrations can suppress corona current). High power is also
needed at the outlet sections to collect small particles that exhibit high resistivity. But, in the
downstream fields, where dust loading is usually lighter, high power would create excessive
sparking, so lower power is needed. If only one T-R set were used in a precipitator, power input
would have to be limited (to avoid the excessive sparking), and thus, the efficiency of the entire
unit would be reduced. Sectionalistion is done to reduce the bad effects of precipitator sparking
and equipment outages and to provide better matching of corona voltages and currents of the
electrical characteristics of the gas and dust.
Individually energizing each corona wire from a separate rectifier set is an obviously
uneconomic arrangement. In practice, the goal is an economic balance among degree of
sectionalisation, precipitator size and cost. The effect of high tension sectionalisation or

precipitator efficiency is typically very large. For example, a fly ash precipitator designed for a
gas flow of 100,000 cfm with just one section typically might produce a collection efficiency of
only 60% but the same precipitator with two corona sections might have an efficiency of 90%
and with four sections it might be 99% efficient. The much greater efficiency of the four section
arrangement basically results from the substantially higher precipitator voltage possible
compared with the single large section.
Typically, a number of fields are arranged in a series along the gas flow path. Some large ESPs
are also divided into parallel chambers. The precipitator is divided into electrical sections that
are cross-wise and parallel to the gas flow to accommodate spatial differences in gas and dust
conditions. Optimization of corona power involves adjusting the corona power (secondary
voltage and current) in each electrical section for optimum conditions.
Partitioning (or sectionalization) allows for operation at optimum electrical conditions and
allows the unit to be isolated for diagnosis and repair. Sectionalization also isolates possible
internal problems to one T-R set without affecting the performance of the other power supplies.

Figure 1: Field, or stage, sectionalization

Figure 2: Parallel sectionalization

Parallel and series sectionalization (mechanical) of an ESP

Basic processes involved in electrostatic precipitation.

Typical wire-weight e l e c t r o s t a t i c p r e c i p i t a t o r
with top housing.

The present emission standards for particule emission for a 210 MW or more utility boiler
are 150mg/nm3, which is likely to revise to 100 mg/nm3 soon.
Particulate Reduction using Intermittent Charging
Intermittent charging/energizing systems are normally used to suppress back corona discharges
in the ESP collecting fly ashes having high electrical resistivity 10 11-1013 Ohmcm. The system
simply energizes ESP unit for a specified number of cycles and suppresses the ESP energization
for specified number of cycles not by gating thyristors. The system works because of time
dependence of the formation of back corona in a resistive dust layer, which can be considered
equivalent to an electrical circuit having capacitor and resistor in parallel. The capacitors must
be charged a voltage across the dust layer just before back corona can form. With normal
continuous operation with high resistivity fly ash this condition is met continuously. However,
with intermittent charging the voltage is never allowed to reach like critical break-down level.
The time it takes the voltage to break-down level depends on number of factors such as

resistivity, dielectric constant, break down strength, current density etc. Intermittent charging is
the periodic gating (on) and suppression of gating (off) of the thyristor. The duty cycle or the
charge ratio is defined as the ratio of the number of on cycle to the sum of the on and off cycle.
Advanced precipitator controllers are used for intermittent charging and controlling the current
to ESP. The charge ratio can be varies in the range 1:1 to 1:159, which is necessitated to tackle
the high resistivity of fly ash encountered in precipitators in India. At higher charge ratios the
base voltage reduces to very low values. The provision of base charging is made during some of
the skipped half cycles there by avoiding the effect of low voltage. A facility is provided for the
measurement of peak and valley voltages of the charging signal. A high peak voltage increases
the effective migration velocity and thus increases the collection efficiencies.
The migration velocity may be optimize by choosing charging current, charge ratio and rapping
rate of collecting electrodes. Enhancement in migration velocities up to 25% may be achieved
there by reducing the emission level drastically from the power plants.
ESP Energization Modes
The waveform of the output voltage can be adjusted in order to cope with different operating
conditions in the precipitator. Three modes, mainly differing in the degree of intermittence, are
commonly used.
Continuous Mode: The average precipitator voltage is as high as possible without triggering
sparkovers too often. Sparkovers are the breakdown of the dielectric strength of the
flowing gas which results in short-circuiting the ESP plates. Higher average voltage and
higher corona current normally result in higher collection efficiency. This mode is suitable for
collecting coarse dust, i.e. containing particles which are not too small and having rather low
resistivity (<1010 cm).
Intermittent Mode: Considering mains frequency energization, the power supply output is
turned off for several cycles before it is turned on again for one (or possibly several) cycles.
There are two benefits associated with intermittent energization mode. Firstly, the energy
consumption can be lowered without reducing the peak voltage that is applied to the precipitator.
Secondly, it can help to reduce problems in back-corona (also called reverse-ionization)
conditions that arise when high-resistivity dust is processed.
Pulsed Mode: When the resistivity of the dust is very high (>10 12 cm), particle charging and
consequently the migration velocity can be significantly improved by the application of short
(some ten s) high-voltage pulses. These pulses can be superimposed on a reduced continuous

dc voltage that is still a sufficient driving force for moving the charged particles to the discharge
electrodes.

Particle Charging
Our typical ESP as shown in Figure 1-1 has thin wires called discharge electrodes, which are evenly
spaced between large plates called collection electrodes, which are grounded.

A negative, high-voltage, pulsating, direct current is applied to the discharge electrode creating a negative
electric field. (Figure 1-2). The field is strongest right next to the discharge electrode, weaker in the areas
between the discharge and collection electrodes called the inter-electrode region, and weakest near the
collection electrode. The region around the discharge electrode is where the particle charging process
begins.
Corona Discharge: Free Electron Generation
Several things happen very rapidly (in a matter of a millisecond) in the small area around the discharge
electrode. The applied voltage is increased until it produces a corona discharge, which can be seen as a
luminous blue glow around the discharge electrode. The free electrons created by the corona are rapidly
fleeing the negative electric field, which repulses them. They move faster and faster away from the
discharge electrode. This acceleration causes them to literally crash into gas molecules, bumping off
electrons in the molecules. As a result of losing an electron (which is negative), the gas molecules
become positively charged, that is, they become positive ions (Figure 1-3). So, this is the first thing that
happensgas molecules are ionized, and electrons are liberated. All this activity occurs very close to the
discharge electrode.
This process continues, creating more and more free electrons and more positive ions. The name for all
this electron generation activity is avalanche multiplication (Figure 1-4)
The electrons bump into gas molecules and create additional ionized molecules. The positive ions, on the
other hand, are drawn back toward the negative discharge electrode. The molecules are hundreds of times
bigger than the tiny electrons and move slowly, but they do pick up speed. In fact, many of them collide
right into the metal discharge electrode or the gas space around the wire causing additional electrons to
be knocked off. This is called secondary emission. So, this is the second thing that happens. We still
have positive ions and a large amount of free electrons.
Ionization of Gas Molecules
As the electrons leave the strong electrical field area around the discharge electrode, they start slowing
down. Now they're in the inter-electrode area where they are still repulsed by the discharge electrode but
to a lesser extent. There are also gas molecules in the inter-electrode region, but instead of violently
colliding with them, the electrons kind of bump up to them and are captured (Figure 1-5). This imparts a
negative charge to the gas molecules, creating negative gas ions. This time, because the ions are negative,
they too want to move in the direction opposite the strong negative field. Now we have ionization of gas
molecules happening near the discharge electrode and in the inter-electrode area, but with a big
difference. The ions near the discharge electrode are positive and remain in that area. The ions in the
middle area are negative and move away, along the path of invisible electric field lines, toward the
collection electrode.
Charging of Particles

These negative gas ions play a key role in capturing dust particles. Before the dust particles can be
captured, they must first acquire a negative charge. This is when and where it happens. The particles are
traveling along in the gas stream and encounter negative ions moving across their path. Actually, what
really happens is that the particles get in the way of the negatively charged gas ions. The gas ions stick to
the particles, imparting a negative charge to them. At first the charge is fairly insignificant as most
particles are huge compared to a gas molecule. But many gas ions can fit on a particle, and they do. Small
particles (less than 1 m diameter) can absorb tens of ions. Large particles (greater than 10 m) can
absorb "tens of thousands" of ions (Turner et al. 1992). Eventually, there are so many ions stuck to the
particles, the particles emit their own negative electrical field. When this happens, the negative field
around the particle repulses the negative gas ions and no additional ions are acquired. This is called the
saturation charge. Now the negatively-charged particles are feeling the inescapable pull of electrostatic
attraction. Bigger particles have a higher saturation charge (more molecules fit) and consequently are
pulled more strongly to the collection plate. In other words, they move faster than smaller particles.
Regardless of size, the particles encounter the plate and stick, because of adhesive and cohesive forces.
Let's stop here and survey the picture. Gas molecules around the discharge electrode are positively
ionized. Free electrons are racing as fast as they can away from the strong negative field area around the
discharge electrode. The electrons are captured by gas molecules in the inter-electrode area and impart a
negative charge to them.
Negative gas ions meet particles and are captured (Figure 1-6). And all this happens in the blink of an
eye. The net result is negatively charged particles that are repulsed by the negative electric field around
the discharge electrode and are strongly attracted to the collection plate. They travel toward the grounded
collection plate, bump into it, and stay there.
More and more particles accumulate, creating a dust layer. This dust layer builds until it is somehow
removed.
Particle Charging Mechanisms
Particles are charged by negative gas ions moving toward the collection plate by one of these two
mechanisms: field charging or diffusion charging. In field charging (the mechanism described above),
particles capture negatively charged gas ions as the ions move toward the grounded collection plate.
Diffusion charging, as its name implies, depends on the random motion of the gas ions to charge
particles.
In field charging (Figure 1-7), as particles enter the electric field, they cause a local dislocation of the
field. Negative gas ions traveling along the electric field lines collide with the suspended particles and
impart a charge to them. The ions will continue to bombard a particle until the charge on that particle is
sufficient to divert the electric lines away from it. This prevents new ions from colliding with the charged

dust particle. When a particle no longer receives an ion charge, it is said to be saturated. Saturated
charged particles then migrate to the collection electrode and are collected.
Diffusion charging is associated with the random Brownian motion of the negative gas ions. The random
motion is related to the velocity of the gas ions due to thermal effects: the higher the temperature, the
more movement. Negative gas ions collide with the particles because of their random thermal motion and
impart a charge on the particles. Because the particles are very small (submicrometer), they do not cause
the electric field to be dislocated, as in field charging. Thus, diffusion charging is the only mechanism by
which these very small particles become charged. The charged particles then migrate to the collection
electrode.
Each of these two charging mechanisms occurs to some extent, with one dominating depending on
particle size. Field charging dominates for particles with a diameter >1.0 micrometer because particles
must be large enough to capture gas ions. Diffusion charging dominates for particles with a diameter less
than 0.1 micrometer. A combination of these two charging mechanisms occurs for particles ranging
between 0.2 and 1.0 micrometer in diameter.
A third type of charging mechanism, which is responsible for very little particle charging is electron
charging. With this type of charging, fast-moving free electrons that have not combined with gas ions hit
the particle and impart a charge.
Electric Field Strength
In the inter-electrode region, negative gas ions migrate toward the grounded collection electrode. A space
charge, which is a stable concentration of negative gas ions, forms in the inter-electrode region because
of the high electric field applied to the ESP.
Increasing the applied voltage to the discharge electrode will increase the field strength and ion formation
until sparkover occurs. Sparkover refers to internal sparking between the discharge and collection
electrodes. It is a sudden rush of localized electric current through the gas layer between the two
electrodes. Sparking causes an immediate short-term collapse of the electric field (Figure 1-8.) For
optimum efficiency, the electric field strength should be as high as possible. More specifically, ESPs
should be operated at voltages high enough to cause some sparking, but not so high that sparking and the
collapse of the electric field occur too frequently.
The average sparkover rate for optimum precipitator operation is between 50 and 100 sparks per minute.
At this spark rate, the gain in efficiency associated with increased voltage compensates for decreased gas
ionization due to collapse of the electric field.

Particle Collection
When a charged particle reaches the grounded collection electrode, the charge on the particle is only
partially discharged. The charge is slowly leaked to the grounded collection plate. A portion of the charge
is retained and contributes to the inter-molecular adhesive and cohesive forces that hold the particles onto
the plates (Figure 1-9). Adhesive forces cause the particles to physically hold on to each other because of

their dissimilar surfaces.

Newly arrived particles are held to the collected particles by cohesive forces; particles are attracted and
held to each other molecularly. The dust layer is allowed to build up on the plate to a desired thickness
and then the particle removal cycle is initiated.

Particle Removal
Dust that has accumulated to a certain thickness on the collection electrode is removed by one of two
processes, depending on the type of collection electrode. As described in greater detail in the next section,
collection electrodes in precipitators can be either plates or tubes, with plates being more common. Tubes
are usually cleaned by water sprays, while plates can be cleaned either by water sprays or a process called
rapping.
Rapping is a process whereby deposited, dry particles are dislodged from the collection plates by sending
mechanical impulses, or vibrations, to the plates. Precipitator plates are rapped periodically while
maintaining the continuous flue-gas cleaning process. In other words, the plates are rapped while the ESP
is on-line; the gas flow continues through the precipitator and the applied voltage remains constant. Plates
are rapped when the accumulated dust layer is relatively thick (0.08 to 1.27 cm or 0.03 to 0.5 in.). This
allows the dust layer to fall off the plates as large aggregate sheets and helps eliminate dust
reentrainment.
Most precipitators have adjustable rappers so that rapper intensity and frequency can be changed
according to the dust concentration in the flue gas. Installations where the dust concentration is heavy
require more frequent rapping.
Dislodged dust falls from the plates into the hopper. The hopper is a single collection bin with sides
sloping approximately 50 to 70to allow dust to flow freely from the top of the hopper to the discharge
opening. Dust should be removed as soon as possible to avoid (dust) packing. Packed dust is very
difficult to remove. Most hoppers are emptied by some type of discharge device and then transported by a
conveyor.
In a precipitator using liquid sprays to remove accumulated liquid or dust, the sludge collects in a holding
basin at the bottom of the vessel. The sludge is then sent to settling ponds or lined landfills for proper
ultimate disposal.
Spraying occurs while the ESP is on-line and is done intermittently to remove the collected particles.
Water is generally used as the spraying liquid although other liquids could be used if absorption of
gaseous pollutants is also being accomplished.

3.2 DETAILS OF EXISTING ESP UNIT (4)

Table 3.1 DESIGN CONDITION
3

Gas flow rate

353.2 m / sec

Temperature

140 C

Dust concentration
Type of precipitator

32.12 gms/Nm
2FAA-7X32-11190-2

Number of precipitator offered per boiler

Two

Number of gas path per boiler

Number of fields in series in each gas pass

Guaranteed collection efficiency for design condition

99.53%

Pressure drop across the precipitator for design conditions

20 mm WC

Velocity of gas at electrode zone on total area

0.88 m/sec

Treatment time

25.45 sec

Table 3.2 COLLECTING ELECTRODES

No. of rows of collecting electrode per field

38

No. of collecting electrode plates per field

(8 plates are arranged in each row per field)

304

Total no. of collecting plates per boiler

8512

Nominal height of collecting plate

9m

Nominal length of collecting plate

400 mm

Specific collecting area

168.95 m /m /sec.

Table 3.3 EMITTING ELECTRODES

Type

Spiral with hooks

Size

2.7 mm DIA

No. of electrodes in the frame forming one row

32

No. of electrodes in each field

1184

Total no of electrodes per boiler

33152

Total length of electrodes per field (5.19x1440 = 74736m)

6642 metres

Plate/wire spacing

150 mm

Table 3.4 RAPPERS FOR COLLECTING ELECTRODES

No. and type of rappers

One drop hammer per row of collecting electrodes having a

collecting surface of 57.6 m

Rapper size

4.9 Kgs.

Frequency of rap

Varying from 12 raps/hr. at the inlet field to 1 rap/hr. at the exit field.
The frequency of rapping for the intermediate fields can be adjusted
between 12 and 1 per hour according to requirement.

Drive

Geared electric motor controlled by synchronous programmer.

Location

On the side panel of casing.

Table 3.5 RAPPERS FOR EMITTING ELECTRODES

No. and type of rappers

Approximately one drop hammer two rows of electrodes.

Rapper size

3.0 Kgs.

Frequency of rap

10 raps/hour

Drive

Geared electric motor controlled by synchronous programmer

Location

On the side panel of the casing.

Table 3.6 HOPPERS

Types

Pyramidal

No. of hoppers

56 (2 per field)

Capacity

12 hours storage

Heating

Electrical heating provided for the bottom of hoppers.

Baffling arrangement

2 sets of deflector plates for each hopper underneath the collecting

plates prevent gas sneakage.

Table 3.7 GAS DISTRIBUTION SYSTEM

Type and quantity

Perforated plate 2 sets

Location

Inlet of precipitator

Table 3.8 ELECTRICAL ITEMS

i. Rectifier
a. Rating

70 KV (Peak) 800 mA (mean)

b. Number/boiler

28

c. Type

Silicon diode, full wave, bridge connection

d. Location

Mounted on the top of precipitator

ii. Rectifier Control Panel

a. Type of control

Thristor/SCR control

b. Number

28

c. Location

In the control room at ground level

iii. Auxiliary control panel

a. Number

4 (one per pass)

b. Equipment controlled

Geared motors of rapping mechanisms of collecting and

emitting electrodes, heating elements on hoppers
insulator housing and shaft insulators

c. Location

In the control room at the ground level.

iv. Motors
Rapping of Emitting Electrodes
a. Quantity

28 Nos.

b. Rating

Geared Motor: 0.33 Hp/1.1 rpm at 3 phase, 415v, 50Hz

c. Location

On the side panels of casing.

Rapping of Collecting Electrodes

a. Quantity

28 Nos.

b. Rating

Geared motor: 0.33 HP/1.1 rpm at 3 phase, 415 Volts, 50

Hz.

c. Location

On the side panels of the casing

v. Heating Elements
Hoppers
For 56 hoppers at the rate of 6
KW/hopper

336 KW

Shaft Insulators
For 28 shaft insulators at the rate of 1
KW

28 KW

Support Insulators
For 112 supplement insulators at the
rate of 1 KW

112 KW

Table 3.9 RECOMMENDED CURRENT SETTING

Field

Current in
mA

200

260

320

390

440

BASE CHARGING

Figure 4.3: Intermittent charging with base charging

In the intermittent charging, the longer the time between each current pulse the lower is the average
current as may be required for the high resistive ash. However the ESP valley voltage also reduces
pulling down the average voltage. To improve the valley voltage/average voltage small current pulses

proportional to operating current pulses are pumped during OFF periods of main current pulses. This
maintains the average ESP voltage always near about the best possible voltage, thus the collection
efficiency also is further increased. This also protects the T/R set against possible core saturation
during higher charge ratios.