DESIGN AND ANALYSIS OF

ELECTROSTATIC PRECIPITATOR AT
PRODUCER GAS PLANT
K.Jeykar1 , S Babu2a, A C Ashokraj2b, S Jaheer hussain2c
1

Assistant Professor

Department of Mechanical Engineering, Tagore Engineering College, Chennai-127

jeykar_28@yahoo.co.in
2

U.G. Student, Department of Mechanical Engineering, Tagore Engineering College, Chennai-127

babu28@gmail.com,ashok.raj@gmail.com,jaheer97@gmail.com

ABSTRACT
The main objective of our project is to increase the efficiency of Electrostatic Precipitator (ESP) in
Producer Gas plant at BHEL/TRICHY. This ESP is used to remove the tar particles coming out with
producer gas generated in the gasifier at producer gas plant. The producer gas produced in this plant was
by gasification of anthracite coal. The PG plant in BHEL/TRICHY produces 10,000 m3 volume of
producer gas (CO+CH4+H2+N2+some traces of O2).
At present the tar collection efficiency of the ESP in the BHEL was 60%. Our aim is to increase the tar
collection efficiency of the ESP by varying the flow rate of producer gas within the ESP. The ESP was
designed in a way to increase the tar collection efficiency more than 60%. The new design was then
verified with ANSYS software
INTRODUCTION

(anthracite coal) in the gas producer(generator).

The reaction of fuel with insufficient air for total
combustion produces carbon monoxide(CO).

1.5 ELECTROSTATIC PRECIPITATOR

This reaction is exothermic and self sustaining

IN BHEL:

and adding steam to the input air would increase

the calorific value of the fuel gas by enriching it
with CO and H2.

1.6 GAS GENERATION PROCESS

In the generator, the carbonaceous material
The producer gas is made by blowing air

undergoes several processes:

and steam through an incandescent fuel bed

1

1.

The dehydration or drying process

C + H2 O

H2 + CO

(Endothermic water gas reaction)

occurs at around 100C.

2. The pyrolysis or devolatilization process

C + 2H2 O

occurs at 400C, where coal in the

2H2 + CO2

(Endothermic reaction)

absence of oxygen rapidly gives carbon

rich char and hydrogen rich volatiles,

CO + H2 O

resulting upto 70% weight loss for coal

3.

H2 + CO2

(Exothermic water gas shift reaction)

The combustion process occurs as the

volatile products and some of the char

The Various Processes Carried Out In the

reacts with oxygen to primarily form

Plant Are As Follows

carbon dioxide and small amounts of

DUST SEPERATION:

carbon monoxide, which provides heat

for the subsequent gasification reactions

The gas from generator is passed into a dust

C + O2

separator upwards. The sepearation dust is done

CO2

by centrifugal force and removed the water

2C + O2

2CO

seals.

4. The gasification process occurs as the char

DIRECT GAS COOLING:

reacts with carbon and steam to produce carbon

Inside the cooler the gas is sprinkled with the

monoxide and hydrogen.

water and the gas temperature is reduced from

C + H2 O

H2 + CO

350c to 100c.

5. In addition, the reversible gas phase water

gas shift reaction reaches equilibrium very fast
WASHING OF GAS:

at the temperature in the generator. This

balances the concentrations of carbon monoxide.

Washing liquid (tar) is brought into the injection

Steam, carbon dioxide and hydrogen.

pipes. By means of the centrifugal forces in the

CO + H2O

rotor in the gas washer causes tar fogs contained

CO2 + H2

in the gas to condense and they sink to the

The various reactions taking place in

bottom of the washer then removed. The gas

gasification process :

leaves the gas washer at a temperature of 60c to

70c.

2C + O2

2CO

(Exothermic

producer gas reaction)

INDIRECT GAS COOLING:

2

Gas is allowed to flow from the upper part along

and they have a charge opposite to that of the

with the tube where the cooling water flows

discharge electrodes.

from the upper part to the lower part.

Electrical Systems;

Condensate is collected in the lower part and

from there exhausting into the oil water

It was used to control the strength of the

separator where the light and middle oils are

electric field between the discharge and

separated from the gas. The gas is cooled to

collection electrodes.

50c.
Shell:
GAS PRESSURE:
The shell encloses the electrodes and supports
A gas fans (BOOSTER) brings the gas pressure

the precipitator components in a rigid frame to

to about 300-400 mm of water column which

maintain proper electrode alignment and

flows through the main pipe to the consumers.

configuration .the shell is covered with

insulation to conserve heat and prevent

COOLER:

corrosion
A closed vessel in which producer gas is cooled
SECTIONALIZATION:

by abstracting the heat from the gas and the

pressure is maintained bellow atmospheric

The discharge electrodes are arranged in fields

pressure is known as cooler, it is one of the types

each power by its own T-R set. This electrical

of condenser.

partitioning also known as sectionalization, is

primarily used because power input

3. ELECTROSTATIC PRECIPITATOR

requirements differ at various locations within a

3.1 SYSTEM COMPONENTS:

precipitator. To adequately charge the incoming

particles, more power is needed at the inlet

Discharge Electrodes:

section. High power is also needed at the outlet

sections to collect small particles that exhibit

Discharge electrodes impart an electrical

high resistivity (resistance of a particle to accept

charge (usually negative) to particles in gas

charge). But in the downstream fields , where tar

stream. The electrodes are usually small

particle loads is usually lighter, high power

diameter wires that hang vertically in the esp or

would create excessive sparking, so lower power

are attached to rigid frame.

is needed. If only one T-R set were used in the

precipitator, power output would have to be

Collection Electrodes:

limited (to avoid excessive sparking), and thus,

Collection electrodes collect the charges

the efficiency of the entire unit would be

particles. they can be either tubes or flat plates,

reduced.
3

strong electric field was created between

them.
This electric field propels the negatively
charged particles towards the positively
charges collection electrodes, where the
particles attach themselves.

Chapter-4
DESIGN CALCULATION

4.1MECHANICAL DESIGN
4.1.1 MIGRATION VELOCITY OF TAR
PARTICLE:
V = (2.95*10-12 *P*(E/S)2*d)/g

Fig 3.1 wet electrostatic precipitator

Where,
V = fluid velocity in m/s

3.2 ESP SYSTEM OPERATION:

A high-voltage direct current is applied

P= dielectric constant

to a discharge electrode, negatively

E= applied voltage in V

charging it.
Voltage to the wire is increased until a

S= distance between the electrodes in m

corona (a visible electric discharge) is

produced around the wires.

d= particle size in m

As the particle-laden flue gas passes

g = kinematic viscosity in m2/s

through the corona, the particle

contained in the gas becomes negatively

4.1.2 COLLECTION EFFICIENCY:

charged.
Because the discharge electrode is

d = 1-e-(A* V/Q)

negatively charged and the collection

electrodes are positively charged, a

Where,
4

d = collection efficiency
A= Electrode area in m2

V = (2.95*10-12 *P*(E/S)2*d)/g

V= velocity of fluid in m/s

16.5808 = (2.95*1012

*2*(50*103/0.12)2*d)/(2.93*10-5)

Q= mass flow rate in kg/s

4.858 = 1.024*d
CALCULATION:
d= 4.74 cm
Area of electrode (A) = length of electrode (le) x
height of electrode (he)

Therefore the average tar particle size is 4.74

cm.

A=le*he
4.1.3 CALCULATION FOR NEW DESIGN:
A=6*0.004
DATA FOUND FROM ANSYS:
2

A=0.024 m

Vexisting = 1.573 x 103 m/s

d = 1-e-(A* V/Q)
Vnewdesign= 1.524 x 103 m/s
Given:
FORMULA:
d = 60%
Q=VxA
Q= 10,000 kg/s
Where
0.6 = 1-e

-(0.024*V/10000)

Q = Mass flow rate in m3/s

e-(0.024*V/10000) = 1-0.6
V = Fluid velocity in m/s
e-(0.024*V/10000) = 0.4
A = Area of cylinder in m2
0.024*V/10000 = 0.39794

(log 0.4 =

0.39794)

SOLUTION:

V= 0.39794*10000/0.024

Now we have to calculate the areas of shell,

V=165.8 *103 m/s

Area of Shell = 2 x 3.14 x (d2-d1) x h

d2 = outer diameter of the shell
5

d1 = inner diameter of the shell

A = 0.0471 + 0.0942 + 0.1413 + 0.1884 + 11.55

h = height of the shell

A = 12.021 m2

Area of the shell 1 = 2 x 3.14 x (264-254) x 10-3

4.1.4 MASS FLOW RATE:

x 750 x 10-3
Q=CxA
-3

A1 = 2 x 3.14 x 10 x 10 x 750 x 10

-3

Q = (1.525 x 103) x 12.021

A1 = 0.0471 m2
Q = 12,848 m3/s
Area of shell 2 = 2 x 3.14 x (d4-d3) x h
COLLECTION EFFICIENCY:
A2 = 2 x 3.14 x (518-508) x 10-3 x 1500 x 10-3
d = 1-e-(A* V/Q)
A2 = 0.0942 m2
d = 1-e-(1524 X 12.021 / 12848)
Area of the shell 3 = 2 x 3.14 x (772-712) x 10-3
x 2250 x 10-3

d = 1-e-0.528

A3 = 2 x 3.14 x 10 x 10-3 x 2250 x 10-3

d = 1-0.32

A3 = 0.1413 m2

d = 0.68 x 100

Area of the shell 4 = 2 x 3.14 x (1026-1016) x

d = 68 %

10-3 x 3000 x 10-3

4.1.5 RELATION BETWEEN ELECTRODE

A4 = 2 x 3.14 x 10 x 10-3 x 3000 x 10-3

DISTANCE AND MIGRATION VELOCITY

A4 = 0.1884 m2

ELECTRODE

MIGRATION

DISTANCE in m

VELOCITY in m/s

0.12

53.05

0.13

45.2

0.14

38.95

0.15

33.97

Area of the shell 5 = 2 x 3.14 x (1500-1270) x

-3

10 x 8000 x 10

-3

-3

A5 = 2 x 3.14 x 230 x 10 x 8000 x 10

-3

A5 = 11.55 m2
Total area of the cylinder = A1 + A2 + A3 + A4 +
A5
6

0.16

29.84

0.17

26.23

Dimensionless position = (TO-T)/(Ti-T)

TO = center plane temperature of cylinder
T = fluid temperature

0.18

23.58

0.19

21.56

0.20

19.1

Ti = temperature of cylinder

D.P = (TO-T)/(Ti-T)
0.8466 = (TO-383)/(423-383)
33.864 = TO 383
TO = 416.846 K or 143.846 c

4.2.1 THERMAL RESISTIVITY

R= 1/(2**k*L) * ln(r2/r1)

4.2.3 REYNOLDS NUMBER:

Data given:

Reynolds number (Re) = * L /

k = thermal conductivity

Re = 16 * 8 / 21.54*10 -6

L= length of cylinder

Re = 5.94*106

r2 == outer radius of cylinder

Since Re value greater than 10 5 the flow is

turbulent

r1 = inner radius of cylinder

4.2.4 NUSSELT NUMBER:

Nu=C*(GrPr)m

R=1/(2**45*8) * ln(1.5/1.27)
R=4.42*10-4 * ln1.18

Pr=Cp/k

R=4.42*10-4*0.1655

Pr =1068*21.54*10-6/45

R=7.3*10-5 k/W
Pr=5.11*10-4
GrPr=1.13*1012*5.11*10-4

4.2.2 TRANSIENT CONDUCTIVITY

Dimensionless Position (D.P) = r/R o

GrPr=5.77*108

r = inside radius of cylinder

Refer HMT DATA BOOK BY

Ro = outer radius of cylinder

C.P.KOTHANDARAMAN page no :138 for

value of c&m
C=0.125

D.P = 1.27/1.5

m=0.33

D.P = 0.8466
7

Nu=C*(GrPr)m

h =Nu*k/d

Nu=0.125(5.77*108)0.33

h=10.3*.03128/1.5

Nu=10.3

h=0.2252w/k.

Nu=hd/k

Fig 4.1 3-D model of existing ESP

WIREFRAME MODEL OF NEW ESP

DESIGN

CFD ANALYSIS OF ELECTROSTATIC

PRECIPITATOR

Fig 4.6

CFD analysis of electrostatic

4.5.2 PLOT BETWEEN FLUID VELOCITY

TO PRESSURE

fig 4.7 plot between fluid velocity to pressure

CFD ANALYSIS OF NEW ESP DESIGN

10

4.5.3 PLOT BETWEEN FLUID PRESSURE TO FLUID VELOCITY FOR NEW DESIGN

CHAPTER-5

RESULT
11

5.0 CONCLUSION:

C.P.Kothandaraman and
S.Subramanyan , HEAT AND

Thus the tar collection efficiency of the

MASS TRANSFER DATA BOOK ,

ESP was calculated and a new design

New Age International Limited

was created with efficiency greater than

Publishers.

the existing ESP. The existing ESP has

an efficiency of 60% and now in our

POWER PLANT ENGINEERING,

new design it was found to be as 68%.

Khanna publishers.

5.1 REFERENCE

G.R.Nagpal and S.C.Sharma,

M.M.El-Wakil , POWER PLANT

P.K.Nag, ENGINEERING
THERMODYNAMICS, Tata

TECHNOLOGY ,McGraw- Hill book

McGraw-Hill Publishing Company.

company .

S.M.Yasha , GAS TABLES FOR

COMPRESSIBLE FLOW
CALCULATIONS, New Age
International Limited Publishers .

Joseph E.Shigley and Charles

R.Mischke , MECHANICAL
ENGINEERING DESIGN (IN SI
UNITS) , Tata McGraw-Hill
Publishing Company.

12

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