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Electrostatic Precipitator

Air Pollution

Air Pollution

CONTRIBUTION FROM POWER STATION

Pollution Distribution Pattern Man Made

POWER POSITION IN INDIA

EFFECTS OF AIR POLLUTION

LUNG CANCER. SKIN, EYE ASTHMA. CENTRAL NERVES SYSTEM. SUFFOCATIONAL DEATH. ACID RAIN. DEPLETION OF OZONE LAYER. GREEN HOUSE EFFECT AND GLOBAL WORMING.

Effect of Air Pollution on Humen

EFFECTS OF AIR POLLUTION

GENERAL
VISIBILITY REDUCTION DUE TO SCATTERING OF LIGHT FROM SURFACES OF AIR BORNE PARTICLES MATERIAL DAMAGE

AGRICULTURAL DAMAGE DUE TO ASH DEPOSITION

LOSS AND REDUCTION OF GREEN PLANT PIGMENT CALLED CHLOROPHYLL RESULTING IN YELLOWING AND EVEN DROPPING OF LEAVES.

DAMAGE TO BUILDINGS, MONUMENTS OF MARBLE ETC.

EFFECTS OF AIR POLLUTION HUMAN HEALTH

OCCUPATIONAL SKIN DECEASE AFFECTS LUNGS - SILICOSIS FOR FOUNDRY WORKMEN RESPIRATORY CONDITION DUE TO TOXIC AGENTS
ACUTE CONJUNCTIONS DUE TO CHEMICAL DUSTS, FUMES AND GASES

DISORDER DUE TO PHYSICAL AGENTS - ENVIRONMENTAL HEAT OR LOW TEMPERATURE EYE IRRITATION, COUGH AND BREATHLESSNESS FORMATION OF CARBOXYL HEMOGLOBIN WHICH PREVENTS O2 CARRIAGE BY BLOOD

GROWTH OF PROBLEMS OF AIR POLLUTION

Rapid economic growth Rapid industrialization and urbanization Increased industrial production Population explosion Growth in demand for power Increase in requirement for thermal power plants More number of old coal based power plants designed for high emission & low ash content coal High ash content or deterioration in quality of coal reserve

National Ambient Air Quality Standards

TYPES OF DUST COLLECTING EQUIPMENTS

Pressure Collection drop effieicny, mmWc %

Sl. NO.

Type of Dust collectors

Remarks

1.

Gravity Settling 25-30 chamber

30 to 40

Less efficiency, more space required and not suitable for power plant Not for power plant Were widely used in power plants but can not satisfy the present day pollution control requirement

2.

Inertial Collectors Impact 30 40 Centrifugal 60-80 (cyclones)

30 40 75 to 80

TYPES OF DUST COLLECTING EQUIPMENTS

Sl. NO. Type of Dust collectors Pressure Collection drop effieicny, mmWc % Remarks

3.

Scrubbers(wet)

50 to 60

80 to 90

4.

Electrostatic precipitators Fabric Filter

15-25

99.99

125 to 150

99.99

Used mainly in process industries and can not satisfy the pollution control requirement Can meet any efficiency and mostly used in all power plants. Can meet any efficiency and used many power plants abroad. Gaining momentum in Indian Power plants also.

PURPOSE OF POLLUTION CONTROL EQUIPMENT

Recovery of material for economic reasons

Pulp and Paper Industries (Sodium Sulphate)

Removal of abrasive material in the dust to reduce wear and tear of the Fan components Removal of objectionable matter in the dust
NO2 and SO2

ADVANTAGES OF ELECTROSTATIC PRECIPITATORS

Very high collection efficiency Low pressure drop capacity to collect sub-micron particles Robust construction - Longer life Less maintenance Adaptability

ELECTROSTATIC PRECIPITATOR PRINCIPLE

ELECTROSTATIC PRECIPITATOR WORKING PRINCIPLE

The precipitation process involves 4 main functions Corona generation Particle charging Particle collection Removal of particles

ESP - CORONA GENERATION

Due to the ionisation of gas molecules, + ve ions, -ve ions and free electrons are generated.

CORONA DISCHARGE IN SPIRAL ELECTRODE

ESP - PARTICLE CHARGING

The -ve charges of ions and free electrons travel towards +ve electrode and the +ve charges of ions travel towards -ve electrodes. When -ve ions travel towards +ve electrodes, the -ve charges get attached to the dust particles and thus the dust particles are electrically charged,

ESP - PARTICLE COLLECTION

ESP - REMOVAL OF PARTICLE

PRINCIPLE

ESP SIZING THEORY

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.

DEFINITIONS

Flue gas velocity, m/s

Flue gas flow in m3 ESP effective cross section m2 Effective length of ESP Collecting electrode height Effective length of ESP in m Flue gas velocity in m/s

Aspect ratio

Treatment time, sec

DEFINITIONS

EFFECT OF VARIOUS PARAMETERS

Gas velocity velocity is decided by the gas flow and collection efficiency required Higher the gas velocity, higher the carryover of dust particles without collection - Re-entertainment Very poor velocity alters the flow distribution and effects settling of dust particles optimum velocity depends upon the application will improve the performance.

EFFECT OF VARIOUS PARAMETERS

Aspect ratio During the rapping, the falling of dust particle take a trajectory form Lower the aspect ratio, the trajectory dust travel along with gas flow without falling in to hoppers - Leads to re-entrainment loss. Higher the ratio, performance will be good optimum aspect ratio depends on allowable velocity, required collection efficiency and available space.

EFFECT OF VARIOUS PARAMETERS

Treatment time Time available for capturing the dust particle more treatment time at reasonable velocity improves the collection efficiency Probability of capturing the re-entrained partilces improves with time.

ENVIRONMENTAL REGULATIONS IN INDIA Prior to 1984 1974 water act 1977 water cess act 1981 air act The cost of compliance was more than that of non-compliance: 1986 Environmental Protection Act comprehensive act with command & control

Future trend is to internalize the environmental improvement cost

REVISED EMISSION STANDARD

(GAZETTE NOTIFICATION BY MINISTRY OF E&F DATED 19 05 93)

SUSPENDED PARTICULATE MATTER (SPM) STANDARD ALSO STATES THAT FOR POWER PLANTS CAPACITY LESS THAN 62.5 MW AND COMMISSIONED BEFORE 01 01 1982 FOR CEMENT PLANTS (TOTAL EMISSIONS) CAPACITY LESS THAN 200 TPD CAPACITY MORE THAN 200 TPD

: < 150 mg/Nm3

: 350 mg/Nm3

: 400 mg/Nm3 : 250 mg/Nm3

ENVIRONMENTAL REGULATIONS TODAYS WORLD

World Banks proposed guide lines For new thermal power plants (TPP) for capacities 50 MW Pollution control at project formulation level itself Site specific emission guide line Propose standard of 50 mg/Nm3 Aided projects are to abide by this Further implication on technical, economic & institutional

National Ambient Air Quality Standards

Emission of various pollutants under the business-as-usual scenario Projection YEAR CO2 1996 2001 2006 2011 428.0 511.0 605.5 736.2 POLLUTANTS (MT) CO 16.162 17.9 19.6 22.0 SPM 0.30 259.1 338.0 434.0 NOX 1.34 1.75 2.19 2.82 SOX 0.049 0.089 0.125 0.158

WORLD BANK NORMS

COMPARISON OF PARTICULATE EMISSION NORMS IN OTHER COUNTRIES

Country USA Germany Europian community Australia Sweden India

Mg/Nm3 36 50 50 250 56 150

ppm 28 39 39 194 43

COAL REQUIREMENT FOR BOILERS TYPICAL

Coal with ash content 45 % and HHV 3000 Kcal / Kg 110 MW Coal required in tph Ash generated tph Ash entering ESP tph 95 42.75 34.2 210 MW 185 83.25 66.6 500 MW 420 189 151.2

Boiler circuit with Precipitator

BHEL ESP for different application

Boiler PF / CFBC / AFBC / stoker Recovery Boiler for paper plant Lime Kiln for paper plant

Biomass Bagasse / Ricehusk / wood chips

Cement plant - cooler / kiln / coal mill / cement mill Steel plant Sponge Iron / Sinter plant Glass plant

ESP REFERENCE
APPLICATION
UTILITY BOILERS - PF Fired - 15 to 660 MW INDUSTRIAL BOILERS CPP, VU40, Stoker, etc AFBC BOILERS 25 to 165 TPH CFBC BOILERS 30 to 250 MW CHEMICAL RECOVERY BOILERS 75 to 900 TPD OIL FIRED BOILERS -125 MW BIOMASS Upto 20 MW CEMENT STEEL

NO. OF PROJECTS
437 104 57 18 46 3 50 16 11

NO. OF ESPs
1074 134 57 33 70 3 50 16 13

GLASS FURNACE
LIME KILN 170 TPD - Paper plant REFRACTORY - Magnesite

2
1 1

2
1 1

TOTAL

746

1454

NOTE: The above list is applicable for the contracts with zero date up to 14.08.2007

BHEL ESP NOMENCLATURE

4 X F A A 8 X 45 M 2 X 96 150 - 2
Type of Hopper: 1 Trough; 2 Pyramidal 3 No hopper Flat bottom

Nominal Height of CE, In deci metre

Nominal width of ESP, in deci metre Number of Bus sections per field Electrode spacing in mm, F - 250; H - 300; M - 400 Nominal length of field, in deci metre Number of fields per ESP Material of casing, A Steel; C - Concrete Direction of gas flow, A Horizontal; T - Vertical F Electrical filter Number of ESP per Unit

ESP DESIGN CONSIDERATIONS

EMISSION VS ESP EFFICIENCY FOR DIFFERENT DUST BURDEN

EFFICIENCY REQUIREMENT - %

100

20g/Nm3 40 g/Nm3 60 g/Nm3 80 g/Nm3

99.75 99.5

99.25 25 50 75 100 125 150 EMISSION REQUIREMENTm g/Nm 3

HIGH INLET DUST REQUIRES LARGER ESP

100 g/Nm3

DESIGN DATA REQUIRED FOR ESP

Application Process data Gas composition Gas pressure Gas moisture Dust composition Particle size distribution Basic design data
Gas flow rate Gas temperature Inlet dust concentration Environmental data Outlet emission

FACTORSW CONSIDERED FOR ESP SELECTION

Gas flow Gas temperature Inlet dust concentration Required outlet emission Required collection efficiency Moisture in gas Sulphur content in coal Ash resisitivity Particle size distribution No. of ESPs per boiler Minimum number of fields required Minimum Specific collecting area Maximum gas velocity Minimum aspect ratio Maximum area connected to one TR set Collecting electrode spacing

Effect of emission over increase of gas flow 600 500 490 360 300 260 200 100 0 100% 110% 115% 120% 125% Gas flow Graph shows the effect on ESP emission, due to increase of gas flow only, without considering variation in gas temp. & dust load. Variation of ESP emission w.r.t. gas flow is not linear. For 25 % increase of gas flow, emission shoots up by about 5 times. 150 100 190 165 172.5 180 187.5

Emission

400 Flow Emission

Effect on emission due to increase of gas temperature

250

200 145 150 152 130 100 50 107 202 155

150

135

140

Emission
100

Gas Temp.
Emission

0 Base 5 10 15 20

Gas temperature

Graph shows the effect on ESP emission, due to increase of gas temperature only, without considering variation in gas flow & dust load. Variation of ESP emission w.r.t. gas temperature is not linear. For 20 deg. C (15 %) increase of gas temperature, emission shoots up by about 2 times.

ESP DESIGN PARAMETERS FOR UNITS 7 & 8, 9&10 NTPC VINDHYACHAL

PARAMETERS UNITS 7&8 UNITS 9&10

ESP TYPE

FAA 7X45H 2X96130

FAA 8X45H 2x90135

GAS FLOW RATE Flue gas temerature

872.74 m3/sec 130 deg C

851.00 m3/sec 130 deg C

INLET DUST CONCENTRATION

40.47 gms / Nm3

38.90 gms / Nm3

OUTLET DUST CONCENTRATION

50 mg / Nm3

27 mg / Nm3

Specific collecting area

240.23 m2 / m3 / sec

274.12 m2 / m3 / sec

BOILER OPERATING PARAMETERS FOR UNITS 7 & 8, 9&10

PARAMETERS LOAD STEAM FLOW UNIT 8 508 MW 1571 T/ Hr UNIT 9 507 MW 15 92 T/HR

STEAM PRESSURE
FURNACE PRESSURE STEAM TEMPERATURE COAL FLOW TOTAL AIR FLOW O2 PERCENTAGE FLUE GAS TEMPERATURE AT APH OUTLET FLUE GAS TEMPERATURE AT ID INLET FD FAN CURRENT ID FAN CURRENT

172 KG/CM2
-3 MM WC 540 DEG C 315 T/Hr 1560 T / Hr 4.5 % A 140 / 170 A 152 45 360 / 370 3.0% B 150/ 175 B 164 43 340 / 328

170 KG/CM2
-8 MM WC 540 DEG C 310 T/Hr 1815 T/Hr 3.6 % A 133 /137 A 127 130 252/270 B 140/130 B 122 124 294/295

FLY ASH RESISTIVITY

Resistivity is an important factor, affecting ESP performance.

Ash with low resistivity is prone to re-entrain when the collecting plates are rapped.

Ash with high resistivity can cause back corona and reduce ESP
performance. Fly ash resistivity dependent on: - Gas temperature - Gas moisture - Sulphur content in coal - Ash composition (SiO2, Na2O3, CaO etc)

- Carbon content in ash

- Particle size of dust

ESP DESIGN CONSIDERATIONS HIGH INLET DUST REQUIRES LARGER ESP

EM ISSION VS ESP EFFICIENCY FOR DIFFERENT DUST BURDEN

EFFICIENCY REQUIREMENT - %

100

20g/Nm3 40 g/Nm3 60 g/Nm3 80 g/Nm3

99.75 99.5

99.25 25 50 75 100 125 150 EM ISSION REQUIREM ENTm g/Nm 3

100 g/Nm3

Variation of Coal ash content

50 45 40 35 30 45

ASH, %

25 20 15 12.98 10 7.7 5 0 1.54 INDONESIA CHINA AUST RALIA SOUT H AFRICA US (OHIO) INDIA 10.76 16

ESP DESIGN CONSIDERATIONS

ESP COLLECTION EFFICIENCY VS SIZE

9

COMPARATIVE ESP SIZE

8 7 6 5 4 3 2 1 0 90

BASE : ESP SIZE FOR 90% = 1

91

92

93 94 95 96 97 98 COLLECTION EFFICIENCY - %

99

100

ELECTROSTATIC PRECIPITATOR

ELECTROSTATIC PRECIPITATOR

ASH COLLECTION & EMISSION PATTERN

FIELD 1 Collection efficiency, % Ash collection, kg / Hr Emission with all fields, mg / NM3 Emission with 1 field off, mg / NM3 Emission with 2 field off, mg / NM3 Emission with 3 field off, mg / NM3 Emission with 4 field off, mg / NM3 81.4 FIELD 2 13,8 FIELD 3 3.5 FIELD 4 0.91 FIELD 5 0.272

26142

4432

1124

292

87

100

265

765

2440

9550

Collection efficiency with 5 fields = 99.882 %

Different ESP size for same boiler capacity

Different fuel Different coal quality (CV / ash) Different emission value (150/100/75/50 mg/Nm3) Emission with all fields or with one field off or both ESP with one dummy field ESP with one dummy filed & one field off ESP selection for worst coal & guarantee for normal operation with Design coal ESP selection based on minimum SCA

EMITTING ELECTRODE

UPGRADING ESP - COMPONENTS FOR REPLACEMENT RAPPING MECHANISM AND TUMBLING HAMMERS

SUSPENSION ARRANGEMENT OF HIGH VOLTAGE SYSTEM

UPGRADING ESP - COMPONENTS FOR REPLACEMENT DISCHARGE ELECTRODE RAPPING MECHANISM

COLLECTING SYSTEM

UPGRADING ESP - COMPONENTS FOR REPLACEMENT RAPPING MECHANISM AND TUMBLING HAMMERS

SUSPENSION ARRANGEMENT OF HIGH VOLTAGE SYSTEM

ESP CASING

UPGRADING ESP - COMPONENTS FOR REPLACEMENT RAPPING MECHANISM AND TUMBLING HAMMERS

ESP HOPPERS

METHODS OF IMPROVING

ESP
PERFORMANCE

FLUE GAS CONDITIONING

FGC HAS BEEN INSTALLED AT BHATINDA, UKAI, KOLAGHAT & HWB MANUGURU M/S CHEMITHON CLAIMS EXCELLENT PERFORMANCE THE SPM FIGURES GIVEN BY UTILITY DOES NOT CONFIRM PERFORMANCE IMPROVEMENT IS NOT PROVEN. THERE IS A HIGH COST OF INSTALLATION AND RECURRING RUNNING COST

USE OF BAG FILTERS

BAG FILTERS ARE EXTENSIVELY USED IN CEMENT INDUSTRY IT HAS 100% EFFICIENCY PERFORMANCE INDEPENDENT OF LOAD DUE TO HIGH AMBIENT TEMPERATURE NYLON BAGS HAVE TO BE USED WHICH ARE EXPENSIVE BAGS REPLACEMENT COST IS HIGH

BAG FILTERS IN SERIES

THIS HAS BEEN TRIED AT KORADI MAHARASHTRA PERFORMANCE IMPROVEMENT IS THERE BY ABOUT 15% REPLACEMENT COST OF NYLON BAGS IS VERY HIGH THIS HAS ALSO NECESSIATED THE REPLACEMENT OF ID FANS

NEED FOR UP-GRADATION

TO MEET REVISED EMISSION REQUIREMENT TO AVOID UNFORESEEN OUTAGES

TO OPTIMIZE INSPECTION AND MAINTENANCE SCHEDULE

UP-RATING / CHANGE IN PLANT CAPACITY CHANGE IN FUEL CHARACTERISTICS CORROSION COMPONENTS OR OR RAW MATERIAL

CHANGE IN OPERATING CONDITION OF BOILER EROSION OF MECHANICAL

DETERIORATION IN PERFORMANCE DUE TO AGING

UPGRADING ESP EXTENDING CASING HEIGHT

OPTION 1

OPTION 2

Thank you
By, G.R.SHARIEF, MANAGER/FES, BHEL,RANIPET.