Electrostatic Precipitator

Thursday, June 21, 2012
ELECTROSTATIC PRECIPITATOR
CONTENTS
INTRODUCTION PRECIPITATOR COMPONENTS ARRANGEMENTS BASIC PRINCIPLE TECHNICAL SPECIFICATION ERECTION SEQUENCE
2 x 600 MW Mahan Thermal Power Project
INTRODUCTION
We are Setting up 2x600 MW Coal Based Thermal Power Plant at Mahan Bandhaura Site. Electrostatic Precipitator is playing a vital role in most of the industries, such as 1) Thermal Power Plant 2) Cement Plant 3) Chemicals industries 4) Steel Plant 5) Paper Industries & etc
An electrostatic precipitator is a large, industrial emission-control unit. It is designed to trap and remove dust particles from the exhaust gas stream of an industrial process. In large power plants may actually have multiple no. of fields for each unit. In our plant, there are 9 no. of fields per unit.
Thursday, June 21, 2012 2 x 600 MW Mahan Thermal Power Project
MAJOR COMPONENTS OF ESP:
1) Rectifier Transformer 2) Discharge Electrodes 3) Collecting Electrodes 4) Gas Distribution Systems 5) Rapping system 6) Hopper. About Rectifier Transformer: The power supply system is designed to provide high voltage to the field to increase the collection efficiency at the highest possible level The power supply system has four basic components: 1) Step-up transformer 2) High-voltage rectifier 3) Sensing device 4) Automatic voltage control
DESCRIPTION ABOUT THE POWER SUPPLY SYSTEM The voltage must be controlled to avoid causing sustained arcing or sparking between the electrodes and the collecting plates 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. AVR monitors protects the internal components from arc-over damages, and protects the transformer-rectifier and other components in the primary circuit. 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.
Spark reaction When the voltage applied to the field is too high, then spark over will occur. A voltage controller will monitor the primary and secondary voltage and current of the circuit, and detect a spark over condition. Once detected, the power applied to the field will be immediately cut off or reduced, which will stop the spark. After a short amount of time the power will be ramped back up, and the process will start over.
Tripping When a condition occurs that the voltage controller cannot control, often times the voltage controller will trip. A trip means the voltage controller (by way of the contactor) will shut off the individual precipitator power circuit.
A short inside the electrostatic precipitator field caused by a fallen discharge electrode (wire), or a shorted out Silicone Controlled Rectifier are examples of conditions that a voltage controller cannot control.
About Discharge Electrodes: Discharge electrodes emit charging current and provide voltage that generates an electrical field between the discharge electrodes and the collecting plates. The particles then precipitate onto the collecting plates. Common types of discharge electrodes include: 1) Straight round wires 5) Rigid frames 2) Rigid spiked pipes 6) Spiral wires 3) Twisted wire pairs 7) Barbed discharge wires 4) Rigid masts
Rigid Electrode Spiral Electrode
About Collecting Electrodes: 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.
About Gas distribution system: Gas velocity distribution can be most effectively influenced by the use of gas distribution devices. Ideally, uniformity is desired in: 1. Gas velocity 2. Gas temperature 3. Dust loading Gas distribution devices consist of turning vanes in the inlet ductwork and perforated gas distribution plates and in the outlet fields of the precipitator, flat distribution plate is used.
INLET GD SCREEN OUTLET GD SCREEN
Rapping System: To improve collection efficiency and ensure proper functional use of the precipitator, a rapping system is applied to the collection and emitting electrodes to dislodge the collected dust layer. 1) Collecting Rapping System: Collecting plate rapping must remove the bulk of the precipitated dust. The collecting plates are supported directly with hooks from the precipitator casing. The impact of the rapping system is directed into the Shock bar located at the leading and/or trailing edge of the collecting plates.
The first electrical field generally collects about 60-80% of the inlet dust load. So the first field plates should be rapped often for the every cycle.
Collecting Rapping System
COLLECTING FRAME
COLLECTING PLATE
SHOCK BAR
Rapping cycle for the each field as follows:Field No. 1 2 3 4 5 6 7 8 Stage Efficiency % 80% 15% 3% 1.2% 0.55% 0.11% 0.032% 0.007% Rapping frequency, Raps/hr 6/Hr 4/Hr 2/Hr 1/Hr 1/2Hr 1/4Hr 1/8Hr 1/day
0.001%
1/2day
1) All the above data are estimated value, especial the rapping mechanism. It should be adjusted iterative according to actual working condition. 2) Each rapping time is 1.5 mins
2) Emitting Rapping System In general, discharge electrodes should be kept as free as possible of accumulated particulate. The rapping system for the discharge electrodes should be operated on a continuous schedule with repeat times in the 2 - 4 minute range, depending on the size and inlet particulate loading of the precipitator.
3) Rapping System for Distribution Screen The gas distribution plates should also be kept free of excessive particulate buildup and may require rapping on a continuous base with a cycle time in the 10-20 minute range, depending on the inlet particulate loading of the precipitator and the nature of the particulate. Gas distribution plates in the outlet of the precipitator may be rapped less often (every 30 - 60 minutes).
4) Bottom Hopper Precipitator hoppers are designed to completely discharge dust load on demand. Typically, precipitator hoppers are rectangular in cross-section with sides of at least 60-degree slope. These hoppers are insulated from the neck above the discharge flange with the insulation covering the entire hopper area. In addition, baffles are provided in the hopper to avoid the seepage.
8400mm
5650mm
Hopper
ESP 1ST PASS

12.7m/s
ARRANGEMENTS: ESP 1 PASS

1 1 1 1
P to Q - 1st FIELD
2 2 2 2
Q to R 2nd FIELD
3 3 3 3
R to S 3nd FIELD
4 4 4
S to T 4th FIELD
Emitting electrodes - RSB Wire
5 5
T to U 5th FIELD

6 6 6 6 7 7 7 7 8 8 8 8 9 9 9 9
U to X 6th FIELD X to Y 7th FIELD Y to V 8th FIELD V to W 9th FIELD

Emitting electrodes - Spiral Wire
12.4m/s
COLLECTING & EMITTING PLATE ARRANGEMENT FOR 1ST TO 6TH FIELD. Emitting plate 4 layers Collecting plate
EACH HEIGHT OF THE COLLECTING PLATE EACH HEIGHT OF THE RSB WIRE DETAILS OF COLLECTING ELECTRODE NO. OF COLLECTING ELECTRODE IN HALF FIELD (8*43) NO. OF COLLECTING ELECTRODE IN ONE FIELD NO. OF COLLECTING ELECTRODE IN SINGLE PASS (688*9) NO. OF COLLECTING ELECTRODE IN TWO PASS (6192*2)
200mm 200mm 400mm
15 M 3.581 M
344 No's 688 No's 6192 No's 12384 No's
COLLECTING & EMITTING PLATE ARRANGEMENT FOR 1ST TO 6TH FIELD.
DETAILS OF EMITTING ELECTRODES (RSB WIRE)

NO. OF RSB WIRE BETWEEN TWO COLLECTING ELECTRODE NO. OF RSB WIRE IN HALF FIELD NO. OF RSB WIRE IN ONE FIELD NO. OF RSB WIRE IN SINGLE PASS FROM 1st TO 6th FIELD(2688*6) NO. OF RSB WIRE IN TWO PASS FROM 1st TO 6th FIELD(16128*2) No's No's No's No's No's 4 1344 2688 16128 32256
COLLECTING & EMITTING PLATE ARRANGEMENT FOR 7TH TO 9TH FIELD
Emitting plate 4 layers

Collecting plate
DETAILS OF EMITTING ELECTRODES (SPIRAL WIRE)
NO. OF SPIRAL BETWEEN TWO COLLECTING ELECTRODE NO. OF SPIRAL WIRE IN HALF FIELD NO. OF SPIRAL WIRE IN ONE FIELD (2688*2) NO. OF SPIRAL WIRE IN SINGLE PASS FROM 7th TO 9th FIELD(5376*3) NO. OF SPIRAL WIRE IN TWO PASS FROM 7th TO 9th FIELD
No's No's No's No's No's
8 2688 5376 16128 32256
COLLECTING PLATE SUPPORTED ARRANGEMENT
Collecting Plate
Emitting Plate
Guide Bar
COLLECTING FRAME
Collecting System
COLLECTING FRAME
COLLECTING PLATE
SHAFT RAPPER
SHOCK BAR
AVIL PLATE
Emitting System Support:
Emitting System Support:
TEMPORARY HANGER BOLT HANGER BOLT SUPPORT INSULATOR CHANNEL WITH INNER ROOF
BEAM
VERTICAL BOX
BEAM
HORIZONTAL EMITTING FRAME
SUPPORT INSULATOR AT FOUR CORNERS
SUPPORT INSULATOR AT FOUR CORNERS
VERTICAL VIEW OF EMITTING SYSTEM SUPPORTTED VERTICAL BOX
EMITTING ELECTRODE (RSB
EMITTING FRAME FOR 1ST to 6TH FIELD:
Emitting Frame TOP VIEW OF EMITTING FRAME
Emitting Frame
RSB Electrode
Collecting Electrode
VERTICAL BOX
INNER WALK WAY
EMITTING FRAME
EMITTING FRAME FOR 7TH TO 9TH FIELD:
Emitting Frame
Spiral Electrode
Collecting Electrode
VERTICAL BOX
HV inlet:
BASIC PRINCIPLES: Electrostatic precipitation removes particles from the exhaust gas stream by Six activities typically and they are 1) Ionization 2) Migration/Drift Velocity 3) Precipitation. 4) Charge Dissipation
5) Particle Dislodging
6) Particle Removal
1.Electron emission 2.Dust particle charging/ corona formation
Dust layer Collecting electrode, grounded
2
3.Migration 3
5.Rapping
5
Discharge electrode with Negative high tension volatge (72 KV)
4
4. Precipitation
Working Principle:
The high voltage supply (72 KV) is applied to the Field, the discharge electrode emits the negatively charged ions. Particles suspended in a gas enter the precipitator and pass through ionized zones around the high voltage discharge electrodes, the particles are get ionized with negative and positive charged ions. This is called as Corona Formation
The negatively charged gas field around each electrode charges the particles causing them to migrate to the electrodes of opposite polarity, i.e. the collecting electrodes.
The charged particles gather on the grounded collecting plates. Rappers dislodge the gathered particulate, which falls into the collection hoppers for removal.
ESP TERMINOLOGY
TECHNICAL SPECIFICATION: [General Information about ESP] S. No
1 2 3 4 Manufacturer Type and No. Overall dimensions (L X W X H) Number of ESP / Steam generator Number of gas stream / ESP
Description
Data
SUNYARD 2SY504-9 73.9353.1533.7m 2/1 2/1
5
6 7 8 9 10 11
Number of electrical fields in series in gas path / stream

Total active treatment length per stream (in m) Treatment time (In sec) Corona power per ESP stream (watts per 1000 m3 per min) No. of hours ESP can run at specified gas flow and dust loading without emptying any hopper (hrs) Total power input to the ESP per steam Generator
9/1
36 40.9 49 2 4400 KW
FLUE GAS: S. NO DESCRIPTION
FLUE GAS Flue gas amount at inlet of E.S.P Flue gas temperature at inlet of E.S.P Excess air coefficient at inlet of E.S.P Dust concentration of flue gas at inlet of E.S.P Dust concentration at the ESP outlet g / Nm3 mg / Nm3
UOM
m3/hr
oC
DESIGN COAL WORST COAL
1 2 3 4 5
1604198 136 1.34 63.573 50mg/Nm3
1696002 135 1.333 74.931 50mg/Nm3
COLLECTING ELECTRODE SPECIFICATION
S. No
1 2 3 Type Material Electrode thickness (mm)
Description
Data
480C SPCC 1.5 400 0.48 5042 15 204.1 26192 2.24 0.88
4
5 6 7 8 9 10 11
Clear distance between collecting electrode plates(mm ) Active length per electrode (in m) Cross sectional area of each passage (in m2) Active height per electrode(in m ) Specific collection plate area (m2/m3/sec) Total number of electrodes per SG Aspect ratio length / height Average gas velocity in the electrical field(m/s )
DISCHARGE ELECTRODE SPECIFICATION S. No
1 Type Material Total number of electrodes / SG (RSB Wire) Total number of electrodes / SG (Spiral Wire) Electrode dimension height (m) Effective length of electrode(m) High Voltage Conductor 7 8 9 Manufacturer Type Size SUNYARD taper 150x400mm
Description
Data
I to VI field RSB,I to IX field spiral wire. I to VI field SPCC,I to IX field stainless steel. 2 X 16128 2 X 16128 3.581 15
2
3 4 5 6
BUS SECTION SPECIFICATION
S. No
1 2 3 4 5 6 Total numbers
Description
Data
36 4 2 72 4400KW 1/2
Number of bus sections in parallel in gas path Number of sections in parallel in gas path HT Voltage [kV (peak)] Total power on HT electrode(kW) Number of sections lost if one transformer is out of service
COLLECTING RAPPER SPECIFICATION
S. No
1 Type
Description
Data
Side driven, flexible arm rapper.
2
3
Total no. of rapper drive

Total number of rappers per SG Maximum number of electrodes rapped by a rapper at any one time Percentage of plates rapped at one time ( % ) Rapping acceleration force minimum / plate(g ) Average input rapping power to rapping system (kW ) Rapper controller type
2 x 18 nos
2 x 774 Nos
4
5 6 7 8
8
50 150 13.32 electronic program
DISCHARGE RAPPER SPECIFICATION S. No
1 2 3 4 5 6 7 Type Total no. of rapper drive Total number of rappers
Description
Data
Top driven, flexible arm rapper. 2 x 18 Nos 1476
Percentage of electrodes rapped at any time ( % )

Rapping energy of each rapper ( kgs.) Average input power to rapping system ( kW ) Rapper controller type
50
50 13.32 electronic program
TRANSFORMER RECTIFIER UNIT
S. No
1 Total numbers Transformer 2 Type of transformer Class of insulation
Description
Data
36
oil immersed F 50 35KV
3
4 5 6
Temperature rise of oil over ambient ( 0C ) Class of bushing Rating of each set Input power kVA
206 kVA 120 kW 72 KV 2000 mA

7 8 9
Output power kW Output Voltage KV Output current mA
S. No
10 Volume of oil (Liters ) Rectifier
Description
Data
900 Liters
11
12 13
Type Half-wave / full wave Guaranteed life ( hours ) Rating-each Rectifier unit
Bridge type full wave 80000 hours
14
Number offered Type of cabinet
36 sets MNS
15
16 17 18 19
Voltage for controller

Arc suppression Protection Instrumentation provided as required
AC 110V
2500V IP42 Volt meters, ampere meters,
POWER CONSUMPTION OF ESP PER SG S. No
1 2 3 4 5 6 7 8 9 10 11 12 Input power (kVA )
Description
206 kVA Output power from TR sets kW Output voltage KV Output current mA Total connected load kW
Data
120 Kw/TR 72 kV 2000 mA 118 kW
Maximum power requirement kW

Corona power available Watts / m2 Auxiliary power kW Rapping system kW Seal air fan kW
154 kW
26 Watts / m2 0.25 kW 0.74 kW 0.01 kW 0.05 kW 4.5 kW
Seal air heaters (during start up/ normal) kW Hopper heaters kW

ERECTION SEQUENCE Check and set out the foundation
Check and set out the foundation
Erection of Steel Structures
Erection of Steel Structures
Erection of pedestal
Assemble the ash Hopper
Assemble the ash Hopper
Erect the ash hopper
Erection the Ash hopper
Erect the casing
CASING STRUCTURE CASING WALL LRB TRB LRB
CHANNEL WITH INNERROOF
GABLE WALL GABLE WALL
OUTLET HOOD DISTRIBUTION SCREEN O/L
GABLE WALL
5600/6192 COLLECTING PLATES ERECTED
PASS A
70
PASS B
71
PASSA PASSB
72
Erect the stairs and approaches
Assemble the emitting frame
Lift the emitting hanging beam
Lift the collecting and emitting frame
Check the emitting and collecting system

Install the roof
Install the pressure-bearing insulator
Assemble the inlet funnel
Assemble the outlet funnel
Install the inlet/outlet funnel

Install the heat insulation can and insulation axis
Install the HV leading-in wire Install the top penthouse and lifting system
Install the rapping system
Install the grounding device
Install and check the electrical equipment

Install the hopper wall vibrator, ash exhaust, level indicator and electric heater.

Electrostatic Precipitator

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Electrostatic Precipitator

Uploaded by

Copyright:

Available Formats

Thursday, June 21, 2012

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

ESP 1ST PASS

ARRANGEMENTS: ESP 1 PASS

Thursday, June 21, 2012

Emitting electrodes - RSB Wire

2 x 600 MW Mahan Thermal Power Project

U to X 6th FIELD X to Y 7th FIELD Y to V 8th FIELD V to W 9th FIELD

344 No's 688 No's 6192 No's 12384 No's

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

DETAILS OF EMITTING ELECTRODES (RSB WIRE)

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Emitting plate 4 layers

No's No's No's No's No's

8 2688 5376 16128 32256

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project

HORIZONTAL EMITTING FRAME

Thursday, June 21, 2012

2 x 600 MW Mahan Thermal Power Project