How an Electrostatic Precipitator Works
Transcript of How an Electrostatic Precipitator Works
How an Electrostatic Precipitator Works
Introduction
Currently, throughout the country, many places and people are pushing for a “greener” way of
life. This doesn’t mean that they want us to turn into Kermit the Frog. It means that they want
us to take a look at the way in which we do things. They want us to look at more fuel efficient
vehicles, what things are made of, and how much pollution is entering our environment. There
are many other factors to the whole “greener” phenomenon, but these seem to be the leading
problems.
Air pollution standards change. With that said, it is important for major refineries to update their
pollution equipment according to the new standards. This costs millions of dollars, but they have
no choice. Electrostatic precipitators are designed to deal mostly with coal fired refineries. In
this country, we have more coal then we know what to do with, however, it does not burn
cleanly. Lately though, coal has been making a comeback in big industries. Electrostatic
precipitators separate the clean from the unclean, and in the end what you have is a refinery that
is releasing air that is almost 99% cleaner. Figure 1 shows an overhead view of how an
electrostatic precipitator works.
Figure 1. Top View of ESP.
ESP’s are similar to the way an ionic breeze works. They take the incoming dirty air and pass it
through a filtration device that purifies the air. Any solid particles left over will fall into a large
storage container called a hopper and the clean air is brought out. Figure 2 illustrates the
operation of an electrostatic precipitator in its simplest form. This procedure will inform you on
what makes up an electrostatic precipitator and how they work once the pieces are put together.
The main components of an ESP are:
- Collecting Plates
- Discharge Electrodes
- Rappers
- Hoppers
A. Collecting Plates
Figure 3. ESP Plate.
Figure 3 shows a typical collecting plate used in electrostatic precipitators.
1. Collecting plates are made from rolled steel, and are welded together in the factory to
reduce the installation time at the jobsite. Each plate contains electrodes which are positively
charged. When the particulate gas enters the electrostatic precipitator and is struck with a
negative charge electrode, the positively charged plates act as a magnet and pull the
particulate gas to them.
2. The plates have both top and bottom stiffeners and plates which allow better mounting and
the ability to deal with more abuse from the rappers. The plates are arranged to form a series
of gas passages.
3. There can be anywhere from 30-35 passages inside the electrostatic precipitator shell. The
plates are placed parallel to the incoming particulate gas.
B. Discharge Electrodes
1. Discharging electrodes are a high voltage unit that negatively charges the particulate gas as
it enters. These electrodes were once wires that were suspended from the ceiling and
weighted at the bottom, but are now a rigid mast.
2. There are many types of configurations of discharge electrodes which can be tailored to
your needs. The most common types are the two spiked and multiple spiked electrodes.
Figure 4 shows the two spiked discharge electrode.
Figure 4. Discharge Electrode
3. The discharge electrode is mounted to a frame in between the collecting plates. The
negatively charged particles that pass by the electrodes and then the counter charge of the
collecting plates; make the particulate like the magnet on a refrigerator.
C. Rappers
1. There are many types of rappers. Rappers are used to dislodge the particulate from the
collecting plates. Some types of rappers are mechanical, pneumatic, and the MIGI rapper.
2. Mechanical rappers work like a hammer and chisel. The hammers are attached to the rods
which are attached to a rolling cam above. The cam is turned by an external motor and gear.
3. The pneumatic rapper uses compressed air to operate. Pneumatic powered rappers work
really well as long as the conditions permit and the factory has compressed air on tap.
4. MIGI stands for magnetic impulse gravity impact rapper. The MIGI uses magnetic coils
to drive the hammer up and down. The magnetic coil is wrapped around the hammer. When
the magnet is electrically energized, the hammer will be pulled up, similar to the way a
positive and negative magnet are attracted. Once the electricity is turned off from the
magnet, the hammer falls, similar to the way two negative or positive magnets repel.
5. All three are effective in what they do. Rappers knock the solid particulate off of the
collecting plates where it is collected and then trucked away.
An example of each can be found in Figure 5, 6, 7.
Figure 5. MIGI Rapper.
Source: http://www.apcnetwork.com/ESP%20Photos/Posters%20Pictures/Rappers/Picture%2001.JPG
Figure 6. Pneumatic Rapper
Source:
D. Hoppers
1. Hoppers look like upside down triangular prisms. They are generally made of steel, and their
only purpose is to store particulate.
2. Once the rappers have done their job, it is then time to collect the falling particulate. Once the
particulate has entered the hopper, it is stored there until it is emptied and the particulate is
carried away by a conveyor.
3. Most hoppers are heated so that the presence of moisture will be minimized. The worst thing
that can happen is that the solid particulate gets wet and hardens in the hopper. This will cause
the hoppers to be unable to be emptied causing serious issues.
Figure 8 gives a general view of what a hopper looks like.
Figure 8. Hopper.
How They Work
1. Once all the previous items have been created, they are placed in a “shell.” This shell is
basically the home of the precipitator. Almost all of the previous components are located in the
shell. The shell is typically comprised of carbon steel. It has holes on either side for the inlet
and outlet ducts. The shell is also insulated to reduce the risk of condensation build up.
2. Condensation will form when the flue gas which can leave the refinery at 200oF hits the inside
of a cold precipitator. Also condensation will interfere with the way in which the electrodes
work and render them useless because the condensation will collect on the walls and will begin
to collect the particulate before it can be properly taken care of.
3. The hoppers are one of the major external elements. Yes, there are wires, piping and
ductwork on the outside, but in the end the hoppers collect the particulate. They, just like the
shell, are typically made of carbon steel. Their main job is to collect what is rapped off the
collecting plates. Once the particulate has been collected, and the hoppers are full, valves and
access doors are used to evacuate the hoppers. The hoppers can have piping running to them for
a vacuum operated system which will pull the particulate from the hoppers and bring it to a
remote storage facility; or they can have trucks driven underneath them that will physically truck
the ash away.
4. Inside of the shell, the collecting electrodes are assembled parallel to the inlet duct. They are
assembled this way because it is the most economical and efficient way to collect the
particulate.
5. The discharge electrode is a different story. The discharge electrode runs perpendicular to the
inlet and collecting electrodes. As the flue gas comes out of the inlet and enters the precipitator
the rigid mast discharge electrodes greet the flue gas and negatively charge them; allowing the
positively charge plates that are running parallel to the inlet to collect the flue gas.
6. The other major external element is the rapper. It sits on top of the roof of the precipitator,
and is programmed to deliver its powerful strike within a certain timed interval. The hammer
end strikes the top of the collecting plates, making all the collected particulate fall into the
hoppers below.
7. Electricity is the major power source to operate just about everything on the precipitator. It is
used to power the electrodes, both positive and negative, and powers the rappers. It can also be
used to power the vacuum system on the evacuation of the hoppers, if the hoppers have this
option. Most precipitators run auxiliary transformers to subsidize the amount of energy needed
to keep the precipitators running.
8. The final element of an electrostatic precipitator is the outlet duct. Although not really
covered in this procedure very much, it does hold one vital role. It is where the new clean gas
will leave the precipitator. So in the end that final piece of ductwork gives the gas a final exit
strategy from inside the shell where all the work had been done previously.
Conclusion
Electrostatic precipitators have been a reliable technology since the early 1900's. They were
originally developed to stop serious smoke and air issues and have definitely helped the
environment. Today electrostatic precipitators are found mainly on large power plants, cement
plants, incinerators, and various boiler applications.