The Smogless Automobile

Demands for high performance and reliability of electrostatic precipitators for collection of fly ash from low sulfur fuels has led to rapid escalation of sizes and uncertainties in sizings of cold-side precipitators. This has led to utilization of the so-called “hot-side” precipitator. The underlying concept of hot-side precipitation is the avoidance of the necessity to operate the precipitator under high resistivity conditions. Data on in-situ measurements of resistivity of low sulfur fuel ash, as well as performance parameters of a number of operating installations, will be reviewed. These data will demonstrate the reduced sensitivity of hot-side precipitator sizing to fuel conditions. Other advantages of hot-side precipitators will be discussed.

Operating experience with hot-side precipitators has focused on structural problems which are peculiar to the larger, higher temperature installations. The nature and solution of these problems will be discussed. General comparative economics of hot-side and cold-side precipitators as they relate to fuel properties will be reviewed.     

Precipitator Design

The various design philosophies and methods used in the engineering design of precipitators for fly ash are reviewed and assessed in light of current stringent environmental standards. The basic precipitator size and electrical parameters are individually analyzed and related to particle and flue gas properties. Actual precipitator design practice is illustrated by data for a wide cross section of power plant installations.     

Economic Comparison of Selected Scenarios for Electrostatic Precipitators and Fabric Filters

Compliance with particulate standards for utility boilers burning low sulfur western coal has resulted in the installation and proposed installation of several fabric filter collectors where cold or hot electrostatic precipitators would have traditionally been applied. Recently, SO3 conditioning has been used to improve cold precipitator performance resulting in considerable reduction in specific collection area (SCA). All this suggests that trade-offs exist indicating ranges of SCA, A/C ratio, and power plant size (Mw) where fabric filters become competitive with electrostatic precipitators. Conceptual cost models are presented which indicate total capital investment and annual costs for the control devices. Precipitator costs are correlated with collecting area, gas flow rate, and power input and are presented as functions of SCA and Mw. Fabric filter costs are keyed to gross filter area, pressure drop, and gas flow rate. Fabric filters become competitive when a cold precipitator requires SCAs in excess of 600 to 800 and competitive when a hot precipitator requires equivalent cold precipitator SCAs in excess of 600 to 1000 depending on A/C ratio, Mw, and hot precipitator SCA credit allowance. The S0₃ conditioned precipitator scenario is shown to be economically competitive with fabric filters.     

Solving Problems in the Electrical Energization of Electrostatic Precipitators

Achieving and maintaining continuous, reliable performance in electrostatic precipitators depends critically upon the proper design, application, operation, and maintenance of the high voltage electrical energization system. Common problems among these factors are discussed, and effects on performance are illustrated from field experience. Practical recommendations for solving problems and for preventing their occurrence in the electrical aspects of precipitation are presented for effective use by designers, operators, and maintenance personnel.     

1985 Update,Operating History and Current Status of Fabric Filters in the Utility Industry

Stringent particulate emissions limits and increasing awareness of stack opacity is leading the utility industry to use high efficiency particulate control systems. In response to this trend, the Electric Power Research Institute (EPRI) is conducting several research programs aimed at improving the operation, maintenance and performance of particulate control systems. One of these programs, RP-1401, “Reliability Assessment of Particulate Control Systems,” is developing operation, maintenance and design data bases for both electrostatic precipitators and fabric filters. This paper discusses some of the intermediate findings of the work done on fabric filters.     

High Temperature,High Pressure Electrostatic Precipitation

This paper presents the results of work conducted by Research-Cottrell under EPA contract 68-02-2104. The feasibility of electrostatic precipitation at temperatures and pressures varying from ambient condition to 1366°K and 3550 kPa, respectively, has been demonstrated in a laboratory wire-pipe electrode system. Stable corona discharges are obtained at all temperatures subject to appropriate choices of electrode dimension, polarity, and pressure. Current-voltage characteristics are reported for dry air, a simulated combustion gas, and a substitute fuel gas. The effects of temperature, pressure, electrode geometry and polarity on sparkover voltage, corona-starting voltage, and current are evaluated. A precipitator performance model is included to incorporate this data into a high temperature, high pressure precipitator design. This model has been evaluated for an electrostatic (HTHP) precipitator following a pressurized fluidized bed combustor at 1089 K and 920 kPa. It is recommended that prototype HTHP electrostatic precipitators be applied to pilot coal gasifiers and fluidized bed combustors to obtain detailed design data and to verify the accuracy of the performance model under actual operating conditions.     

A State of the Art Report on Industrial Precipitator Control Equipment

Informative report No. 3 has been prepared to provide background information on the origin, purpose, and general theory of operation of automatic power controls for industrial electrostatic precipitators. A comprehensive body of literature describing the process and mechanisms of dust collection in precipitators is readily available to those interested, but information on the control equipment used with the process is widely scattered. This report is intended to provide assistance toward the understanding of manufacturers’ literature describing specific control apparatus, and it may be used as a starting point for more intensive investigation of the subject. To the latter end, a history of the development of these controls and a bibliography of pertinent literature and patents has been included. It is expected that this report will be of particular interest to technical and supervisory personnel concerned with the selection, evaluation, and operation of precipitation equipment.     

Effects of Design and Fuel Moisture on Incinerator Effluents

The particle and gas properties that profoundly affect design and performance of fly ash precipitators are discussed and evaluated in this section. Relation of the coal burned to these properties and to the precipitator gas cleaning problem is broadly examined. The need for a high order of technology consistently applied to cope successfully with the wide and often uncertain variations in coal and ash properties encountered in precipitation practices is emphasized.     

Operating Experience with the Alcoa 398 Process for Fluoride Recovery

During the 1940’s, aluminum smelting installations were increased in size to provide aluminum necessary for World War II. Increased evolution of fluorides made necessary the capture and treatment of pot gases. Following the application of water scrubbers, cyclones, and electrostatic precipitators, Alcoa Research Laboratories at New Kensington, Pa., discovered that small quantities of HF gas would react at low temperature with alumina. Following a series of design efforts, the Alcoa 398 Process was developed, incorporating a fluidizedbed reactor to contact pot gases with incoming feed alumina. Bag filters are used to separate entrained solid materials from pot gases. Ninety-five percent interception of pot gases is reported with 99% recovery of fluorides from gases treated. No significant effect is observed on purity of metal produced.

Installation costs are in the range of $>28-$37 per annual ton for new installations and about 50% more for conversion of old plants. These are somewhat less than the conventional electrostatic precipitators and water scrubbers at today’s prices. Direct operating costs for the Alcoa 398 Process range from $2.90 to $4.70/ton of aluminum and recover $8 worth of fluorine, giving a net credit. This contrasts with $3.93/ton of aluminum to operate existing precipitator scrubber combinations. The Alcoa 398 Process is being rapidly extended throughout the Alcoa system.     

The Importance of Maintenance for Lime Flue Gas Desulfurization Systems

The successful, reliable operation of a power plant flue gas desulfurization (FGD) system depends largely on a good program of maintenance. Identifying the FGD equipment that is most critical to an FGD system’s overall reliability or its ability to meet emission regulations plays an important role in determining the extent of a maintenance program for a particular site. FGD maintenance programs vary considerably, depending on site-specific requirements and the support of plant owners. Many owners are reluctant to spend money on FGD maintenance because an FGD system is a nonproductive part of a power plant; however, a good maintenance program can result in longer equipment life, improved equipment performance, increased system availability, better safety, and lower operating costs. This paper uses wet and dry lime FGD systems to illustrate the advantages of good maintenance and the consequences of poor maintenance. Examples of specific tasks for preventive, scheduled, planned, and emergency maintenance are described. Also, because of the importance of FGD maintenance personnel, a section on organization and training is included.     

Reducing Opacity by Optimizing Maintenance and Operating Practices

Titus Generating Station, owned and operated by the Metropolitan Edison Company, a subsidiary of the General Public Utilities Corporation, is located in the Reading Air Basin as defined in the Pennsylvania State Law applicable to air resources. Titus Station consists of three boilers which provide steam to generate 240 megawatts of electricity. The station consumes about 600,000 tons of western Pennsylvania bituminous coal each year. Because of its location in an air basin, the operation of Titus Station in compliance with visible and SO₂ emissions standards has been under close scrutiny since 1972. Since that date, Titus Station has operated under various consent orders, variances, and temporary operating permits as Issued by the Pennsylvania Department of Environmental Resources. During this period, efforts were made in all areas of station operation and maintenance to bring Titus Station emissions into compliance, including; Increase of precipitator collector area, revision of coal specifications, closer scrutiny of coal deliveries, implementation of comprehensive precipitator maintenance practices, revision of boiler operating procedures, installation of stack monitoring equipment, and revision of SO₂ emissions regulations. These efforts resulted in continuous compliance with SO₂ regulations and nearly complete compliance with opacity regulations.     

Two-Stage,Dry FGD and Particulate Removal System

The results of the Kansas City-Wyandotte County Department of Health study of operation and maintenance ( O &; M) practices at a fiberglass manufacturing facility and a secondary metals smelter demonstrate the substantial impact of O &; M practices on particulate emissions. Both facilities have a history of O &; M problems leading to excessive particulate emissions.

Over a period of time, detailed O &; M information was obtained from facility management and operating personnel. Extended periods of in plant observation of O &; M procedures were correlated with simultaneous outside observations of visible emissions. O &; M related excessive emission problems at the secondary metals smelter were found usually to be caused by operator errors, compounded by marginally effective control equipment. In contrast, the excessive emissions problems at the fiberglass plant were almost always caused by actual process or control equipment malfunctions. These malfunctions appear to be almost inherent in the types of control equipment used, e.g. water washed high voltage electrostatic precipitators, and occurred despite a comprehensive O &; M program at the fiberglass plant.     

“Hot” versus “Enlarged” Electrostatic Precipitation of Fly Ash: A Cost-Effectiveness Study

An article in the February 1974 issue of the Journal of the Air Pollution Control Association entitled “Hot” versus “Enlarged” Electrostatic Precipitation of Fly Ash: A Cost Effectiveness Study,¹ by D. R. Selzler and W. D. Watson, Jr., arrives at the generalized conclusion that “enlarged” precipitation is likely to be a less costly method of attaining high collection efficiencies for low sulfur fly ash. The basis of this conclusion is a multivariate regression analysis of 37 full-scale cold electrostatic precipitators. Using the predictive ability of the resulting equation, modified to include a 95% probability of attaining design efficiency, together with functions describing capital and operating costs, the authors arrived at the above conclusion.

It is our contention that while the overall approach presented is a good attempt to develop a more systematic method of attacking the problem and arriving at a generalized solution, there are many errors in the development which have resulted in incorrect conclusions. Among the more serious errors in this work is the development and acceptance of a regression model based on cold precipitation performance data which is not compatible with the observed performance of cold precipitators. The use of the same equation for hot precipitator sizing can also be shown to be invalid. Additionally, one of the basic parameters used by the authors to distinguish precipitation performance of coals is not meaningful for hot precipitation and of questionable validity for cold precipitation. And, finally, the authors do not appear to recognize that power input to the precipitator (actually power density) is a constrained function which can hardly ever be increased to levels defined by their “optimum” precipitator sizing.     

Simulation of stack plume opacity

The visual impact of primary particles emitted from stacks is regulated according to stack opacity criteria. In-stack monitoring of the flue gas opacity allows plant operators to ensure that the plant meets U.S. Environmental Protection Agency opacity regulations. However, the emission of condensable gases such as SO3 (that hydrolyzes to H2SO4), HCl, and NH3, which may lead to particle formation after their release from the stack, makes the prediction of stack plume opacity more difficult. We present here a computer simulation model that calculates the opacity due to both primary particles emitted from the stack and secondary particles formed in the atmosphere after the release of condensable gases from the stack. A comprehensive treatment of the plume rise due to buoyancy and momentum is used to calculate the location at which the condensed water plume has evaporated (i.e., where opacity regulations apply). Conversion of H2SO4 to particulate sulfate occurs through nucleation and condensation on primary particles. A thermodynamic aerosol equilibrium model is used to calculate the amount of ammonium, chloride, and water present in the particulate phase with the condensed sulfate. The model calculates the stack plume opacity due to both primary and secondary particles. Examples of model simulations are presented for three scenarios that differ by the emission control equipment installed at the power plant: (1) electrostatic precipitators (ESP), (2) ESP and flue gas desulfurization, and (3) ESP and selective catalytic reduction. The calculated opacity is most sensitive to the primary particulate emissions. For the conditions considered here, SO3 emissions showed only a small effect, except if one assumes that most H2SO4 condenses on primary particles. Condensation of NH4Cl occurs only at high NH3 emission rates (about 25 ppm stack concentration).     

Factors Affecting Resistivity in Electrostatic Precipitation

The following material is taken from a new book, “The Art of Electrostatic Precipitation,” authored by Mr. Katz and based on his 30 years of field experience with the subject. The book provides practical information on maintaining and upgrading precipitators; chapter titles include fundamentals, operation and maintenance, trouble solving, corrosion factors, methods to improve performance, test evaluation techniques, gas distribution and conditioning, case histories, and optimum designs.     

Costs of Air Cleaning with Electrostatic Precipitators at TVA Steam Plants

Cost data were analyzed from thirty steam power plant units utilizing electrostatic precipitators with or without mechanical centrifugal collectors. Operational, maintenance, and total costs for the years 1969, 1970, and 1971 were expressed in 1972 dollars as $/cfm-yr and $/^cf^m-yr-efficiency. The latter parameter is a new one which normalizes the cost of air cleaning by accounting for the amount of particulate matter collected. Large differences in the costs of air cleaning were found between plants and even between units operating in the same plant. Maintenance costs appeared to be the main contributor to large total cost differences, but improved, more specific accounting procedures are required to focus more closely on the reasons for cost differences.     

Some Factors in Minimizing Precipitator Costs

This paper is directed to those individuals involved in design of electrostatic precipitators. The Deutsch-Anderson model is usually employed by industry for the design of electrostatic precipitators. The so-called process design variable in this approach is the total capture area in the precipitator. Unfortunately, little is available on the equipment design of this unit, i.e., the geometric arrangement of the plates that constitute the capture area and the external dimensions of the physical structure that houses the precipitator components. These are important economic considerations, and it is to this subject that this paper is directed. It is relatively easy to predict equipment costs for “off-the-shelf” electrostatic precipitators; it is more difficult to closely predict the cost for a custom-made unit, which is more often the case encountered in practice. Once the capture area is calculated, the total precipitator cost becomes a strong function of the outer casing and outer accessories of the physical system. In this paper, a model is presented that can help minimize precipitator cost. An illustrative example complements the development of the model.     

Purification characteristics of fine particulate matter treated by a self-flushing wet electrostatic precipitator equipped with a flexible electrode

A self-flushing wet electrostatic precipitator was developed to investigate the removal performance for fine particles. Flexible material (polypropylene, 840A) and carbon steel in the form of a spiked band were adopted as the collection plate and discharge electrode, respectively. The particle concentration, morphology, and trace-element content were measured by electric low-pressure impactor, scanning electron microscope, and energy-dispersive x-ray spectroscopy, respectively, before and after the electrostatic precipitator. With increasing gas velocity, the collection efficiency of fine particles (up to 0.8 μm in diameter) increased, while it decreased for particles with diameters larger than 0.8 μm. Increasing the dust inlet concentration increased the collection efficiency up to a point, from which it then declined gradually with further increases in the inlet concentration. The particulate matter after the wet electrostatic precipitator showed different degrees of agglomeration. The collection efficiency of trace elements within PM₁₀ was less than that of the PM₁₀ itself. Notably, the water consumption in the current setup was significantly lower than for other treatment processes of comparable collection efficiencies.

Implications: Wet electrostatic precipitators, as fine filtration equipment, were generally applicable to coal-fired plants to reduce PM_2.5 emissions in China. However, high energy consumption and unstable operation, such as water usage and spray washing directly in the electric field, seriously restricted the further development. The utilization of self-flushing wet electrostatic precipitator can solve these problems to some extent.     

Economic comparison of emission control systems for glass manufacturing furnaces with heat recovery

Glass manufacturing, like other process industries, is faced with air pollution compliance problems due to ever stricter emission limits. Several waste gas cleaning equipment options are available for air pollution control (APC) in glass plants, the most common arrangements being based on electrostatic precipitator (ESP) or fabric filter (FF) dust collectors and semi-wet or dry processes for acid gas removal. However, several counteracting aspects affect the choice of gas cleaning technologies, which are confirmed by the discrepancies encountered in actual suppliers' bids. In this paper, the main pollution control options are analyzed by carrying out a critical comparison under the cost-effectiveness point of view to select the lowest cost arrangement considering capital investment, operating expenses, and energy-saving revenues from heat recovery processes. The analysis is carried out with reference to a case study involving actual float glass production lines at Pilkington plants in Italy.     

ESP Bus Section Failures: Design Considerations

This paper addresses a common operation and maintenance problem encountered with sectionalized electrostatic precipitators—bus section failure. ESPs are normally designed to meet a specific minimum collection efficiency in order to comply with emission standards; the loss of several bus sections may cause the unit to be out of compliance. In this paper, the effect of bus section failure on precipitator performance is analyzed. The study is presented in two parts. First, a simplified procedure to estimate the effect of bus section failure on the overall collection efficiency is developed. An illustrative example is presented to demonstrate the use of the technique. Secondly—and this is the main thrust of this study—the technique is extended to include calculations on whether a unit is out of compliance due to the failure of a given number of bus sections. This development clearly shows that this latter effect can only be expressed in terms of a probability. Two additional examples, based on a field unit using actual test data, complement the presentation and illustrate this probability calculation.