Precipitator Gas Flow Distribution

An electrostatic precipitator, furnished on a 500-Mw tan-gentially-fired steam generator burning coal, was to collect 99.6% of the fly ash being generated in the furnace of this unit. Preliminary measurements indicated that the installation was not meeting its collection guarantee. Precipitator outlet flue dust distribution indicated that poor gas flow distribution might be one of the causes of the low performance. When observation ports were installed in the outlet flue to permit a direct visual evaluation of the problem, it was found that high velocity jets were present in the collecting electrodes, and that hopper sweepage was present. A model study along with velocity distribution measurements of the installation were authorized. Flow analysis indicated that the field and model correlated well. Extensive changes were made in the model, which eliminated or minimized the high velocity jets and hopper sweepage. After these changes were made in the field installation, it was able to achieve the required dust collection efficiency.     

Turbulent mixing in a barbed plate-to-plate electrostatic precipitator

The electrical and fluid dynamical characteristics of a barbed plate-to-plate electrostatic precipitator are compared with those of a conventional wire-to-plate precipitator under particle-free conditions. The barbed plate electrode design is based on the concept that a more uniform distribution of current within the flow channel may reduce the scale of the corona-induced electrohydrodynamic flow and thus decrease particle mixing. Current-voltage relationships and hot-film anemometer measurements of turbulence intensities, integral length scales and eddy diflusivities are presented for current densities as high as9mAm⁻²at gas speeds of 0.5,1.0 and 2.0 m s⁻¹. Visual inspection of the discharge pattern indicates that the scale of the current inhomogeneity is reduced. Flow visualization and measurements of integral length scales confirm that the barbed plate design does reduce the scale of the electrically induced flow. Even though downstream turbulence levels are increased in the planar geometry, gas diffusivities are not substantially reduced. Additional study of the inter-electrode gas flow field and particle collection efficiency is necessary to determine the practical viability of the barbed plate precipitator.     

An Integrated Program to Achieve Maximum Performance of Electrostatic Precipitators

The objective of this paper is to describe the Tennessee Valley Authority's efforts and plans in designing an operating and maintenance program that will ensure maximum performance of the electrostatic precipitators at our power generating stations. Detailed operating and maintenance manuals are being prepared for each plant for the use of plant personnel. These manuals include instructions on operation, maintenance, and testing of the precipitators. Instructions on internal and external equipment inspections to be performed during unit operation, emergency and scheduled outages, and problem diagnostic procedures are included to help the plant personnel solve problem areas. Performance curves are included in the manuals which show the effect of gas volume flow, gas temperature, gas resistivity, coal changes, and loss of transformer-rectifier sets on the precipitator performance. In addition, opacity monitors that record continuous opacity readings are being installed at all our plants to assist the plant in monitoring precipitator performance. Full-time operating and maintenance crews are being organized at the plants to monitor and maintain the precipitator and ash-removal systems. Also, a staff of technical personnel is being organized at the central office to provide technical advice and assistance in design, operation, and maintenance problems and liaison and coordination for all the plants concerning the precipitators. Periodic precipitator field inspections, performance and operating parameter optimization testing, and review of the equipment operating logs are made by the central office technical personnel. Recommendations and technical assistance are then furnished to the plant with regard to the precipitator overall performance and operating characteristics.     

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.     

PCDDs, PCDFs emission control by dry scrubbing system

Presently, in Japan there are no limitations on the emission of PCDDs or PCDFs, but in order to study the feasibility of dry type air pollution control, a pilot plant was constructed in 1988 and the removal efficiencies for PCDDs, acid gas and heavy metals were measured.At the same time PCDDs concentration was compared with that of a previously installed electrostatic precipitator (ESP) plus wet scrubber line.In this paper, the following two items are reported.

1. (1) The difference in the amounts of PCDDs and PCDFs produced due to differences in gas temperature and retention time in ESP and fabric filter (FF).

2. (2) Removal efficiencies of PCDDs and PCDFs of fabric filter.

PCDDs concentration, generally 100–200 ng/Nm³ at the boiler outlet (ESP inlet and/or Quench Reactor (QR) inlet), increased several times at the ESP outlet, but it showed almost no increase at the QR outlet due to a sudden temperature drop. The temperature was 280–310°C, and the gas retention time was 12 sec. during passage through ESP so that it is thought that PCDD was formed under these conditions.On the other hand, a removal efficiency of approx. 90% was obtained with the fabric filter, and the PCDD at the bag outlet was at a sufficiently low level.     

Assessment of emissions and removal of polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) at start-up periods in a hazardous waste incinerator

A study was conducted to observe the changes in polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (PCDD/F) levels and congener profiles in the flue gas of a hazardous waste incinerator during two start-up periods. Flue gas samplings were performed simultaneously through Air Pollution Control Devices (APCDs) (including boiler outlet, electrostatic precipitator (ESP) outlet, wet scrubbers (WS) outlet, and activated carbon (AC) filter outlet) in different combustion temperatures during a planned cold (long) start-up and an unplanned warm (short) start-up. The results showed that PCDD/F concentrations could be elevated during the start-up periods up to levels 3–4 times higher than those observed in the normal operation. Especially lower combustion temperatures in the short start-ups may cause high PCDD/F concentrations in the raw flue gas. Assessment of combustion temperatures and Furans/Dioxins values indicated that surface-catalyzed de novo synthesis was the dominant pathway in the formation of PCDD/Fs in the combustion units. PCDD/F removal efficiencies of Air Pollution Control Devices suggested that formation by de novo synthesis existed in ESP also when in operation, leading to increase of gaseous phase PCDD/Fs in ESP. Particle-bound PCDD/Fs were removed mainly by ESP and WS, while gaseous phase PCDD/Fs were removed by WS, and more efficiently by AC filter.

Implications: This paper evaluates PCDD/F emissions and removal performances of APCDs (ESP, wet scrubbers, and activated carbon) during two start-up periods in an incinerator. The main implications are the following: (1) start-up periods increase PCDD/F emissions up to 2–3 times in the incinerator; (2) low combustion temperatures in start-ups cause high PCDD/F emissions in raw gas; (3) formation of PCDD/Fs by de novo synthesis occurs in ESP; (4) AC is efficient in removing gaseous PCDD/Fs, but may increase particle-bound ones; and (5) scrubbers remove both gaseous and particle-bound PCDD/Fs efficiently.     

Control of Diesel Gaseous and Particulate Emissions with a Tube-Type Wet Electrostatic Precipitator

Abstract

In this study, experiments were performed with a bench-scale tube-type wet electrostatic precipitator (wESPs) to investigate its effectiveness for the removal of mass- and number-based diesel particulate matter (DPM), hydrocarbons (HCs), carbon monoxide (CO), and oxides of nitrogen (NO_x) from diesel exhaust emissions. The concentration of ozone (O₃) present in the exhaust that underwent a nonthermal plasma treatment process inside the wESP was also measured. A nonroad diesel generator operating at varying load conditions was used as a stationary diesel emission source. The DPM mass analysis was conducted by means of isokinetic sampling and the DPM mass concentration was determined by a gravimetric method. An electrical low-pressure impactor (ELPI) was used to quantify the DPM number concentration. The HC compounds, n-alkanes, and polycyclic aromatic hydrocarbons (PAHs) were collected on a moisture-free quartz filter together with a PUF/XAD/PUF cartridge and extracted in dichloromethane with sonication. Gas chromatography (GC)/mass spectroscopy (MS) was used to determine HC concentrations in the extracted solution. A calibrated gas combustion analyzer (Testo 350) and an O₃ analyzer were used for quantifying the inlet and outlet concentrations of CO and NO_x (nitric oxide [NO] + nitrogen dioxide [NO₂]), and O₃ in the diesel exhaust stream. The wESP was capable of removing approximately 67–86% of mass- and number-based DPM at a 100% exhaust volumetric flow rate generated from 0- to 75-kW engine loads. At 75-kW engine load, increasing gas residence time from approximately 0.1 to 0.4 sec led to a significant increase of DPM removal efficiency from approximately 67 to more than 90%. The removal of n-alkanes, 16 PAHs, and CO in the wESP ranged from 31 to 57% and 5 to 38%, respectively. The use of the wESP did not significantly affect NO_x concentration in diesel exhaust. The O₃ concentration in diesel exhaust was measured to be less than 1 ppm. The main mechanisms responsible for the removal of these pollutants from diesel exhaust are discussed.     

Joint US/USSR Test Program for Reducing Fly Ash Resistivity

An electrostatic precipitator preceded by a wet scrubber was tested at the Reftinskaya Power Station. The unit collects a high resistivity fly ash from the combustion of low sulfur Ekibastuz coal. The operating parameters of the precipitator were measured as well as the mass emissions and the in-situ electrical resistivity of the fly ash. Density, particle size distribution, electrical resistivity, and chemical composition were determined for collected samples of the fly ash. The fly ash was also characterized by x-ray diffraction and scanning electron microscopy. When a centrifugal wet wall scrubber was installed ahead of the electrostatic precipitator, the temperature of the flue gas entering the precipitator was decreased and the moisture content increased. The electrical resistivity of the fly ash was attenuated a decade, but not enough to overcome the adverse effects of back corona in the precipitator. Lowering the flue gas temperature to about 85°C by the addition of a venturi scrubber ahead of the centrifugal scrubber reduced the electrical resistivity of the fly ash another decade and allowed the operation of the precipitator without back corona.     

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.     

Integration of novel hybrid composite discharge electrode with semi-pilot novel cross-flow electrostatic precipitator

ABSTRACT

Wet electrostatic precipitators (WESPs) are modern-era pollution control systems specifically designed to capture ultrafine particles as well as acid mist, highly resistive and sticky particles; however, this requires the use of expensive corrosion-resistant metal alloys. The work presented here is part of a continuing study at Ohio University aimed at reducing the cost of WESPs by using a novel combination of a polymer collector surfaces with a hybrid composite discharge electrode. In this study, a hybrid composite discharge electrode was tested, for the first time, inside a semi-pilot-scale experimental setup, with collection surfaces consists of a vertical array of strands. Particle laden gases were passed through this array of polymer ropes, which were kept wet by a small flow of water. The discharge electrodes were composite laminates of carbon fibers in a polymer matrix enclosing a metal mesh. The preliminary results showed that this new integrated system of composite discharge electrode and polymer collector surfaces can match or exceed the performance of a conventional metal alloy electrostatic precipitator (ESP) with metal discharge electrodes. There are additional advantages due to the system being compact, lightweight, and highly corrosion resistant.

Implications: This study focused on integrating and assessing performance of a novel hybrid composite electrode (HCE) inside semi-pilot novel cross-flow electrostatic precipitator at conditions typically observed in coal-fired power plant exhausts. The results were collected for particulate collection efficiencies and were compared with a rigid metal electrode. The HCE outperformed metal electrode by showing higher particulate collection efficiency. This result showcases substantial potential for these two new technologies (HCE and cross-flow system) as a substitute for conventional metal based wet ESPs.     

静电除尘器烟道进口处流场的数值模拟

利用Fluent软件对静电除尘器烟道进口处流场进行了数值模拟,在此基础上提出一种新型的能有效均风的电晕线布置方法.结果表明,两相邻(垂直叠放)烟道进口处的电晕线平行放置时,在强电场力作用下产生的高速离子风会阻碍气流的均匀分布；两相邻烟道进口处的电晕线交叉放置时,可以起到明显的均风效果,更有利于除尘器内气流的均匀分布和提高除尘效率.该方法为静电除尘器的改造和设计提供了一种新的思路.     

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.     

并流旋转床气体出口压降数值分析

气体出口是旋转床的重要组成部分,对旋转床流场与气相压降有着重要的影响。研究并流旋转床结构、构建气体出口物理模型,利用RNG k-ε湍流模型,探索不同气体出口结构对并流旋转床流场的影响。模拟结果表明:具有4个切向气体出口的DCRPB3615型旋转床有利于旋转床内速度分布均匀、降低湍动能,减小气相压降。模拟与实验对比表明,DCRPB3615压降比单一径向出口的CRPB3615型旋转床降低10%左右。     

电除尘器气流分布与粉尘沉降规律试验研究

简要介绍了斜气流技术机理,进行了均匀气流和斜气流状态下的粉尘沉降试验.通过试验数据分析,总结出了电除尘器内部两种气流分布状态下的粉尘沉降规律,指出斜气流技术的应用在提高除尘效率方面具有重大意义,并为斜气流技术的应用提出了一些建议.     

Feasibility Demonstration of Electrostatic Precipitation at 1700°F

An experimental high-temperature, high-pressure electrostatic precipitator module has been designed, fabricated and then evaluated in a gaseous environment having the characteristics anticipated for the combustion chamber of a system for generating electric power from the incineration of municipal solid wastes.

Stable positive and negative corona discharges were established in combustion gases from the burning of methanol and air (temperature and pressure approximately 1700°F and 100 psig, respectively) without any apparent deleterious effects due to thermal ionization and/or emission. At gas conditions of about 1700°F and 50 psig, positive polarity energization of the discharge electrode appeared superior to that of negative polarity in terms of voltage level that could be applied and electrical stability.

However, precipitator performance on removal of alumina dust injected under controlled conditions with the methanol fuel, showed negative polarity to be superior to positive polarity at the selected conditions of 1650°F and 100 psig which closely correspond to those required for optimum operation of the gas turbine presently under consideration. Removal efficiencies ranging from 25% for positive polarity to as high as 87% with negative polarity were measured.

In order to check whether materials having a low ionization potential would thermally ionize to such an extent that the voltage-corona current characteristics of the precipitator would be impaired, rendering it ineffective, potassium chloride salt in solution was injected with the fuel. Results indicated that amounts of approximately one part by weight of potassium ion in 2500 to 3000 parts by weight of gas at 1700°F tripled the current measured for a given voltage when compared to non-injection.

Although a limited test program was conducted, sufficient data were obtained to allow preliminary design and sizing of larger scale units.     

输煤皮带转载点密闭罩流场模拟与结构优化

为了研究输煤皮带转载点密闭罩内流场对吸尘效果的影响,采用Fluent软件对某转载点密闭罩内气固两相流动情况进行了数值模拟。通过气流分布和煤尘浓度分布的分析,发现溜槽转折处较大的气流偏转会增加煤尘起尘量和导致局部煤尘积聚,吸尘罩的开口角度对吸尘效果也有较大影响。为了疏导气流并加强吸尘效果,提出了溜槽转折处和吸尘罩的结构优化设计方案。研究表明,改进后气流分布更加均匀,吸尘效果有所提高,从而为转载点密闭罩的优化设计提供了参考。     

Economic Comparison of Emission Control Systems for Glass Manufacturing Furnaces with Heat Recovery

ABSTRACT

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.     

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.     

On the forming mechanism of the cleaning airflow of pulse-jet fabric filters

To reveal the formation mechanism of a pulse-jet airflow’s cleaning effect in a filter bag, a theoretical model is built by using the theory of the gas jet and unitary adiabatic flow according to given specifications and dimensions of the bags and resistance characteristics of the cloth and dust layer. It is about the relationship between cleaning system structure and operating parameters. The model follows the principle that the flow and kinetic energy of jet flow injected into a filter bag should be consistent with the flow of cleaning airflow in the bag and the pressure drop flowing through the filter cloth and dust layer. The purpose of the model is to achieve the peak pressure of cleaning airflow, which dominates the effect of the pulse-jet cleaning process. The cleaning system structure includes air pressure in the nozzle, structure and size of nozzle, exit velocity of nozzle, jet distance, and diameter of jet cross section. Based on the condition of the cleaning system structure and operating parameters established by using the theoretical model, Fluent software is applied to carry out a numerical simulation of the jet airflow field at the nozzle’s outlet, jet airflow field between nozzle and bag top, and cleaning airflow field in the filter bag. Experimental results are used to verify the reliability of the theoretical model. They are obtained in a pilot-scale test filter with a single bag, with length 2 m and in general full-scale dimensions of the cleaning system. The results show that when any rectification measure is not installed at the bag opening, the cross-sectional area covered by the jet gas is hardly sufficient to cover the entire area of the bag opening. A large portion of the gases injected into the filter bag will overflow reversely upward from the edge due to pressure differences between the upper area and lower area inside the bag opening. This led to a serious shortage of the cleaning airflow and ar limited increase in static pressure. When a venturi-type rectifier tube is installed at the bag opening, the jet flow is converted to funnel flow for which the cross-section velocity distribution is more uniform at the throat of the rectifier tube due to the guided effects of the upper tapered pipe. Then it is transited to stressful flow below the bag opening via rectified effects of the lower dilated pipe. The results show that the gap between the static pressure of gas in the bag and the expected value is significantly reduced. The theoretical value of the nozzle diameter is enlarged to compensate for two aspects of adverse effects of cleaning airflow and energy. This is because the flow is not a purely free-form jet from the nozzle to the entrance of the rectifier tube and because the gas suffers from local resistance while flowing through the rectifier tube. The numerical simulation and experiment show that the peak pressure of cleaning airflow in the filter bag is able to reach the expected value. The results confirm that the mechanism of the pulse-jet cleaning airflow and the calculation method of the pulse-jet cleaning system structure and operating parameters offered in this study are correct. The study results provide a scientific basis for designing the system of pulse-jet fabric filters.

Implications: Pulse-jet cleaned fabric filters are commonly used for air pollution control in many industries. Pulse-jet cleaning is widely used for this purpose as it enables frequent cleaning while the filter is operating. However, the theoretical system of the forming mechanism of the pulse-jet cleaning has not formed so far. This indicates the theoretical model plays an important role in designing effective pulse-jet cleaned fabric filters.     

Reduction of dioxin emission by a multi-layer reactor with bead-shaped activated carbon in simulated gas stream and real flue gas of a sinter plant

A laboratory-scale multi-layer system was developed for the adsorption of PCDD/Fs from gas streams at various operating conditions, including gas flow rate, operating temperature and water vapor content. Excellent PCDD/F removal efficiency (>99.99%) was achieved with the multi-layer design with bead-shaped activated carbons (BACs). The PCDD/F removal efficiency achieved with the first layer adsorption bed decreased as the gas flow rate was increased due to the decrease of the gas retention time. The PCDD/F concentrations measured at the outlet of the third layer adsorption bed were all lower than 0.1 ng I-TEQ Nm⁻³. The PCDD/Fs desorbed from BAC were mainly lowly chlorinated congeners and the PCDD/F outlet concentrations increased as the operating temperature was increased. In addition, the results of pilot-scale experiment (real flue gases of an iron ore sintering plant) indicated that as the gas flow rate was controlled at 15 slpm, the removal efficiencies of PCDD/F congeners achieved with the multi-layer reactor with BAC were better than that in higher gas flow rate condition (20 slpm). Overall, the lab-scale and pilot-scale experiments indicated that PCDD/F removal achieved by multi-layer reactor with BAC strongly depended on the flow rate of the gas stream to be treated.