Optimization of collection efficiency by varying plate spacing within an electrostatic precipitator

Use of the Deutsch equation as an evaluation tool of electrostatic precipitators has resulted in the restriction design to a single plate spacing and has not enabled optimal use of the space charge arising from the presence of charged dust particles. Space charge is dependent on dust loading and plate spacing and also influences the electric field, hence the migration velocity and, therefore, collection efficiency. Thus a trade-off is indicated between plate spacing and collection efficiency as a function of dust loading. A first step examination of this trade-off indicates that varied spacing can be used in precipitators while maintaining high levels of efficiency and decreasing the required specific collection area by 15% to 25%.     

Control of fine particle emissions with wet electrostatic precipitation

This paper presents the results, both pilot and full-scale, of experience with the application of wet electrostatic precipitation technology for the control of fine particle emissions from industrial processes. Performance data involving the collection of such difficult-to-clean emissions as a sulfuric acid mist and recovery boiler salt fume are presented. The measured wet precipitator performance parameters (e.g., SCA, effective migration velocity) are compared to those reported in literature for dry precipitators operating on equivalent processes. Particular emphasis is directed toward examining wet electrostatic precipitator performance levels in controlling very high concentrations of submicron fume with the accompanying problem of space charge corona quenching. Relationships between these performance data and specific wet precipitator operating parameters such as operating voltage and current density are also examined.     

Precipitator energization utilizing an energy conserving pulse generator

The performance of a conventional two-electrode type precipitator collecting high resistivity dust can be improved by pulse energization. Pulses of a suitable duration and repetition rate superimposed on the DC voltage permit higher peak-voltage without sparkover, improve particle charging and current distribution, and allow independent regulation of the precipitator voltage and current. A considerable quantity of energy, however, is required for each pulse to charge the precipitator to the pulse voltage level. For high pulse voltages only a minor part of this energy is necessary for the discharge current in the precipitator. For reasons of economy, the recovery of the energy stored in the precipitator capacitance during each pulse is therefore extremely important for pulse energization of large precipitators. An energy conserving pulse generator with pulse transformer, a pulse initiating switch element, and a feed-back diode for the energy recovery is described. The design and the instrumentation of a pilot precipitator specially developed for the comparison of different kinds of precipitator energization are outlined. The ability of the applied pulse energization system for controlling the corona discharge current independently of the precipitator voltage is demonstrated. Further, results from field tests showing the performance of the system under operating conditions are presented.     

Towards a microscopic theory of electrostatic precipitation

The statistical mechanics of particles at the surface of a dust deposit are presented as a step towards a microscopic theory of electrostatic precipitation. The paper consists of three major divisions: (1) field induced entrainment, (2) particle condensation at the surface, and (3) hydrodynamic limits on precipitation.In the first part of this paper, the entrainment of dust from surfaces by electrostatic forces was considered as a simple Markov process. A choice of x⁻¹ for the dependence of the adhesive potential (van der Waals particle attraction) led to an exponential emission rate in the Kramers-Chandrasekhar approximation. This result suggested a simple experimental procedure for determining the adhesive properties of the dust. In addition it was found that both thermal Brownian and particle-deposit collisions contribute to the entrainment.In the second part, the precipitation problem was discussed in terms of a two-dimensional Ising model. The Markovian assumption demanded that the efficiency of the electrostatic precipitator be divided into a product of factors depending on particle migration and condensation in the two-dimensional surface. From this perspective a new collection criterion was established and the importance of particle collisions at the surface of the deposit was demonstrated.Finally, in the third part the role of bulk fluid flows in particle condensation and migration was addressed. The superficial gas flow and secondary flow were found to introduce anisotropy into the Ising lattice and also to enhance the mean particle energy at the surface. The Navier Stokes Equation was numerically integrated for the case of a wire-plate type corona. Plots of the stream function and gas velocity profile were presented and these suggested the existence of a lower limit on the shear stress that acts on surface particles.     

Theoretical methods for computing electrical conditions in wire-plate electrostatic precipitators

A new semi-empirical, approximate theory for predicting electrical conditions is described. In the approximate theory, analytical expressions are derived for calculating voltage-current characteristics and electric potential, electric field, and space charge density distributions. Comparisons of numerical and approximate solutions over a wide range of possible precipitator geometries and electrical operating points indicates that for practical purposes the approximate theory can be used in lieu of the more rigorous numerical theory. This saves large amounts of computer time and makes possible hand calculator usage. Recent in situ gaseous ion mobility data which are needed in the models are presented. For coal fired power plants, the reduced effective ion mobility in positive corona is found to be 1.6 times that for negative corona. Approaches for describing particulate space charge effects in the gas and electrical conditions in the collected particulate layer are briefly discussed.     

Criteria for designing electrostatic precipitators

This paper discusses the concepts of effective migration velocity and specific collector area as derived from the Deutsch equation. These two factors are commonly used as a means of specifying plant size and comparing proposals by different suppliers.It is demonstrated that effective migration velocity is not a constant dependent only on the fuel, being subject to large variations according to various features of the design of the precipitator. It is also shown that specific collector area cannot be used without at the same time considering the contact time of the gases in the electrostatic field.The removal of dust by a precipitator is carried out in two stages. The dust is first deposited on the collecting electrode, and a layer of significant thickness must be allowed to form so that when, in the second stage, it is dislodged by rapping, the layer breaks into agglomerated masses sufficiently large to fall into the hoppers below the collecting electrodes before being carried by the moving gas stream into the outlet flue. This requires that the frequency of rapping of each field of the precipitator shall be set at the correct rate according to the concentration of dust entering the field.Currently much stress is being placed on the intensity of the rapping blow and there is a tendency to specify increasing values of this blow. Due to the necessity of allowing a layer of dust to form, no increase in rapping intensity can overcome the effect of highly resistive dust. While the rapping force must be enough to shear the dust layer, any increase above this level is likely to result in the breakdown of agglomerates with an increase in dust emission and may also cause metal fatigue problems.     

Particulate collection in a high temperature cyclone

A new particle collection technique is analyzed and presented for its potential application in a high temperature, high pressure gas cleaning system. The technique is based on the collision and the aglomeration phenomena among the coal-ash particles when the cyclone is operated near the coal-ash fusion temperature. The percent increase of agglomeration rate is estimated by mathematical modeling for particles smaller than five microns in diameter. Particulate collection efficiency with or without agglomeration is presented. Experimental results in a high temperature cyclone are presented. The output dust loading varied from 0.025 to 5 grains per cubic foot (0.057–11 g/m³) as the input dust loading is increased from 4 to 35 grains per cubic foot (9.2–80g/m³) of gas flow.     

Aerosol filtration by a cocurrent moving granular bed: Penetration mechanisms

An experimental apparatus has been constructed to investigate aerosol filtration by a cocurrent moving granular bed filter (CMGBF). In a CMGBF, aerosol passes downward through a descending bed of dirty granules while clean granules are added continously at the bed top. The effect of an intergranular dust deposit on penetration in a CMGBF was investigated in a 2⁴ factorial experiment in which the control variables were superficial gas velocity (100 and 250 mm/s), bed depth (130 and 230 mm), granule size (2.1 and 2.7 mm), and the intergranular dust deposit expressed as percent by weight of collected dust in the bed (1% and 5%). All tests were conducted at ambient temperature and pressure using resuspended utility boiler fly ash as the test aerosol.Mass penetration data identified two major penetration mechanisms: (1) straight through penetration and (2) reentrainment due to granular motion. A static, intergranular dust deposit produced high filtration efficiency (>99%) at the low superficial velocity. When the bed was moving, reentrainment of collected dust was significant and accounted for about three-quarters of the penetrating dust. Particle size analyses reveal that the two penetration mechanisms are size dependent. Most particles larger than about one micrometer in diameter that penetrate the CMGBF do so by reentrainment after being collected initially. Virtually no particles smaller than about 0.3 μm in diameter penetrate by reentrainment; when these small particles penetrate, they pass straight through without being collected.     

Electrode cleaning systems: Optimizing rapping energy and rapping control

Methods for improving electrostatic precipitator performance by increasing electrode excitation level during rapping, and by optimizing rapping control, are presented in this paper. Design modifications can reduce mechanical impedence to vibration transmission during rapping. These same modifications can eliminate areas of high stress concentration where fatigue failure often occurs. Rapping system control parameters are presented as they relate to variations in field collection and shedding rates. Anti-coincident rapping control for plate rappers minimizes peak opacity levels during rapping if sufficient “rest times” between raps can be maintained. When anti-coincidence must be sacrificed due to insufficient rest times on large installations, suggestions for anti-coincident rapping by section are presented. Methods for optimizing field rapping repeat rates using available opacity, ash pull, and precipitator power information are discussed.     

The effects of corona electrode geometry on the operational characteristics of an ESP

Experiments were run in a pilot scale electrostatic precipitator (ESP) to determine the effects of corona wire-to-wire spacing on the operating conditions. Tests were run, using a reentrained low sulfur fly ash at both hot- and cold-side conditions. The effects of varying wire-to-wire spacing were determined. Results are given which show that varying wire spacing at cold-side conditions has little operational effect on the ESP while improved efficiency can be obtained at hot-side (low resistivity) conditions by reducing wire spacing. The increased efficiency results from a higher average operating voltage. The effects of back ionization are clearly demonstrated by a set of experiments in which dust was selectively removed from the wires or plate. These tests show that the lower operating voltage caused by back ionization is a combined effect of high resistivity dust on both the wires and plate.     

Pressure drop in electrostatic fabric filtration

Fabric filtration systems have been employed in industry for over a century with relatively few technological modifications. However, with the recent substantial increase in energy costs, conservation in energy consumption has become vitally important. As a result, the filtration systems of yesteryear may not be the best approach for future applications. Recently, an external electrical field was considered in fabric filtration of industrial dust with very promising initial results. An increase in the collection efficiency, particularly for fine particulates, and a decrease in the pressure drop was observed. In this paper the further results of an experimental program in the investigation of pressure drop in the electrostatic fabric filtration in industrial dust control are presented. The basic apparatus, a bench-scale electrostatic fabric filtration system, creates a representative dust cake under specific conditions of operating parameters and charge levels. The results clearly indicate that filter and dust cake resistance, or pressure drop, decreases substantially with the increased electrostatic field strength for all industrial dust samples tested, regardless of fabric type and other relevant parameters.     

Condensational enlargement as a supplement to particle control technologies

An experimental study has been undertaken at the Colorado School of Mines to evaluate the feasibility of using condensational enlargement to enhance the collection efficiency of existing dust control technologies for sub-micron particulates. Although the study was begun to consider the problem of respirable dust control in the underground coal mine environment, this enhancement technique shows promise for a more general class of applications. In the experiments to be reported on, particulates are injected into a continuous flow thermal diffusion chamber and subjected to varying environmental conditions; saturation ratio (rel. humidity), temperature, and residence time were the parameters. The results show that condensation on a dust nucleus (≈0.1 micron) can bring it to a size of several microns in a sufficiently short period of time as to indicate engineering applicability of the concept.     

Filtration efficiencies in electrostatically augmented granular beds

Fine particle filtration efficiencies of electrically enhanced granular beds are computed and compared with available experimental data. Collection efficiencies of a single bed sphere in a gaseous flow are first calculated by numerically solving the equations of particle motion. The collection mechanisms incorporated here are inertial impaction, interception, and charged fine particle-imposed electric field interaction. The approach is based upon a “unit cell” model which enables one to include the effects of surrounding bed particles on the collection process. Stokes' flow and potential flow are used to model the gas flow around the bed particle. Total efficiency is computed by integrating the single-sphere collection efficiency over the bed volume. These calculated total bed efficiencies compare satisfactorily with data obtained from an existing granular bed facility over a range of parameter values. Both theory and experimental data show that the electrical force significantly enhances particulate collection in granular beds.     

Electrostatic enhancement of moving-bed granular filtration

The electrostatic granular filter developed by Combustion Power Company combines a moving-bed filter with an electrostatic grid for high-efficiency collection of particulate. The coulomb charge occurring naturally on particulate from combustion or other processes in which tribocharging occurs is sufficient such that imposition of an electric field substantially enhances mechanical collection in the packed filter. A mathematical model is presented which accounts for the major parameters affecting electrostatic performance. Experimental data developed in an industrial unit retrofitted with electrostatic equipment and a pilot-scale filter demonstrates dramatic improvement in opacity and outlet loading; the industrial unit achieved 99% collection efficiency with less that 4 Iwd (1kPa) pressure drop. Data from the pilot-scale filter has shown that collection of micron-size particulate is especially enhanced with the electric field and has confirmed the 99% overall collection capability demonstrated in the industrial unit. The design of a 420,000 acfm (1200 m³/min) system being installed at Weyerhaeuser Company's Longview, Washington plant is also discussed.     

Ambient aerosol sampling: Problems,goals and wind tunnel test results of hi-volume samplers

The area of ambient air sampling and its inherent problems and current goals are discussed in general. In particular, recently completed tests of the collection effectiveness of the Rocky Flats Hi-Volume Sampler are compared to previously completed tests of the Standard EPA Hi-Volume Sampler for a variety of field realistic conditions. Collection effectiveness is defined as the ratio of the aerosol collected on the collection substrates of the sampler to that collected by an isokinetic sampling system.The collection effectiveness of the Standard EPA Hi-Volume Sampler was determined as a function of particle size (5–50 μm) and sampler orientation (0° and 45°) at a base condition wind speed of 4.6 m/s and 8% relative turbulence intensity. The results indicated a strong effect of orientation on collection effectiveness at a sampling rate of 1416 l/min. Wind speed over the range of 1.5–4.6 m/s does not greatly influence the collection effectiveness of 15 μm particles. Free stream turbulence levels of 1 and 8% relative intensity has no effect upon collection characteristics.The collection effectiveness of the Rocky Flats Hi-Volume Sampler was determined as a function of particle size (1–34 μm), wind speed (1.52–12.19 m/s) and sampler orientation to the mean flow (0°, 45°, 180°). The results show the sampler, with an inlet flow rate of 880 l/min, has an inlet effectiveness that was a slight function of orientation angle for particles 1–10 μm with a larger effect seen for 20–34 μm; a strong effect of velocity was seen up to 5 m/s where a further increase showed only a slight decrease in effectiveness.The Microsorban-98 filter that is presently used in the Rocky Flats Sampler was tested for efficiency over the size range of particles from 0.01–1 μm and with three different face velocities using the sampler flow rates of 600, 800 and 1 000 l/min corresponding to pressure drops of 20–24 in. of water (3.74–4.49 cm HaG). The filter paper, which was of the fiber type, was found to be 99.9% efficient over the range of particle sizes and pressure drops tested.     

Morphology,spatial distribution,and concentration of flame retardants in consumer products and environmental dusts using scanning electron microscopy and Raman micro-spectroscopy

We characterized flame retardant (FR) morphologies and spatial distributions in 7 consumer products and 7 environmental dusts to determine their implications for transfer mechanisms, human exposure, and the reproducibility of gas chromatography–mass spectrometry (GC–MS) dust measurements. We characterized individual particles using scanning electron microscopy/energy dispersive x-ray spectroscopy (SEM/EDS) and Raman micro-spectroscopy (RMS). Samples were screened for the presence of 3 FR constituents (bromine, phosphorous, non-salt chlorine) and 2 metal synergists (antimony and bismuth). Subsequent analyses of select samples by RMS enabled molecular identification of the FR compounds and matrix materials. The consumer products and dust samples possessed FR elemental weight percents of up to 36% and 31%, respectively. We identified 24 FR-containing particles in the dust samples and classified them into 9 types based on morphology and composition. We observed a broad range of morphologies for these FR-containing particles, suggesting FR transfer to dust via multiple mechanisms. We developed an equation to describe the heterogeneity of FR-containing particles in environmental dust samples. The number of individual FR-containing particles expected in a 1-mg dust sample with a FR concentration of 100 ppm ranged from < 1 to > 1000 particles. The presence of rare, high-concentration bromine particles was correlated with decabromodiphenyl ether concentrations obtained via GC–MS. When FRs are distributed heterogeneously in highly concentrated dust particles, human exposure to FRs may be characterized by high transient exposures interspersed by periods of low exposure, and GC–MS FR concentrations may exhibit large variability in replicate subsamples. Current limitations of this SEM/EDS technique include potential false negatives for volatile and chlorinated FRs and greater quantitation uncertainty for brominated FR in aluminum-rich matrices.     

Electrical augmentation of granular bed filters

A study of the enhancement of the collection efficiency of granular bed filters by electrical means is reported. By applying electric fields of a few kV/cm (DC or AC) across a bed of insulating granules, the efficiency for submicron charged aerosol is greatly increased, to the point where the efficiency minimum normally observed with such filters in the size range 0.1–1 μm is removed. The performance of such filters is explored as a function of granule size, applied field, face velocity and charge state of the entering aerosol with both a bench-scale flow system (to 40 ft³/min; 1.1 m³/min) and a wind tunnel (to 600 ft³/min; 17 m³/min). Some theoretical estimates are made to identify the most likely physical mechanism of electrical enhancement, and a number of potential application possibilities are discussed.     

Design of high intensity ionizer—electrostatic precipitator systems

This paper presents the results of a comprehensive set of analytical and experimental studies concerning the application of high intensity ionization technology to retrofit a flyash electrostatic prepitator.Described in detail are the computer-aided methods of performing functional design for ionizer-precipitator systems, selected results of ionizer-precipitator flow model tests, and the chosen physical retrofit. Also presented is the projected performance of an ionizer-precipitator system, derived from two independent design procedures which take into account the effect of space charge and gas velocity distribution on system performance.Results of these studies confirm that high intensity ionizer technology can be applied to significantly improve the collection efficiency of conventional wire-plate electrostatic precipitators.     

Size dependent cytotoxicity of fly ash particles

Fly ash samples were collected from the electrostatic precipitator of a coal-fired power plant in Hong Kong. The particles of the respirable range (smaller than 10 μm) were divided into 4 groups according to their particle size (mass median aerodynamic diameters). The surface morphology and the metal contents (Fe, Mn, Al and Zn) of fly ash particles were examined by a scanning electron microscope and an inductively coupled plasma spectrophotometer, respectively. The particles were very heterogenous in size and shape as well as the concentration of metals. The cytotoxicity of these four groups of fly ash particles was evaluated using an in vitro rat alveolar macrophages culture assay. The viability of alveolar macrophages was lower when incubated with smaller size particles. This relationship was also reflected by the damage of the surface morphology of the cells and the release of cytoplasmic (lactate dehydrogenase) and lysosomal (acid phosphatase and β-glucuronidase) marker enzymes into the culture media.     

Experimental measurements of aerosol concentrations in offices

A new automated version of the piezoelectric microbalance measures the mass concentration of airborne particles smaller than a preselected aerodynamic cutoff diameter. It is designed for near-real-time, unattended, round-the-clock measurements of nearly any aerosol environment inhabited by humans. The instrument uses an electrostatic precipitator to deposit particles with greater than 95% efficiency onto a piezoelectric quartz crystal sensor which is able to detect a deposit of 0.005 μg. The precipitator and sensor are nearly identical to those in the portable instrument reported previously. Measurements comparing within ± 15% with gravimetrically measured filter samples are documented for a wide variety of aerosols in the 50 μg/m³ to 5.5 mg/m³ range. The instrument measures particles from 10 μm down to 0.01 μm in diameter, including submicron combustion smokes and metallic fumes. The piezoelectric microbalance technique senses the mass concentration of the aerosol, rather than light scattering properties as is done by photometers and nephelometers. The piezobalance, with 1 L/min sample flow, is more sensitive than any other mass-sensing instrument, making it especially suited for low concentration indoor measurements, even below 50 μg/m³. An automatic piezobalance recently measured respirable aerosol mass concentrations in several offices. Each measurement was the average concentration during a 30-min period. The 24-h/day measurements continued for several days. Especially interesting is the diurnal pattern, both for offices with and without smokers. The effect of a single nearby smoker was clearly illustrated when the smoker was absent one day in the middle of a week. Normal daytime peak concentrations in that office reached 80–110 μg/m³ with a smoker present, but only 50–60 μg/m³ when the smoker was absent. Curious smokers who briefly stopped byt o see the instrument caused single half-hour averages to triple, to values as high as 294 μg/m³ in one office.