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New Electrostatic Precipitator Technologies in
the Pulp & Paper Industry
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Charles Hayes
Regional Sales Director
SOUTHERNenvironmental ,INC
.
Pensacola, Florida
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Introduction
New technologies which may be of particular
interest in the Brazilian Pulp & Paper Industry
• Customized discharge electrodes to reduce outlet emissions
• High frequency SMPS to replace conventional T/R sets
• New techniques for better gas distribution
• Top-rapped ESP design – advantages compared to “European” design
• ESP Conversion – Tumbling Hammer to Top-rapped design – a case study
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Techniques to improve performance
in ESP Rebuilds/Upgrades
Your logo • Customized RDEs
• Increase Electrical Sectionalization
• Increase Rapping Sectionalization
• Enhance ESP Flow Distribution by Modeling
• Enhance Hopper & Anti-Sneakage Baffling
• Advanced SMPS Power Supplies
• Convert Tumbling Hammer to Top-Rapped design
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ELEX Rigid Discharge Electrode
• Rigid –Unbreakable – Electrode Design
• Variable Emitter Point Settings
• Variable Emitter Tab settings
• Low Corona Onset Voltage
• Uniform Current Distribution to Plates
• Plate Spacing Between 250 and 400 mm
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ELEX Rigid Discharge Electrode
• Customized throughout ESP fields
• More Points – for high dust load in Inlet Fields
• Superior in overcoming space charge effects
• Optimum Particulate Charging
• Eliminates lower frame spit sparking
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ELEX RDE Configurations
Aggressive – More
points per meter
Standard – fewer
points per meter
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ELEX Rigid Discharge Electrode
(Optimized)
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ELEX VRS Pipe & Spike
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ELEX vs. Pipe & Spike
Airload V-I Curves
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Top-Rapped ESP Internals
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Internals showing DE & CE Rappers
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Collecting Plate Design
• 1.3 – 1.6 mm thick A-366 Steel
• 445 mm Segments or Opzels
• Cold roll Formed
• Edge Arc-Over Prevention
• Uniform Thermal Movement
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Rapping System
• Design Objectives: • To Clean Collecting and Discharge Electrodes
• Minimize Re-entrainment, Stack Puffs, and Back Corona
• Maintenance Needs: • Reliability, Low Maintenance, and Serviceability
• Types: • Electromagnetic, Hammer, and Vibrators
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ICAC Gas Distribution Criteria
• 3.2.1 Guaranteed precipitator operating efficiency. Gas flow uniformity becomes
• increasingly important as operating efficiencies approach 100% due to:
• 3.2.1.1 The tendency for the smaller particles to follow the gas flow streamlines more
closely.
• 3.2.1.2 The increased need for almost total suppression of gas bypassing and hopper
sweepage. Thus, the higher the guaranteed operating efficiency of a precipitator, the more
important the optimization of the gas flow.
• 5.1.1 Within the treatment zone near the inlet and outlet faces of the precipitator collection
chamber, the velocity pattern shall have a minimum of 85% of the velocities not more than
1.15 times the average velocity, and 99% of the velocities not more than 1,40 times the
average velocity. Average velocity refers to the mean of all velocity measurements made at
a given face of the precipitator.
• Copied from: Institute of Clean Air Companies – Publication ICAC – EP- 7
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CFD of Recovery Boiler ESP
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High Frequency Power Supply
Features
• Operating Frequency = 25 kHz compared to 50
to 60 Hz for conventional T/R set energization
• Typically provides 10% increase in secondary
voltage & about a 25–40% increase in secondary
current
• 3-phase input results in higher power factor
• Performance Enhancement Factor (w’/w) for
moderate to low resistivity applications
• Similar installed cost as conventional T/R sets
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SMPS offer Big Benefits
• More efficient – up to 30% more power into the ESP
• Combines T/R, controller, Reactor and ground switch in one package
• Higher power factor (.94 vs .63) means lower power consumed per kw of power to ESP
• Easier to install – no AVC room
• Field serviceable – plug-in, plug-out components
• Smaller & lighter than Traditional T/R’s
• Less/limited bus duct required
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[ms]
[kV]
0
20
40
60
80
Conventional T/R
SMPS
Time (ms)
ESP
Current
[mA]
SMPS wave form vs conventional T/R
SMPS - No Ripple
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New High Frequency Power Supply
70 kV@1000mA SMPS Smaller & lighter
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SMPS INSTALLATIONS
• Results and Benefits
• More power into ESP
• Lower emissions
• Less line power consumed
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Electromagnetic Rapping Advantages
• External Location Allows Online Servicing
• Control Sequencing, Timing, Rapping Forces
• Same Rapping System on CEs & Des – Copper coil (10 kg)
– 27 joules capacity
– Variable intensity
– 10 kg Piston with Stainless Steel Tip
Common Parts for All Rapping Systems
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Modern Rapper Controls
• Microprocessor Control
• Password protected
• Variable duration, lift, and sequence
• Anti-coincidence Grouping
• Rapper failure alarms
• Remote display option with fiber optics
• Multiple rapper programs
• DCS compatible
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Top-Rapped
vrs Tumbling Hammer Design vrs Tumbling Hammer Design
Top Rapped
Tumbling Hammer
• Two- point suspension
• MIGI Rappers
• Rappers out of gas stream
• Variable rapping frequency
• Variable rapping intensity
• Short (1 m – 4 m) field length
• 0.3 m – 0.5 m between-field
length
• Typically penthouse design
• Typically single CE plate
• Heavy duty, reliable DE’s
• Four point suspension
• Tumbling hammers
• Rappers in gas stream
• Variable rapping frequency
• Fixed rapping intensity
• Large (2 m – 5.5 m) fields
• 1.5 m – 5.5 m between-field
space required
• Insulator Compartments
• Panel plate assembly
• DE’s subject to breakage &
tension loss
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Top-Rapped
vrs Tumbling Hammer Design
• Multiple CE plates per rapper
• Typical CE rapping ratio -
< 138 m2 per rapper
• Customizable DE emitter
points
• Straightforward assy of DE
• Bottom frame simplifies
alignment
• More shop fabrication –
lower field erection cost
Typical CE rapping ratio - Typical CE rapping ratio - Typical CE rapping ratio - Typical CE rapping ratio -
• One CE plate per rapper
• Rapping ratio could be
higher w/long field
• Limited customization
possible
• Frame assembly is field-
labor intensive
• No bottom frame
• Overall field erection is labor
intensive
Tumbling Hammer TOP RAPPED
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Top-Rapped
vrs Tumbling Hammer Design
• Typically smaller ESP for a
given gas flow
• Greater cost effective
electrical sectionalization
available
• Minimal internal maintenance
• Routine maintenance can be
performed on line
• Typically better performance
for a given SCA (f value)
• Typically more cost-effective
for a given gas volume
• Typically larger ESP for a
given gas flow
• Minimal sectionalization;
larger TR sets
• Internals are maintenance
intensive
• Most routine maintenance
performed off line Typically
Inferior performance for a
given SCA
• Typically less cost-effective
for a given gas volume
Tumbling Hammer TOP RAPPED
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Improving ESP Performance
in a
SHORT TIME
a
Case History
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The rebuilt Unit uses the same casing as the
existing ESP, but with internals converted from
tumbling hammer to top-rapped design. The
other design changes are:
Old New
3 Mechanical fields 6 mechanical fields
250 mm CE spacing 400 mm CE spacing
Conventional TR’s SMPS
Opacity 15-20% Opacity <<10%
Converting a Tumbling Hammer ESP to
Top-rapped Design - a case history
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Pre Outage work to pre-assemble the roof
extension and penthouse
Penthouse
Ring/Roof
Girder
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This shows that the unit was originally a tumbling
hammer design
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Day 4
Starting to remove the old collecting electrodes
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Day 7
Internals removal complete
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Day 8
Lifting the pre-assembled ring/roof girder
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Day 8
Lowering the pre-assembled
ring/roof girder onto the prepared flange
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Day 12
Lifting a bundle of new Collecting electrodes
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Day 12
Installing the new Collecting electrodes
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Day 20
Starting to install the hot roof
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Day 23
Cold roof installation complete
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Day 24
Installing the CE rapper sleeves & shafts
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Day 25
Rappers, T/R sets installed, LV wiring started
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Day 27
Nighttime lifting of weather enclosure
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Day 28
Weather enclosure in place - finish LV wiring
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Day 29
Rebuild
complete
Ready for
Startup
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Startup
Successful
After
4 week
outage
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Contact Information
Charles Hayes
Regional Sales Director
SOUTHERNenvironmental,INC.
6690 West Nine Mile Road
Pensacola, Florida 32526
850-941-3001
Renato Greco
New Technologies Development Manager
ENFIL