selection of design features and configurations of …

QUARTERLYISSN 1232-9312 1/2017 (104)

Problemy eksPloatacji

Journal of MachineC o n s t r u c t i o n and Maintenance

Bolesław kARWAT, Ryszard MACHNIk, jerzy NIEDŹWIEDZkI, Marek NOCUŃ*AGH University of Science and Technology, Cracow, PolandFaculty of Mechanical Engineering and Robotics* Department of Materials Science and [email protected], [email protected], [email protected], [email protected]

SElECTION OF DESIGN FEATURES AND CONFIGURATIONS OF THE CORONA ElECTRODES OF INDUSTRIAl ElECTROSTATIC PRECIPITATORS USED IN POWER INDUSTRy

key words: electrostatic precipitator, discharge electrode, emissivity, migration velocity.

Abstract: The article presents the studies results of corona electrodes used in industrial electrostatic precipitators (ESP). For selected types of mast electrodes, measurements of their electrical parameters have been performed. Based on the analysis of measurement data, the effect of the geometry (shape and position emission elements) on the emissivity of the discharge electrode was established. The influences of the geometry and configuration of the electrodes on the current density distribution at the surface of the collecting electrodes of an ESP have also been investigated. The results were based on the determined change of the power spectral density magnitude PSD (Power Spectrum Density) as a function of the distance between the emission electrodes and the distance between the electrodes. This allows the selection of the corona electrodes geometry and their configurations to ensure high efficiency electrostatic precipitator. ESP efficiency and migration velocity of fly ashes from industrial combustion of fuels were studied, including lignite, coal, mixed coal with biomass, and biomass. The data obtained allowed the determination of indicators for the selection of the geometry of the discharge electrode, depending on the physicochemical properties and concentrations of separated fly ashes.

Wybór cech konstrukcyjnych i konfiguracji elektrod ulotowych w elektrofiltrach przemysłowych wykorzystywanych w energetyce

Słowa kluczowe: elektrofiltr, elektroda ulotowa, emisyjność, prędkości migracji.

Streszczenie: Artykuł przedstawia wyniki badań elektrod ulotowych wykorzystywanych w przemysłowych elektrofiltrach (ESP). Pomiary parametrów elektrycznych przeprowadzono dla wybranych typów elektrod masztowych. Na podstawie analizy da-nych pomiarowych ustalono wpływ geometrii (kształt i położenie elementów emisyjnych) na emisyjność elektrod emisyjnych.Zbadano także wpływ geometrii i rozmieszczenia elektrod na rozkład gęstości prądu na powierzchni jego elektrod zbiorczych w ESP. Wyniki bazowały na ustalonej zmianie magnitudy gęstości widmowej mocy (PSD) jako funkcji odległości pomiędzy elek-trodami emisyjnymi raz odległości pomiędzy tymi elektrodami. Umożliwiło to wybór korzystnych parametrów geometrycznych i konfiguracji elektrod ulotowych w celu zapewnienia wysokiej efektywności elektrofiltru. Przeanalizowano efektywność ESP i prędkość migracji popiołów lotnych powstałych w wyniku spalania paliw: węgla brunatnego, węgla, mieszanki węgla i biomasy oraz biomasy. Uzyskane wyniki umożliwiły wyznaczenie warunków selekcji parametrów geometrycznych elektrody emisyjnej, w zależności od właściwości fizykochemicznych i koncentracji rozdzielonych popiołów lotnych.

Introduction

Electrostatic methods of flue gas cleaning arecommonlyused in theenergysector (coalfiredpowerplants) [1] andmany industries, e.g., heat production,metallurgy, chemical plants, cement and paperproduction and so forth. In power plants, due to theamountofexhaustgasgeneratedduringtheproduction,

theonlyreasonableeconomicsolutionisgaspurificationusingelectrostaticprecipitators(ESP-s).

ESP-s are structures, which are designed for usein thespecificenergy installation.Theselectionof theESP design, corona electrodes, collection electrodes,and power systems, are determined by the type ofboilerandthetypeoffuelcombustionintheboiler,andconsequently, the properties of the resultingfly ashes,whichareseparatedintheESP.

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66 Journal of Machine Construction and Maintenance | PROBlEMy EkSPlOATACjI | 1/2017

Combustion of types of fuel other than the one for whichtheindividualdevicesweredesigned,forexample,burning coal of different chemical compositions [2]or the addition of additives to the primary fuel, i.e.biomass, will disturb the fly ash collection process.Action to meet the conditions for proper operation of theESPcanbedividedintotwobasicgroups.ThefirstoftheseareissuesrelatedtothedesignofESP[3],andin particular, the selection of discharge and collectingelectrodes [4, 5, 6]. The electrode arrangement mustmeet the criteria of the principle of the operation of the electrostaticprecipitator,i.e.allowingthegenerationoftherequiredelectricfieldanditsdistributioninthespacebetweenelectrodes[7,8,9].

The requirements for the correctness of mechanical design, mechanical strength (including resistance tocorrosion),divisionforcollectionzones,andsectionsofjointregenerationdevices,aswellashighvoltagepowersupplymustbefulfilled.

Thesecondgroupis theactivities involvedin thetechnologicalprocess,whichisthesourceoftheflyash.Theyresult fromthecharacteristicsof theaerosol, i.e.pressureandtemperature,thechemicalcompositionofcollected fly ash, the particle size distribution, shapeandresistivity[10,11],andthesurfacepropertiesoftheashparticles[12].Hence,inthedesignandselectionofequipment, it is necessary to know the characteristicsand properties of fly ash, including their changes inthe technological process [13].Themain criterion forthe selection of the configuration of discharge andcollecting electrodes of an electrostatic precipitator is toachievesuchconditions that theashgrainsenteringthe electrostatic chamber obtain an electrical charge sufficient for their migration and deposition on thecollectingelectrode.

The main role is played by charge transfer processesfromgasionstoflyashgrains.Thesourceofgas ionization phenomena lies in the proximity of the discharge electrode, andmore specifically frompointsonitssurface,whichdevelopanelectronavalanche.

The charged fly ash particles move towards thecollecting and corona electrodes. The vast majorityof dust particles are negatively charged and depositedon the grounded collecting electrodes with positivepotential.

Duetothestrengthcriteria,contemporary-operatedelectrostatic precipitators are equipped mainly with mast typecoronaelectrodes.Theseelectrodeshaveacircularcross section of the supporting mast with welded emissionelements,whichare thesourceof thecoronadischarge[14].

The article presents the results of research conducted for three selected industrial mast types of corona electrodes: – SPIKE,typewithelementsintheformofsharpened

rods Ø =4mmandlengthL =100mm; – DELTA, shape of emission elements is delta (Δ)

withaheightof70mmmadeofsteelrodhavinga diameter of Ø =4mm;and,

– U-typewithemissionelementsinaU-shape,madeof steel wire with a diameter of Ø = 4mm. Theheightoftheemissionelementisabout100mm,andthebendingradiusisabout25mm.The diameter of the supporting mast in the case of

all electrodes was the same and was Ø =40mm.

1. Research methodology

For each of the three mast type electrodes, thefollowingelectricalparameterswereinvestigated: – Current-voltagecharacteristics(changesincurrent

asafunctionofelectrostaticvoltageappliedtotheelectrode),and

– Current density at the surface of the collecting electrode.The study of electrical parameters of discharge

electrodes were carried out on a test station and the schematicisshowninFig.1.

Fig. 1. Schematic of the equipment to test corona electrode parameters: 1 – switch power supply circuits, 2 – isolation transformer, 3 – circuit for over-current protection, 4 – high voltage control loop, 5 – set of high voltage transformers, 6 – set of HV rectifiers, 7 – HV measuring circuit, 8 – corona electrode, 9 – collecting electrode, 10 – current measuring circuit (current density at the surface of collecting electrode), 11 – decade resistor, 12 – current measuring circuit (I-U characteristic)

Journal of Machine Construction and Maintenance | PROBlEMy EkSPlOATACjI | 1/2017 67

Current-voltage characteristics show the intensityoftheelectricfieldgeneratedbythedischargeelectrode.The intensity of the electric field affects the time forobtainingtheflyashparticleschargeallowingthemtomigrate and deposit on the collecting electrode. Thecurrent density on the surface of the collecting electrode affects the mechanical properties of the deposited dust layer on the surface of the collecting electrode. Thevalueofcurrentdensityatthesurfaceofthecollectingelectrode isaffectedby theemissivityof theelectrodeand the conductance of two-phase medium present in the inter-electrode space for a particular electrode configuration. Current-voltage characteristics aredetermined by recording the voltage at the dischargeelectrodeandthecurrentintheinter-electrodespace.Thevalueofthiscurrentiscalculatedfromthevoltagedropacrossgroundeddecaderesistorbox(11Fig.1).VoltagesignalsfromthevoltagemeasuringcircuitofadischargeelectrodeandthecurrentflowingbetweentheelectrodesandthegroundofthecircuitisfedtotheinputoftheNIUSB-6039cardconnectedwiththecomputer.

Themeasurementisconductedforsupplyvoltagesofthedischargeelectrodeintherangeof0-75kV.Foreachof themeasuringpoints,measured in incrementsofΔU=500V,thecardworkingwithasamplingrateof 2 kS/s registers the average value of themeasuredvoltages. The program for the acquisition enables thevisualizationofthedatarecordedon-line.Therecordeddataisstoredinafileinordertoundergofurtheranalysis.Current density distribution at the surface of collecting electrodeisdeterminedonthesamestation.Thecircuitdiagram of measurement is shown in Fig. 2. On thesurfaceof thecollectingelectrode (1) is16measuringfields(2)arrangedwithaconstantinterval.

Thecurrentsflowingbetweeneachof thesensorsandgroundareprovidedbythemultiplexer16 to1 tothemeasuringamplifier,buildontheintegratedcircuitINA 114 Burr-Brown. The measuring signals areswitchedsequentially.TheamplifiedsignalisrecordedbymeasuringcardNIUSB-6039usingacomputer.Dataarerecordedfivetimesinthecycle,whichmeansthatthemeasuredvalueofthecurrentcorrespondingtothevalueofcurrentflowingthrougheachofthemeasurementfieldistheaverageofthe10000measurements.

Analyses of the current density distribution on the surface of the collecting electrode were performed using a program developed for this purpose with advancedstatisticalfunctions,servingforthetimeseriesanalysisTSA (Time SeriesAnalysis) of the LabView program[15]. This program, after the initial processing ofmeasureddata,allowstheirsmoothingdeterminingforthe analysed magnitude of power spectral density PSD (Power Spectrum Density),timeseriesXt.

For the calculation of the power spectrum and powerspectraldensity,theprocedurescontainedinthelibrariesoftheLabViewprogramwereused.

Analysis of the measurement results allowed the determination of the effect of the distance between the

emission elements of a single electrode – dI and the distance between the electrodes – Hontheelectricfieldparametersinthechamberofprecipitator.

Combustionefficiencywasstudiedforselectedbestgeometryandelectrodeconfigurationmigrationvelocityand the collection of fly ash coming from industrialfuels,includingthefollowing: – Lignite, – Coal, – Amixtureofcoalandbiomass,and – Biomass(fuelofvegetableorigin).

Themigrationvelocityisthespeedatwhichtheflyashparticles(havinganelectricalcharge)advanceintheinter-electrode space in the direction of the electrostatic precipitator-collecting electrode. Migration of theparticlesaretheresultofthefollowingforces:theflowofthegas,gravityforces,theresistanceofthegaseousmedium,forcesinducedbythegrainspolarization,andespecially the reaction of grain charge with the electric field.Knowingthemigrationvelocity,theESPefficiencycanbedeterminedusingtheDeutschequation(1):

Fig. 2. Schematic of the circuit current density distribution measurements on the surface of the collecting electrode, 1 – collecting electrode, 2 – measurement fields, 3 – measurement signals

(1)

whereη –collectionefficiency,L–thelengthoftheelectricfield[m],h–distancebetweendifferentpoleselectrodes[m],v–gasvelocity[m/s],m–migrationvelocity[m/s].

This equation takes into account the parameters of the electrical, geometrical, and aerodynamiccharacteristicofESP.Althoughitwasderivedassuminga number of simplifications, it is still useful in thepracticeofdesign.

Researchonthemigrationvelocityofflyashfromcoal combustion was carried out in the laboratory plate electrostatic precipitator with the following parameters:


– Theactivelengthofthechamber:2m; – Theheightofchamber:1m; – Theinter-electrodepitch:400mm; – Collectingelectrode:flat; – Coronaelectrodes:replaceable,matchedtospecific

measurements; – Gasflowrate:0.1m/sto0.8m/s; – The source of fly ash: fluidized bed chamber fed

fromasourceofcompressedair;and, – Theadministrationofflyash:theverticalsystemof

nozzlesintheareaoftheinletoftheESP.Because the multi-zone electrostatic precipitator

concentrationofflyashinthemediumisvaried,testingwas performed for four fly ash concentrations in therangeof2.7–7.2g/m3.Duringstudyingtheelectrostaticfly ash separation in the laboratory, itwas establishedthat a voltage supply of discharge electrodes and theparameters of movement of the medium through thechamberasfordischargeelectrodesofhighestemissivitydustparticlemigrationvelocitydidnotexceed1m/s.

Almost all manufacturers of the currently operated electrostatic precipitators use the inter-electrode scale (the distance between the collection electrodes) Hz = 400 mm. Reducing the distance between thecollecting electrodes allows for high current density in the inter-electrode space. This gives higher migrationvelocityofthedust,whichaffectstheeffectivenessoftheflyashcollectionprocess.However,withthereductionof Hz scale, the number of sparks in space betweenthe electrodes is growing, consequently lowering theefficiencyoftheESP.Duetothefactthatthecommonlyused industrial electrostatic precipitator scale size Hz betweencollectingelectrodesisstrictlydefined,astudyofgeometricalfeaturesandconfigurationsofthecoronaelectrodes on the combustion gases treatment was carried out for scale Hz =400mm.

2. Test results

2.1. The electrical parameters of discharge electrodes

The electrical parameters of mast type industrial electrodes determined on the basis current-voltagecharacteristicsandthevalueoftheinitialcoronavoltageareshowninTable.1.

Table 1. Electrical parameters and initial corona voltage of the mast electrodes

Electrode EmissivityInitialcoronavoltageU0,

[kV]spike high 8.0

DELTA low 39.0

U-type verylow 44.5

Based on current density distribution J on the surfaceofthecollectingelectrodemeasurement,onecandetermine the electrode configurations and geometriesin away that yieldshigh currentdensity.At the sametime, the distance between the corona electrodesshould be selected in a way that the current density distribution along a collecting electrode is as uniform aspossible.Suchoptimization ispossibleon thebasisof the magnitude of the spectral power density PSD as a function of distance between electrodes H and between emission elements dIofthecoronaelectrode.TheresultsoftheanalysisareshowninFigs.3–5.

Fig. 3. The magnitude of the power spectral density PSD as a function of the distance between electrodes H and the distance between emission elements dI for spike type electrodes

The results of current density distribution on the surfaceof the collecting electrode show that,withan increasing distance between electrodes H and thedistance between emission elements dI for spike type electrodes, the corona electrodemaximumPSD valuecorresponds to the scale H =490mm(Fig.3).Increasingthe distance between the emission elements of the electrode affects the growth of the current density J.Themaximumvalueofthiscurrentisfortheinteremissionelements distance dI =250mm.At the same time, anincrease in the distance between the corona electrodes causesadecreaseinthevalueofcurrentdensityatthesurface of the collecting electrode in the axis of corona electrodessymmetry.

In caseofDELTA type electrodes, increasing thedistance between the emission electrodes affects the growth of the current density J(Fig.4).ThemaximumPSD value of the current density distribution at thesurface of the collecting electrode corresponds to the scaleH=500mmanddI =250mm.The increase inthe distance between the corona electrodes causes adecreaseinthevalueofcurrentdensityonthesurfaceof the collecting electrode at the axis of symmetry of the coronaelectrodes.


Fig. 4. The magnitude of the power spectral density PSD as a function of distance between electrodes H and distance between emission elements dI for a DELTA type electrode

Analysis of changes in the magnitude of power spectral density PSD as a function of inter electrode and inter emission elements scale of the U-type electrodeindicates that the increase in the distance between the corona electrode and the distance between the emission elements cause an increase in the value of the PSD for the studied group of electrodes (Fig. 5).With theincreaseofthedistancebetweenthecoronaelectrodes,there are increases in the current density J. Themaximum PSDvalueofthecurrentdensitydistributionat the surface of the collecting electrode corresponds to the scale H =540mmanddI =220mm.Theincreasein distance between the corona electrodes causes adecreaseinthevalueofcurrentdensityonthesurfaceof the collecting electrode at the axis of symmetry of the coronaelectrodes.

2.2. The migration velocity of fly ash and ESP efficiency

The migration velocity is conditioned by thedistributionandintensityoftheelectricfieldintheESPchamber,and,basedonitsvalue,onecandeterminethefutureoperatingparametersof theESP.Themigrationvelocityisduetothepropertiesoftheelectricfieldintheinter-electrode space and the physicochemical properties of the medium gas-dust. Therefore, the migrationvelocityoftheflyashinthedirectionofthecollectingelectrode of the precipitator was adopted as a criterion for selecting the type of the discharge electrode. ThevaluesofthemigrationvelocityarepresentedinTables2and3.InTables2‒5,theflyashsamplesaremarkedas follows: FA1‒lignite,FA2‒coal,FA3‒amixtureofcoalandbiomass,andFA4‒biomass.

Table 2. The migration velocity of fly ash particles in the laboratory ESP for fly ash concentrations s < 5 g/m3

Electrode type

Themigrationvelocity[m/s],flyashparticlesconcentrationss<5g/m3

SymboloftheflyashsampleFA1 FA2 FA3 FA4

spike 0.65 0.79 0.62 0.73DELTA 0.49 0.57 0.45 0.38U-type 0.43 0.56 0.49 0.38

Table 3. The migration velocity of fly ash particles in the laboratory ESP for fly ash concentrations s > 5 g/m3

Electrode type

Themigrationvelocity[m/s],flyashparticlesconcentrationss<5g/m3



The results of the relative efficiency of thelaboratory ESP calculated using the equation (1) aregiveninTables4and5.

Table 4. The laboratory ESP efficiency for fly ash concentrations s < 5g/m3

Electrode type

Collectionefficiency[%],flyashconcentrationss<5g/m3



Fig. 5. The magnitude of the power spectral density PSD as a function of distance between electrodes H and distance between emission elements dI for a U-type electrode


Table 5. The laboratory ESP efficiency for fly ash concentrations s > 5 g/m3

Electrode type

Collectionefficiency[%],flyashconcentrationss>5g/m3



Studying the dust separation in the laboratoryESP,thevoltagesupplyofdischargeelectrodesandtheparameters of movement of the medium through thechamberwassetonsuchalevelthatforthedischargeelectrodeshadthehighestemissivity,andthemigrationvelocityofflyashparticlesdidnotexceed1m/s.Tothevaluesofmigrationvelocity,wm was assigned weight n in the rangeof 1 to 10, taking asn =1 formigrationvelocitywm=0.1m/sandn=10formigrationvelocityof wm = 1 m/s. This allowed for easy assessment ofthe impact of discharge electrode geometry on the efficiency of the deposition process on the surface ofcollectingelectrode.Thesumoftheweightscalculatedforeachtypeofelectrodeandtypesofflyash,providingevidenceforuniversalapplication,wasdeterminedfromthefollowingequation(2):

Table 6. The indicators for the selection of the geometry of the discharge electrode at the supply voltage 65 kV, for the fly ash at the different physicochemical properties and concentrations s < 5 g/m3

Electrode

Symboloftheflyashsample

The sum of weights

∑np

The sum of weights in%∑nppFA1 FA2 FA3 FA4

Spiketype 7 8 7 8 30 75.0%

DELTA 5 6 5 4 20 50.0%U-type 5 6 5 4 20 50.0%

Table 7. The indicators for the selection of the geometry of the discharge electrode at the supply voltage 65 kV, for the fly ash at the different physicochemical properties and concentrations s > 5 g/m3

Electrode

Symboloftheflyashsample The sum

of weights ∑np

The sum of weights

in% ∑npp

FA1 FA2 FA3 FA4

Spiketype 7 6 7 6 26 65.0%

DELTA 4 6 4 6 20 50.0%U-type 4 6 4 4 18 45.0%

Conclusions

Research on the influence of the geometryand configuration of the corona electrodes on theeffectiveness of ESP were targeted for industrialapplications.Thedataobtainedbymeasuringelectricalparameters of selected corona electrodes used on an industrial scale were aimed to help design industrial ESPsusedforcombustiongasespurificationresultinginenergyproduction.

The study showed that the parameters of the electric fieldintheprecipitator’schamberarestronglydependenton the distance between the corona electrodes H.Basedon the distance H, ranges towhich thecurrentdensitydistribution at the surface of the collecting electrodes is mostfavourableweredefined.

The results show that, depending on the type ofthedischargeelectrode,thepreferreddistancesbetweencorona electrode H and emission elements dI are as follows: – Spiketype:460–500mm,200–250mm; – DELTA:480–540mm,190–250mm;and, – U-type:500–540mm,220–250mm.

In the process of designing an electrostatic precipitator,accordingtotheadoptedtypeofdischargeelectrodes, the top value ofH should be applied.Thefinal selection of this value, however, is dependenton the planned width of the elements constituting the collectingelectrode. Inaddition to theselectionof thevoltagesupplyingcoronaelectrodesineachzoneofan

wherenp1−np4−weightsforparticularflyash.

The sum of the weights was calculated from equation(3)

wherenpp − thesumoftheweightinpercentage.

Because,inamulti-zoneESP,theconcentrationofflyashisvaried,testingwasperformedforfourflyashconcentrationsintherangeof2.7–7.2g/m3.

Indicators for the selection of the geometry of the discharge electrode depending on the physicochemical propertiesandconcentrationsoftheflyashareshowninTables6and7.

Inthesetables,ashesaremarkedasfollows:FA1‒lignite,FA2‒coal,FA3‒amixtureofcoalandbiomass,and FA4‒biomass.

(2)

(3)


electrostatic precipitator, thepredictedmodeof powersuppliers and the frequency of cleaning of the collecting andcoronaelectrodearealsoimportant.

Analysis of the results expressed as a percentage of sum weights for different types of electrodes and all types of studied dusts indicates that the established evaluationcriteriaisbestmetbyspiketypeelectrodes.TheU-type electrodemeets the established evaluationcriteria below 50% for dust concentrations above5 g/m3; therefore, it does not qualify for extractionprocesses at these concentrations of dust in the exhaust gas. Incaseof theflyash from theburningofcoalatconcentrationsabove5g/m3,achange in theshapeoftheelectrodedoesnotchangethecriterion.Designatedindicators for the studied types of corona electrodes and types of dust do not allow an unambiguous choice of electrodes for all kinds of dust in the full range of their concentrations.Theexpressionusingthepercentageofthe sum of the weights for different types of electrodes andtesteddustsindicatesthat,atthesupplyvoltageof65kV,highdepositionratesarefoundonlyinmasttypespikeelectrodes.Forothertypesofelectrodes,migrationvelocityintheprecipitator’schamberislowerthanthatof the spike electrode. This particularly concerns thedustfromtheburningoflignite.

DELTAandU-typeelectrodescanbeused in thelastzonesoftheESP.Inthesezones,theconcentrationofdustislow,andtheirdiametersaresmall(≤10um).Theseparationofflyashwithsuchgrainsizesrequiresa higher supply voltage of corona electrodes. Lowemissions of these types of electrodes allow increasing their power supply without disturbing the extraction process (increasing the number of sparkles in the chamberofelectrostaticprecipitator).

Presentedresultsdonotcoverthewholeissueoftheselection of the corona electrodes used in electrostatic precipitatorsbut representonlya fractionofextensiveand complicated problems of electrostatic fly ashremovalsystems.Theresearchresultsmaycontributetosuch changes in of the mast type corona electrode design that will increase their operational advantages, whileloweringtheirmanufacturingcosts.

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