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ELECTROSTATIC PRECIPITATOR
CONTENTS
INTRODUCTION PRECIPITATOR COMPONENTS ARRANGEMENTS BASIC PRINCIPLE TECHNICAL SPECIFICATION ERECTION SEQUENCE
ELECTROSTATIC PRECIPITATOR
INTRODUCTION
We are Setting up 2x600 MW Coal Based Thermal Power Plant at Mahan Bandhaura Site. Electrostatic Precipitator is playing a vital role in most of the industries, such as 1) Thermal Power Plant 2) Cement Plant 3) Chemicals industries 4) Steel Plant 5) Paper Industries & etc
An electrostatic precipitator is a large, industrial emission-control unit. It is designed to trap and remove dust particles from the exhaust gas stream of an industrial process. In large power plants may actually have multiple no. of fields for each unit. In our plant, there are 9 no. of fields per unit.
Thursday, May 03, 2012 2 x 600 MW Mahan Thermal Power Project
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MAJOR COMPONENTS OF ESP:
1) Rectifier Transformer 2) Discharge Electrodes 3) Collecting Electrodes 4) Gas Distribution Systems 5) Rapping system 6) Hopper. About Rectifier Transformer: The power supply system is designed to provide high voltage to the field to increase the collection efficiency at the highest possible level The power supply system has four basic components: 1) Step-up transformer 2) High-voltage rectifier 3) Sensing device 4) Automatic voltage control
Thursday, May 03, 2012 2 x 600 MW Mahan Thermal Power Project
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DESCRIPTION ABOUT THE POWER SUPPLY SYSTEM The voltage must be controlled to avoid causing sustained arcing or sparking between the electrodes and the collecting plates Automatic voltage control varies the power to the transformer-rectifier in response to signals received from sensors in the precipitator and the transformer-rectifier itself. AVR monitors protects the internal components from arc-over damages, and protects the transformer-rectifier and other components in the primary circuit. Automatic voltage control would produce the maximum collecting efficiency by holding the operating voltage of the precipitator at a level just below the spark-over voltage.
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Spark reaction When the voltage applied to the field is too high, then spark over will occur. A voltage controller will monitor the primary and secondary voltage and current of the circuit, and detect a spark over condition. Once detected, the power applied to the field will be immediately cut off or reduced, which will stop the spark. After a short amount of time the power will be ramped back up, and the process will start over.
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Tripping When a condition occurs that the voltage controller cannot control, often times the voltage controller will trip. A trip means the voltage controller (by way of the contactor) will shut off the individual precipitator power circuit.
A short inside the electrostatic precipitator field caused by a fallen discharge electrode (wire), or a shorted out Silicone Controlled Rectifier are examples of conditions that a voltage controller cannot control.
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About Discharge Electrodes: Discharge electrodes emit charging current and provide voltage that generates an electrical field between the discharge electrodes and the collecting plates. The particles then precipitate onto the collecting plates. Common types of discharge electrodes include: 1) Straight round wires 5) Rigid frames 2) Rigid spiked pipes 6) Spiral wires 3) Twisted wire pairs 7) Barbed discharge wires 4) Rigid masts
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Rigid Electrode Spiral Electrode
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About Collecting Electrodes: Collecting plates are designed to receive and retain the precipitated particles until they are intentionally removed into the hopper. Collecting plates are also part of the electrical power circuit of the precipitator.
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About Gas distribution system: Gas velocity distribution can be most effectively influenced by the use of gas distribution devices. Ideally, uniformity is desired in: 1. Gas velocity 2. Gas temperature 3. Dust loading Gas distribution devices consist of turning vanes in the inlet ductwork and perforated gas distribution plates and in the outlet fields of the precipitator, flat distribution plate is used.
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INLET GD SCREEN OUTLET GD SCREEN
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Rapping System: To improve collection efficiency and ensure proper functional use of the precipitator, a rapping system is applied to the collection and emitting electrodes to dislodge the collected dust layer. 1) Collecting Rapping System: Collecting plate rapping must remove the bulk of the precipitated dust. The collecting plates are supported directly with hooks from the precipitator casing. The impact of the rapping system is directed into the Shock bar located at the leading and/or trailing edge of the collecting plates.
The first electrical field generally collects about 60-80% of the inlet dust load. So the first field plates should be rapped often for the every cycle.
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Collecting Rapping System
COLLECTING FRAME
COLLECTING PLATE
SHOCK BAR
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Rapping cycle for the each field as follows:Field No. 1 Stage Efficiency % 80% Rapping frequency, Raps/hr 6/Hr
2
3 4 5 6 7 8 9
15%
3% 1.2% 0.55% 0.11% 0.032% 0.007% 0.001%
4/Hr
2/Hr 1/Hr 1/2Hr 1/4Hr 1/8Hr 1/day 1/2day
1) All the above data are estimated value, especial the rapping mechanism. It should be adjusted iterative according to actual working condition. 2) Each rapping time is 1.5 mins
Thursday, May 03, 2012 2 x 600 MW Mahan Thermal Power Project
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2) Emitting Rapping System In general, discharge electrodes should be kept as free as possible of accumulated particulate. The rapping system for the discharge electrodes should be operated on a continuous schedule with repeat times in the 2 - 4 minute range, depending on the size and inlet particulate loading of the precipitator.
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3) Rapping System for Distribution Screen The gas distribution plates should also be kept free of excessive particulate buildup and may require rapping on a continuous base with a cycle time in the 10-20 minute range, depending on the inlet particulate loading of the precipitator and the nature of the particulate. Gas distribution plates in the outlet of the precipitator may be rapped less often (every 30 - 60 minutes).
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4) Bottom Hopper Precipitator hoppers are designed to completely discharge dust load on demand. Typically, precipitator hoppers are rectangular in cross-section with sides of at least 60-degree slope. These hoppers are insulated from the neck above the discharge flange with the insulation covering the entire hopper area. In addition, baffles are provided in the hopper to avoid the seepage.
8400mm
5650mm
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Hopper
P to Q - 1st FIELD
2 2 2 2
Q to R 2nd FIELD
3 3 3 3
R to S 3nd FIELD
4 4 4
S to T 4th FIELD
5 5
T to U 5th FIELD
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12.4m/s
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COLLECTING & EMITTING PLATE ARRANGEMENT FOR 1ST TO 6TH FIELD. Emitting plate 4 layers Collecting plate
EACH HEIGHT OF THE COLLECTING PLATE EACH HEIGHT OF THE RSB WIRE DETAILS OF COLLECTING ELECTRODE NO. OF COLLECTING ELECTRODE IN HALF FIELD (8*43) NO. OF COLLECTING ELECTRODE IN ONE FIELD NO. OF COLLECTING ELECTRODE IN SINGLE PASS (688*9) NO. OF COLLECTING ELECTRODE IN TWO PASS (6192*2)
200mm 200mm 400mm
15 M 3.581 M
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COLLECTING & EMITTING PLATE ARRANGEMENT FOR 1ST TO 6TH FIELD.
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COLLECTING & EMITTING PLATE ARRANGEMENT FOR 7TH TO 9TH FIELD
NO. OF SPIRAL BETWEEN TWO COLLECTING ELECTRODE NO. OF SPIRAL WIRE IN HALF FIELD NO. OF SPIRAL WIRE IN ONE FIELD (2688*2) NO. OF SPIRAL WIRE IN SINGLE PASS FROM 7th TO 9th FIELD(5376*3) NO. OF SPIRAL WIRE IN TWO PASS FROM 7th TO 9th FIELD
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COLLECTING PLATE SUPPORTED ARRANGEMENT
Collecting Plate
Emitting Plate
Guide Bar
Thursday, May 03, 2012 2 x 600 MW Mahan Thermal Power Project
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COLLECTING FRAME
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Collecting System
COLLECTING FRAME
COLLECTING PLATE
SHAFT RAPPER
SHOCK BAR
AVIL PLATE
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Emitting System Support:
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Emitting System Support:
TEMPORARY HANGER BOLT HANGER BOLT SUPPORT INSULATOR CHANNEL WITH INNER ROOF
BEAM
VERTICAL BOX
BEAM
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VERTICAL VIEW OF EMITTING SYSTEM SUPPORTTED VERTICAL BOX
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EMITTING FRAME FOR 1ST to 6TH FIELD:
Emitting Frame TOP VIEW OF EMITTING FRAME
Emitting Frame
RSB Electrode
Collecting Electrode
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VERTICAL BOX
EMITTING FRAME
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EMITTING FRAME FOR 7TH TO 9TH FIELD:
Emitting Frame
Spiral Electrode
Collecting Electrode
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VERTICAL BOX
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HV inlet:
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BASIC PRINCIPLES: Electrostatic precipitation removes particles from the exhaust gas stream by Six activities typically and they are 1) Ionization 2) Migration/Drift Velocity 3) Precipitation. 4) Charge Dissipation
5) Particle Dislodging
6) Particle Removal
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1.Electron emission 2.Dust particle charging/ corona formation
2
3.Migration 3
5.Rapping
5
Discharge electrode with Negative high tension volatge (72 KV)
4
4. Precipitation
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Working Principle:
The high voltage supply (72 KV) is applied to the Field, the discharge electrode emits the negatively charged ions. Particles suspended in a gas enter the precipitator and pass through ionized zones around the high voltage discharge electrodes, the particles are get ionized with negative and positive charged ions. This is called as Corona Formation
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The negatively charged gas field around each electrode charges the particles causing them to migrate to the electrodes of opposite polarity, i.e. the collecting electrodes.
The charged particles gather on the grounded collecting plates. Rappers dislodge the gathered particulate, which falls into the collection hoppers for removal.
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ESP TERMINOLOGY
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TECHNICAL SPECIFICATION: [General Information about ESP] S. No
1
2 3 4
Description
Manufacturer
Type and No. Overall dimensions (L X W X H) Number of ESP / Steam generator
Data
SUNYARD
2SY504-9 73.9353.1533.7m 2/1
5
6 7 8
2/1
9/1 36 40.9
9
10 11
Corona power per ESP stream (watts per 1000 m3 per min) No. of hours ESP can run at specified gas flow and dust loading without emptying any hopper (hrs)
Total power input to the ESP per steam Generator
2 x 600 MW Mahan Thermal Power Project
49
2 4400 KW
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FLUE GAS: S. NO DESCRIPTION
FLUE GAS Flue gas amount at inlet of E.S.P Flue gas temperature at inlet of E.S.P Excess air coefficient at inlet of E.S.P Dust concentration of flue gas at inlet of E.S.P Dust concentration at the ESP outlet g / Nm3 mg / Nm3
UOM
m3/hr
oC
2
3 4 5
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COLLECTING ELECTRODE SPECIFICATION S. No
1
2 3 4 5 6 7 8 9 Type Material Electrode thickness (mm) Clear distance between collecting electrode plates(mm ) Active length per electrode (in m) Cross sectional area of each passage (in m2) Active height per electrode(in m ) Specific collection plate area (m2/m3/sec) Total number of electrodes per SG
Description
Data
480C SPCC 1.5 400 0.48 5042 15 204.1 26192
10
11
2.24
0.88
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DISCHARGE ELECTRODE SPECIFICATION S. No
1 2 Type Material Total number of electrodes / SG (RSB Wire) Total number of electrodes / SG (Spiral Wire) Electrode dimension height (m) Effective length of electrode(m) High Voltage Conductor 7 8 9 Manufacturer Type SUNYARD taper
Description
Data
I to VI field RSB,I to IX field spiral wire. I to VI field SPCC,I to IX field stainless steel. 2 X 16128 2 X 16128 3.581 15
3
4 5 6
Size
150x400mm
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BUS SECTION SPECIFICATION
S. No
1 2 3 4 5 6 Total numbers
Description
Data
36 4 2 72 4400KW 1/2
Number of bus sections in parallel in gas path Number of sections in parallel in gas path HT Voltage [kV (peak)] Total power on HT electrode(kW) Number of sections lost if one transformer is out of service
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COLLECTING RAPPER SPECIFICATION
S. No
1 2 3 4 5 6 7 8 Type
Description
Data
Side driven, flexible arm rapper. 2 x 18 nos 2 x 774 Nos 8 50 150 13.32 electronic program
Total no. of rapper drive Total number of rappers per SG Maximum number of electrodes rapped by a rapper at any one time Percentage of plates rapped at one time ( % ) Rapping acceleration force minimum / plate(g ) Average input rapping power to rapping system (kW ) Rapper controller type
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DISCHARGE RAPPER SPECIFICATION S. No
1 2 3 4 5 6 7 Type Total no. of rapper drive Total number of rappers Percentage of electrodes rapped at any time ( % )
Description
Data
Top driven, flexible arm rapper. 2 x 18 Nos 1476 50
50
13.32 electronic program
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TRANSFORMER RECTIFIER UNIT
S. No
1 Total numbers Transformer 2 3 4 5 6 Type of transformer Class of insulation
Description
Data
36
Temperature rise of oil over ambient ( 0C ) Class of bushing Rating of each set Input power kVA
206 kVA
7
8 9
Output power kW
Output Voltage KV Output current mA
2 x 600 MW Mahan Thermal Power Project
120 kW
72 KV 2000 mA
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S. No
10 Volume of oil (Liters ) Rectifier 11 12 13 Type Half-wave / full wave Guaranteed life ( hours ) Rating-each Rectifier unit 14 15 16 17 18 19 Number offered Type of cabinet Voltage for controller Arc suppression Protection Instrumentation provided as required
2 x 600 MW Mahan Thermal Power Project
Description
Data
900 Liters
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POWER CONSUMPTION OF ESP PER SG S. No
1 2 3 4 5 6 7 8 9 10 11 12 Input power (kVA )
Description
206 kVA Output power from TR sets kW Output voltage KV Output current mA Total connected load kW Maximum power requirement kW Corona power available Watts / m2 Auxiliary power kW Rapping system kW Seal air fan kW
Data
120 Kw/TR 72 kV 2000 mA 118 kW 154 kW 26 Watts / m2 0.25 kW 0.74 kW 0.01 kW 0.05 kW 4.5 kW
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ERECTION SEQUENCE Check and set out the foundation
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Check and set out the foundation
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Erection of Steel Structures
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Erection of Steel Structures
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Erection of pedestal
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Erection of pedestal
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Erection of pedestal
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Erection of pedestal
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Assemble the ash Hopper
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Assemble the ash Hopper
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Erect the ash hopper
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Erection the Ash hopper
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Erect the casing
CASING STRUCTURE CASING WALL LRB TRB LRB
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GABLE WALL
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PASS A
70
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10768/6192 COLLECTING PLATES ERECTED
PASS B
71
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PASSA PASSB
72
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Install the roof
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Install the HV leading-in wire Install the top penthouse and lifting system
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