New Electrostatic Precipitator Technologies in the Pulp & Paper Industry

Charles Hayes Regional Sales Director SOUTHERNenvironmental,INC . Pensacola, Florida

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 Toprapped design a case study

Techniques to improve performance in ESP Rebuilds/Upgrades

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

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

ELEX RDE Configurations

Standard fewer points per meter

Aggressive More points per meter

ELEX Rigid Discharge Electrode (Optimized)

ELEX VRS Pipe & Spike

ELEX vs. Pipe & Spike Airload V-I Curves

Top-Rapped ESP Internals

Internals showing DE & CE Rappers

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

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

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

CFD of Recovery Boiler ESP

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 2540% 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

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/Rs Less/limited bus duct required

SMPS - No Ripple SMPS wave form vs conventional T/R

[kV]

SMPS
80 60 40 20

ESP
Current [mA]

Conventional T/R
0

[ms]

Time (ms)

New High Frequency Power Supply

70 kV@1000mA SMPS Smaller & lighter

SMPS INSTALLATIONS
Results and Benefits More power into ESP Lower emissions Less line power consumed

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

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

Top-Rapped vrs Tumbling Hammer Design

Top Rapped
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 DEs

Tumbling Hammer
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 DEs subject to breakage & tension loss

Top-Rapped vrs Tumbling Hammer Design

TOP RAPPED Tumbling Hammer

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

One CE plate per rapper Rapping ratio could be higher w/long field Limited customization possible Frame assembly is fieldlabor intensive No bottom frame Overall field erection is labor intensive

Top-Rapped vrs Tumbling Hammer Design

TOP RAPPED 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

Tumbling Hammer
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

Improving ESP Performance in a

SHORT TIME
a Case History

Converting a Tumbling Hammer ESP to Top-rapped Design - a case history

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 TRs SMPS Opacity 15-20% Opacity <<10%

Pre Outage work to pre-assemble the roof extension and penthouse

Penthouse Ring/Roof Girder

This shows that the unit was originally a tumbling hammer design

Day 4 Starting to remove the old collecting electrodes

Day 7 Internals removal complete

Day 8 Lifting the pre-assembled ring/roof girder

Day 8 Lowering the pre-assembled ring/roof girder onto the prepared flange

Day 12 Lifting a bundle of new Collecting electrodes

Day 12 Installing the new Collecting electrodes

Day 20 Starting to install the hot roof

Day 23 Cold roof installation complete

Day 24 Installing the CE rapper sleeves & shafts

Day 25 Rappers, T/R sets installed, LV wiring started

Day 27 Nighttime lifting of weather enclosure

Day 28 Weather enclosure in place - finish LV wiring

Day 29 Rebuild complete Ready for Startup

Startup Successful After 4 week outage

Contact Information
Charles Hayes Regional Sales Director SOUTHERNenvironmental,INC. 6690 West Nine Mile Road Pensacola, Florida 32526 850-941-3001 chayes@sei-group.com Renato Greco New Technologies Development Manager ENFIL Renato.greco@enfil.com