Application of ESP for gas cleaning in cement industry — with reference to India

Abstract

Electrostatic precipitators (ESP) are used for gas cleaning in almost every section of cement manufacture. Application of ESP is studied, keeping in view Indian conditions. The characterisation of dust emissions has been done for different units, such as rotary kiln and raw mill, alkali by-pass, clinker cooler, cement and coal mill, in terms of exit gas quantity, temperature, dew point, dust content and particle size. It is seen that all these characteristics have a wide range of variance. The ESP system must effectively deal with these variations. The fundamental analytical expression governing the performance of ESP, i.e. the Deutsch equation, and that for particle migration velocity, were analysed to predict the effect of major operating parameters, namely particle size, temperature and applied voltage. Whereas the migration velocity (and the efficiency) varies directly with the particle size, it is proportional to the square and square root of applied voltage and absolute temperature of the gas, respectively. The increase in efficiency due to temperature is not seen in dc based ESP, perhaps due to more pronounced negative effect on the applied voltage due to the increase in dust resistivity at higher temperatures. The effect of gas and dust characteristics on the collection efficiency of ESP, as seen in the industrial practice, is summarised. Some main process and design improvements effectively dealing with the problem of gas and dust characteristics have been discussed. These are gas conditioning, pulse energisation, ESP-fabric filter (FF) combination, improved horizontal flow as well as open top ESP. Generally, gas conditioning entails higher operating and maintenance costs. Pulse energisation allows the use of hot gas, besides reducing the dust emission and power consumption. The improved horizontal flow ESP has been successfully used in coal dust cleaning. The open top or vertical flow ESP has a limitation on collection efficiency as it provides for only one electric field.