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The flue gas volume of the wet electrostatic precipitator in a brick and tile tunnel kiln in Shanxi is no more than 100,000 m³/h, and the designed gas velocity is 1 m/s.

This set of equipment is a wet electrostatic precipitator for the 200,000 m³/h coal gangue flue gas of a brick and tile tunnel kiln in Shandong. The equipment is installed behind the tower. It utilizes high - voltage pulsed direct current and an electric field to drive the fine dust in the flue gas, accelerating its settlement on the anode surface to remove dust particles, fog droplets, aerosols and some odors from the flue gas, thereby achieving the purification of the flue gas.

The dust content of the flue gas at the inlet of this wet electrostatic precipitator is 200 mg/m³, the dust content of the flue gas at the outlet is ≤ 15 mg/m³, and the dust removal efficiency is ≥ 92%. It has passed the acceptance inspection of the local environmental protection department.
 

The above picture shows the project of a fiberglass wet electrostatic precipitator for brick - making flue gas undertaken by our company. This set of wet electrostatic precipitator is designed for a gas volume of 2 × 200,000 m³/h. The dust content of the flue gas at the inlet is 200 mg/m³, and the flue gas temperature is 70 °C. The dust at the outlet of the precipitator is required to be lower than 30 mg/m³. Currently, standard - compliant emission has been achieved.

Wet Electrostatic Demister for Zinc Calcine & Zinc Chloride Flue Gas Dispatched to Inner Mongolia. The picture below shows the delivery site.

One of the two sets of wet electrostatic demisters is used for in-depth purification of zinc calcine flue gas, with a flue gas volume of 50,000 m³/h, a designed gas velocity of 1 m/s, and a designed dust removal efficiency of over 90%.

The wet electrostatic demisters in-depth purification of zinc calcine flue gas

The other set of wet electrostatic demister is used for in-depth purification of zinc chloride evaporation flue gas, with a flue gas volume of 36,000 m³/h, a designed gas velocity of 0.9 m/s, and a designed dust removal efficiency of over 90%.

Our company is responsible for the manufacturing, transportation, installation and commissioning of the main bodies of the two sets of electrostatic demisting equipment (including the electrical components and cables from the high-voltage power control cabinet to the main body). We will follow up on the progress of the installation and commissioning of the wet electrostatic equipment subsequently.

The wet electrostatic demisters in-depth purification of zinc chloride evaporation flue gas

The wet electrostatic precipitator shipped this time is customized for a comprehensive chemical enterprise integrating chemical fertilizer and chemical industry in Hebei. This set of wet electrostatic precipitator is applied to the company's 20,000-ton cyanuric acid project. Hebei Weimei is responsible for the functional design, manufacturing, supply, installation and commissioning of the main body of the high-voltage electrostatic demister and its auxiliary equipment system. The equipment has a flue gas volume of 25,000 m³/h, a flue gas temperature of ≤60℃, and a designed flow rate of 0.5 m/s, which is consistent with the professional manufacturing and transportation standards of our company's wet electrostatic series products.

wet electrostatic precipitator is applied to the company's 20,000-ton cyanuric acid project

Delivery of shell and accessories for wet electrostatic precipitator

Conductive FRP wet electrostatic precipitators are generally applied to flue gas purification in the environmental protection industry, as well as gas purification, mist elimination and dust removal in industries such as metallurgy, chemical engineering and petroleum.

Conductive FRP wet electrostatic precipitators boast the following features:

1. Excellent electrical conductivity, and high efficiency in mist elimination and dust removal.
2. Strong corrosion resistance, good flame retardancy, long service life, as well as safe and reliable performance.
3. Compact and reasonable structure, high strength and light equipment weight.

Features of Conductive FRP Wet Electrostatic Precipitators

The wet electrostatic precipitator is equipped with an intermittent spray method. Spraying plays a remarkably significant and effective role in improving the efficiency of the wet electrostatic precipitator, as well as maintaining the cleanliness, long-term stability and safe operation of the electric field. It is especially crucial for the safe operation of the wet electrostatic precipitator and the initial commissioning phase. All users should attach great importance to this and strictly follow the relevant requirements. For intermittent spraying, impurity-free weakly acidic circulating water or clean water can be selected.
 

Schematic Diagram of Spraying for Wet Electrostatic Precipitator

1. Clean up impurities in the spray circulation water tank, and conduct water filling and leakage testing.
2. Open the inlet valve of the circulating water pump, start the circulating pump and flush the spray pipeline.
3. After the pipeline flushing is completed, stop the circulating water pump and install the spray nozzles.
4. Start the circulating water pump, open the pump outlet valve, and control the pressure of the wet electrostatic precipitator flushing water pipeline between 0.3 and 0.4 Mpa.
5. Manually adjust the wet electrostatic precipitator intermittent spraying device to confirm that the pressure is normal, there is no leakage in the pipelines inside and outside the electric field, the spraying is uniform, and there are no obvious dead zones for spraying and washing in the electric field.
6. Switch the intermittent spraying to automatic interlock control on the DCS in the control room, and verify that the actions are accurate, reliable, in-place and flexible.
7. Stop the circulating water pump, close the pump inlet valve, and the commissioning of the spray system is completed.

Anode tubes constitute the anode system of wet electrostatic precipitators. The fiberglass reinforced plastic (FRP) anode tubes produced by Hebei Weimei Environmental Protection Co., Ltd. boast the advantages of strong corrosion resistance, excellent electrical conductivity, high efficiency in dust and mist removal, light weight, high strength, and compact structure. The honeycomb structure enables both the inner and outer surfaces of each tube to serve as precipitation surfaces. They also feature good flame retardancy, with the oxygen index of the material reaching over 32. Their service life can be as long as 20 years.

FRP Anode Tubes

Layered Structure and Fabrication of FRP Anode Tubes

The layered structure of the FRP used for conductive FRP anode tubes is, from the inside to the outside, as follows: 1 layer of carbon fiber mat, 2 layers of chopped fiber strip mats, 3 layers of glass fiber cloth with a thickness of 0.4mm, and 1 layer of glass surface mat. Vinyl resin is adopted as the base resin, which contains high-carbon-content (>98%) graphite, flame retardants and other additives. The conductive FRP made of this material has the advantages of high strength, good rigidity, excellent electrical conductivity and flame retardancy.

Characteristics of FRP Anode Tubes

1. Light Weight and High Strength
   The FRP anode tubes are light in weight yet high in strength, with fixed external dimensions. Unlike lead precipitation electrodes that tend to deform after long-term use, these tubes avoid such deformation issues, thereby extending the service life of the equipment.
2. Compact Structure
   The honeycomb structure allows both the inner and outer surfaces of each tube to act as precipitation surfaces, with no dead zones in between. Therefore, for treating flue gas of the same scale, the equipment has a smaller volume and occupies less floor space.
3. Strong Corrosion Resistance
   They can resist corrosion by various dilute acids, alkalis, salts and other media.
4. Good Flame Retardancy
   Tested by national professional testing institutions, the oxygen index of the material can be below 28%. Thus, even if arcing occurs inside the electric field, it will not ignite the precipitation components.

Anode System of Wet Electrostatic Precipitator

During the operation of a wet electrostatic precipitator, damage and cracking of insulating porcelain insulators often occur, which will lead to failure to apply high external voltage or transmit power. What are the causes of this situation?

1. Condensation Leakage: During the operation of the dust collection chamber, the temperature drops and SO? condenses on the surface, which often causes leakage. Therefore, the equipment must be operated at an appropriate temperature (300℃ at the outlet).
2. Damage During Installation: The installation work shall be carried out with caution, and care must be taken to avoid collision or improper installation.

Replacement of Insulating Porcelain Insulators for Wet Electrostatic Precipitator

Phenomenon: Excessively frequent flashover, accompanied by decreased dust collection efficiency

Causes:
(1) Discharge occurs outside the electric field of the electrostatic demister, such as discharge at the isolating switch, high-voltage cable, damping resistor, etc.
(2) The spark rate of the electric control cabinet is not properly adjusted.
(3) Fluctuations in operating conditions lead to drastic changes in flue gas parameters.
(4) Improper adjustment of the distance between cathode wires and anode plates.

Troubleshooting:

(1) Eliminate the discharge at the faulty parts.
(2) Adjust the spark rate potentiometer and switch the device to automatic mode.
(3) Notify the chief operator to optimize process conditions and improve flue gas parameters.
(4) Adjust the distance between cathode wires and anode plates to the standard range.

Phenomenon:
 
Low primary and secondary voltage; low secondary current. The primary current is much higher than normal, rises rapidly, and is disproportionate to the secondary current rise.Cause: Turn-to-turn short circuit occurs in the rectifier transformer, or the silicon stack is open-circuited or broken down.

Troubleshooting: 

Conduct an open-circuit test. If current is detected on the primary side, it indicates internal component damage, magnetic bias or short circuit in the transformer. Lift the transformer core for maintenance and replace the damaged components.

Phenomenon: 

Low primary and secondary voltage; low secondary current. The primary current is extremely high, rises disproportionately to the secondary current, surges and changes abruptly. This may blow the quick fuse, and the transformer emits obvious abnormal noise.

Causes:

(1) Short circuit fault in the low-voltage winding of the rectifier transformer;
(2) Insulation damage to the rectifier transformer core (including through-core bolts), resulting in severe eddy current.

Troubleshooting:

(1) Replace the low-voltage winding;
(2) Re-insulate the transformer core.

Phenomenon: 

When primary and secondary currents reach rated values, the primary voltage stays between 280–330V, the secondary voltage ranges from 40–50kV, and no flashover occurs.Cause: Severe leakage at the high-voltage cable and its terminal.

Troubleshooting: Reconstruct the high-voltage cable and its terminal.

Phenomenon: 

Frequent frequency conversion of the alkali supply pump, large fluctuation in rotation speed, and drastic changes in the pH value of the circulating water tank.Cause: Clogging of the neutralization pipe in the circulating water system by foreign matters.

Troubleshooting: 

Clean the foreign matters inside the anode tubes of the electrostatic demister.

Phenomenon: 

Gradual decrease in circulating water flow, accompanied by a progressive drop in dust collection efficiency.

Cause:

Scaling on the pipelines of the electrostatic demister and the circulating water pump.Troubleshooting: Appropriately reduce the pH value of the circulating water tank to 5.2 during operation.

Wet Electrostatic Precipitator (WESP)

To ensure the long-term stable operation of an electrostatic precipitator and achieve the expected dust removal efficiency, a designated person shall be assigned to be responsible for its operation and maintenance. The person in charge must meet the four understandings and three competencies requirements for the electrostatic precipitator.The four understandings refer to: understanding the structure, understanding the working principle, understanding the performance, and understanding the functions.The three competencies refer to: being competent in operation, being competent in maintenance, and being competent in troubleshooting.

An inspection shall be conducted on the electrostatic precipitator every time it is shut down, including cleaning the electric field, straightening severely deformed anode plates and cathode wires, wiping the insulating porcelain components, measuring the insulation resistance, and troubleshooting faults occurring during operation. In addition, a medium maintenance shall be carried out once a year, which includes replacing damaged parts. For each overhaul, the electric field shall be comprehensively cleaned and adjusted, all parts that affect performance or are damaged shall be replaced, and the lubricating oil shall be changed regularly.

Routine Inspection and Maintenance of Electrostatic Precipitators

1.1 First check the dust accumulation status inside the electric field before cleaning it.

1.2 Check the side walls of the electric field, access doors, insulator chambers on the top cover, and other parts for air leakage, condensation, dust caking, corrosion, or dust accumulation, and remove these defects accordingly.

1.3 Check the temperature of each drive motor, the oil level inside the reducer, whether the rapping shaft bearings are jammed, whether the hammer heads rotate flexibly and are not loose or missing, and whether the impact contact positions are accurate. Apply lubricating oil to the motors in accordance with the product specifications.

1.4 Sometimes the gas distribution plates in areas with low flue gas velocity may be prone to dust accumulation and clogging; inspect and perform manual cleaning on them.

1.5 Check the cathode frame and cathode wires for deformation and dust accumulation.

1.6 Check the anode plates and rapping rods for deformation and dust accumulation.

1.7 Insulating porcelain sleeves are used to support and insulate the discharge system. During operation, a layer of dust and dirt often accumulates on the surface of the porcelain sleeves, which may easily lead to surface high-voltage breakdown and thus crack the insulators. Therefore, the porcelain sleeves shall be kept clean. Wipe the inner and outer walls of the porcelain sleeves every time the equipment is shut down, and carefully check for tiny cracks with a flashlight.

1.8 Check the porcelain rotating shafts for the discharge electrode rapping device for dust adhesion and wipe them clean; replace them immediately if cracks are found.

1.9 Check whether the high-voltage silicon rectifier transformer (in accordance with the manufacturer’s instructions), high-voltage isolating switch, relays, heating element functions, temperature measurement and control instruments, alarm devices, and grounding devices are in normal condition, and eliminate any faults detected.