PB 248 220
PARTICULATE COLLECTION EFFICIENCY MEASUREMENTS ON
THREE ELECTROSTATIC PRECIP ITATORS
Grady B. Nichols, et al
Southern Research Institute
P re pared for :
Environmental Protection Agency
October 1975
DISTRIBUTED BY:
mi\
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TECHNICAL REPORT DATA
fFleaif read Instructions on the revche before eomplttingj
1. REPORT NO.
EPA-600/2-7
4. TITLE AND SUBTITL
056
Particulate Collection Efficiency Measurements on
Three Electrostatic Precipitators
UTHOR*. Grady B Nichols and Joseph D. McCain
Southern Research Institute, Birmingham, AL 35205
The M.W. Kellogg Company
1300 Three Greenway Plaza
Houston, Texas 77046
12. SPONSORING AGENCY NAME AND ADDRESS
EPA. Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
3. RECIPIENT'S ACCESSION-NO.
5. REPORT DATE
October J975
,6. PERFORMING ORGANIZATION CODE
SORI-EAS-75-428 (3296-H)
0. PROGRAM ELEMENT NO.
1AB012; ROAP 21ADL-004
68-02-1308, Task 21
13. TYPE Or REPORT AND PERIOD COVERED
Final Task: 7/73-7/75
14. SPONSORING AGENCY CODE
IS. SUPPLEMENTARY NOTES
" ,- The report gives results of a determination of the operating characteristics
of three full-scale electrostatic precipitators (ESP's), made to provide definitive
data on their performance. The measured performance of these ESP's was compared
with the theoretically predicted efficiencies computed by an ESP mathematical model.
Field measurements of total inlet and outlet mass concentrations, particle size
distributions, and electrical data were used for these comparisons. Descriptions of
the measurement procedures and the mathematical model are included. Two of the
ESP's were at electric power generating stations; the third, at a cement kiln.
TOG&S
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lOENTIFIERS/OPEN ENDED TERMS
Air Pollution Efficiency
Dust Electric Power
Measurement Generation
Electrostatic Cements
Precipitators . Kilns
Collection
S DISTRIBUTION STATEMENT
Unlimited
c. COSATI Field/Group
Air Pollution Control
Stationary Sources
Particulate
13B
11G
14B 10A
11B.13C
13A
20. SECURITY CLASS (Ttii*pagtl
EPA Form 2220-1 (9-73)
NATIONAL TECHNICAL
INFORMATION SERVICE
*
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development,
U. S. Environmental Protection Agency, have been grouped into
five series. These five [broad categories were established to
facilitate further development and application of environmental
technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in
related fields. The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology o
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. Thas series describes research performed
to develop and dmonstrate instrumentation, equipment and
methodology to repair or prevent environmental degradation from
point and non-point sources of pollution. This work provides the
new or improved technology required for the control and treatment
of pollution sources to meet environmental quality standards.
EPA REVIEW NOTICE
This report has been reviewed by the U. S. Environmental Protection
Agency, and approved for publication. Approval does not signify that
the contents necessarily reflect the views and policies of the Agency, nor
does mention of trade names or commercial products constitute endorse-
ment or recommendation for use.
This document is avialable to the public through the National
Technical Information Service, Springfield, Virginia 22161.
-------
EPA-600/2-75-056
PARTICULATE COLLECTION EFFICIENCY
MEASUREMENTS ON THREE
ELECTROSTATIC PRECIPITATORS
by
Grady B. Nichols and Joseph D. McCain
Southern Research Institute
2000 Ninth Avenue, South
Birmingham, Alabama 35205
for
The M.W. Kellogg Company
1300 Three Greenway Plaza
Houston, Texas 77046
in
-o
i
Contract No. 68-02-1308, Task 21
ROAPNo. 21ADL-004
Program Element No. 1AB012
EPA Task Officer: Leslie E. Sparks
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
October 1975
II
ABSTRACT
The operating characteristics of three full scale electro-
static precipitators were determined to provide definitive
data on their performance. The measured performance of
these precipitators was compared with the theoretically
predicted efficiencies computed by an electrostatic precipi-
tator mathematical model. Field measurements of total
inlet and outlet mass concentrations, particle size
distributions, and electrical data were used for these
comparisons. Descriptions of the measurement procedures and
the mathematical model are included.
iii
-------
CONTENTS
.Abstract
List'Of Figures
List'of Tables
Page
iii
v
viii
Sections
I
II
III
IV
V
VI
VII
VIII
IX
Introduction 1
Measurement Techniques 2
Gorgas Power Station -Alabama"Power
Company 9
Performance Tests at a-Hot'Side
'Electric Utility Burning Western Coal 23
Citadel Cement,- Birmingham, -Alabama 44
Comparison of Measured and Theo-
retically-Predicted Collection
Efficiencies -57
Impactor Substrate and Filter Media
Interference-in a Flue Gas Environ-
ment 65
References '74
Conversion Factors 75
iv
FIGURES
No. .Page
'2-1 Comparison.of sedimentation and equivalent
optical diameters 5
2-2 ' Optical and diffusional sizing'system 6
3^1 ' Precipitator layout-at Gorgas Unit 10 -10
3^2 Velocity traverse -at inlet . 11
3-3 Velocity.traverse at outlet 12
3-4 .Inlet 'size distribution obtained from modified
Brink irapactor .15
3-5 .Outlet size distribution obtained from
Andersen impactor 16
3-6 Measured and computed efficiency as a 'function
of particle size for precipitator installlation
-at the Gorgas plant of Alabama Power Company 17
3-7 Voltage-current relationships obtained on
precipitator »B" 22
4-1 Cumulative particle size distribution of the
inlet particulate at a hot.side precipitator
installation 28
o
4-2 Cumulative outlet particle size distribution
hot side precipitator 29
4-3 Cumulative particle number concentration at
the hot side precipitator installation 31
4-4 Measured fractional efficiencies for the
hot side electrostatic precipitator 32
4-5 Laboratory resistivity as a function of
temperature for fly ash from the hot side
precipitator. 35
4-6 ,Precipitator information and layout for the
collector 37
-------
No.
5-1
5-2
5-3
5-4
5-5
6-1
6-2
6-3
6-4
6-5
6-6
7-1
7-2
FIGURES
(continued)
Cumulative inlet mass concentration as a
function of particle size for the Citadel
Cement installation
Page
48
Cumulative mass as a function of particle size
from the outlet of the Citadel Cement installa-
tion, runs 3-6 49
Cumulative mass as a function of particle size
from the outlet of the Citadel Cement installa-
tion, runs 7-9 51
Minimum collection efficiency as a function of
particle size, Citadel Cement electrostatic
precipitator 52
Precipitator layout. Citadel Cement 56
Mass efficiency as a function of specific
collection area at the Gorgas Power Station 58
Comparison of the average and computed fractional
collection efficiencies at the Gorgas Power
Station 60
Mass efficiency as a function of specific
collection area for the hot side precipitator
61
Comparison of the average and computed fractional
collection efficiencies for the hot side pre-
cipitator 62
Mass efficiency as a function of specific
collection area at the Citadel Cement Plant 63
Comparison of the average and computed frac-
tional collection efficiencies at the Citadel
Cement Plant . 64
Comparison of weight and sulfate on blank
Andersen impactor substates and observed
anomalous weight increases 68
Anomalous weight increases of Andersen glass
fiber impaction substrates at different flue
gas temperatures 69
vi
No.
7-3
7-4
7-5
FIGURES
(continued)
Anomalous weight gains of various 47 mm dia.
glass fiber filters at different temperatures
Anomalous weight gain of 64 mm diameter Reeve
Angel 900 AF glass fiber filters
Anomalous weight gains of Andersen impactor
glass fiber impaction substrates
Page
70
71
72
-------
TABLES
Page
No.
3-1 Dust loading measurements at inlet and outlet 14
of precipitator "A"
3-2 Summary of data from Gorgas plant. Unit 10,
Precipitator A 18
3-3 pH and soluble sulfate of ash obtained from
an exit hopper and an inlet traverse 20
3-4 Overall composition of ash samples obtained
from inlet traverse 21
4-1A EPA Method 5 inlet mass concentration tests,
hot side precipitator installation 25
4-1B EPA Method 5 outlet mass concentration tests 26
4-2 Mass concentrations at inlet and outlet of a
hot side precipitator as measured by two
methods 27
4-3 Proximate coal analysis 30
4-4 Chemical analysis for fly ash 33
4-5 Power supply readings, hot side tests 36
4-6 Power station test data 39
4-7 Summary, hot side test 40
4-8 Impactor stage weights 41
4-9 Operating and generating station test data 42
5-1 Citadel Cement outlet mass test results 45
5-2 Schedule of sampling runs 47
5-3 Outlet impactor/mass train comparisons.
Citadel Cement 50
5-4 Optical-diffusional data 53
5-5 Power supply readings. Citadel Cement Company 55
7-1 Soluble sulfate analyses of hot side test
filters 66
SECTION I
INTRODUCTION
This report describes the results of tests conducted on three
full scale electrostatic precipitators installed in commercial
operations for the control of particulate emissions. 'These
installations selected are considered to be representative of
operating field precipitators in the U. S. The plants selected
for tests are a station with a precipitator located prior to
the air preheater; Gorgas Power Station, Alabama Power Company,
Birmingham, Alabama; and the Citadel Cement Plant, Birmingham,
Alabama.
The "hot side"precipitator represents an installation utilizing
low -sulfur western coal with the electrostatic precipitator
installed between the air preheater and the economizer sections
of the plant (hot side location). The Gorgas Power Station
was selected as a representative power station for eastern
coal with the electrostatic precipitator located downstream
from the air preheater (cold side). The Citadel Cement
Installation represents a reasonably modern installation on
a cement kiln.
viii
-------
SECTION II
MEASUREMENT TECHNIQUES
The measurement techniques utilized for providing the required
field data are discussed individually below. The methods
utilized follow standard techniques for the mass train measure-
ments. Special measurement techniques were utilized in the
measurement of particle size, gas analysis, and resistivity.
MASS CONCENTRATION MEASUREMENTS
The inlet and outlet particle mass loadings were measured with
the EPA Method 5 technique. The sampling procedure followed
was that described in the Federal Register, Vol. 36, No. 247,
December 23, 1971. The probe cleaning and sample extraction
procedure is described in detail below since it deviates from
the recommended procedure.
EPA Mass Train Cleaning Procedure
Cleaning of the "front half" of the EPA Method 5 Mass Train is
extremely important in determining the particulate concentra-
tion of gas streams. Frequently the majority of the particulate
sampled from the gas stream will be collected in the probe
and associated glassware and never reach the filtration media.
The following cleaning procedure has been demonstrated to be
very effective in removing particulate captured in the mass
train hardware and was the technique used during this test.
Probe Cleaning -
Immediately after removing the probe assembly from the gas
stream both the tip and ball are taped to prevent gain or loss
of particulate. The area where the tip if screwed to the probe
body is washed to prevent outside contamination when the tip
is removed. The tip is removed and rinsed with the wash
bottle. After the initial wash the tip is brushed from both
ends with a tube brush ,of correct size to remove "stuck"
particles. The brush is washed to remove particles which
become entangled in the brush fiber.
The probe body is held at a slight angle with the "front" end
down and is washed from the ball end. This usually required two
people (one to hold the collection container and one to actually
wash the probe). After washing with rotation to assure wetting
all walls of the liner, the probe is brushed with a steel or
brass brush assembly similar to that used for cleaning guns.
The brush is attached to a rigid assembly and forced from the ball
to the "front". Care is exercised to allow the brush to exit
the front slowly and thus reduce "splatter". With the brush
extending through the probe, the brush is carefully rinsed to
remove particulate from the bristles. After complete rinsing of
the brush it is withdrawn from the probe. The probe is again
rinsed and rotated to remove the last traces of particulate from
the liner. The interior surface of the probe should have a bright
metal sheen at all points after an effective cleaning.
Glassware Cleaning -
All glassware connecting the probe to the filter is carefully
brushed and washed with distilled water with quantitative
techniques to remove all particulate and transfer this material
to the collected washings from the probe and probe tip.
PARTICLE SIZE MEASUREMENTS
The particle size distribution measurements were made by the
use of both in-stack inertial impactors and optical counters
for particle diameters greater than about 0.3 ym and by diffusion^
techniques with condensation nuclei counters in conjunction with
diffusion batteries. The inertial impactors provide information
on a mass per unit volume basis for particles with diameters of
approximately 0.25 vim and larger. The optical technique provides
information on the number per unit volume basis rather than a
mass basis. The mass equivalent can be determined when the partic
density is considered and a simple computation performed. A
detailed description of the particle size distribution measurement
equipment is described by Smith et.al.1 Therefore, only a brief
discussion of the technique is given in this report.
OPTICAL AND .DIFFUSIONAL MEASUREMENTS
The optical and diffusional measurements utilize a dark field
photometer to detect the number of particles per unit volume in
the view field. Extensive dilution of the gas stream being samplt
is usually required because of the limitations imposed by the
useful range of both the optical counter and condensation nuclei
counter. Dilution ratios are selected to provide number
-------
concentrations that fall within the dynamic range of the measure-
ment equipment. As a general practice, checks of the linearity
of particle count .with dilution changes are performed to determine
whether any anomalies .resulting from condensation or other
phenomena are occurring within the measurement system.
Due to limitations imposed by equipment availability, it is not
possible to obtain simultaneous measurements at the precipitator
inlet and outlet with the optical and diffusional measurements.
However, the stability of the particulate concentration is in
general sufficient to enable meaningful fractional efficiency
data to .be derived by first obtaining inlet data, and subsequently
moving the equipment to the outlet to obtain the necessary data
at that location.
The optical particle counter is calibrated with polystyrene
latex spheres. The indicated diameter of the particulate in the
stack gas can differ from the true diameter because of the
difference in the refractive index of the material from that of
polystyrene latex. In order to check the diameter obtained for
the effluent, the diffusion batteries are used as sedimentation
chambers, and the particle diameters obtained from the calcu-
lated sedimentation rates are compared with the indicated
optical particle diameters. Figure 2-1 shows a sample com-
parison using values for particle density of 1.0 and 2.0 grams/
cm3 in the sedimentation calculations. Partxcle densities are
estimated to range from about 1 to 4 grams/cm3 in most field
installations.. The comparison indicates fair agreement between
the sedimentation diameters, which are independent of refractive
index, and the equivalent optical diameters. Figure 2-2 shows
the optical and diffusional sizing system. The sampling probe
is typically heated to avoid condensation.
Inertial Impactor Sizing Techniques
The inlet size distribution measurements were made with modified
Brink impactors while the outlet measurements were made with
modified Andersen Mark III impactors. The Brink impactor -is .a
low volume flow device and the Andersen impactor operates at a
relatively high volume flow. The selection of the low flow
instrument for the inlet and a high flow instrument for the
outlet allows near simultaneous testing at both locations. This
difference in sampling rates is required because of the great
difference in mass concentrations across a high efficiency
collection device, typically on the order of a factor of 100.
The impactors are operated in the gas stream with the flow rates
and sampling nozzles selected to provide near isokinetic sampling
rates for both the inlet and outlet measurements. Thus, simultaneous
inlet and outlet measurements are made with the impactors operating
at approximately the same size distribution cut points to
facilitate the interpretation of the data for evaluating the
performance of the control device.
1.4
e
i.o
IE
UJ
0.8
O
tu
S 0.6
o
JH
0.4
O.2
LINE INDICATING
PERFECT AGREEMENT
O SP GH = 2.0IN SED CAUC
A SP GR = 1.0 IN SED CALC
02 0.4 0.6 0.8 1.0 |.2
EQUIVALENT OPTICAL DIAMETER , ym
Figure 2-1. Comparison of sedimentation and
equivalent optical diameters
-------
Flowmeters
Cyclone Pump
Process
Exhaust
Line
Neutralizer
Flowmeter
CN Counters
p
Aerosol
Photometer
Diffusional Dryer
(Optional)
Balancing
Line
Recirculated
Clean Dilution
Air
Filter
Bleed
Figure 2-2. Optical and diffusional sizing system
Both types of impactors are operated with a back-up filter to
collect the fraction of particles smaller than the last stage
of collection. The Brink inlet impactor is equipped with a
precollector cyclone that removes the large particle size
fraction of the material before it reaches the actual impaction
stages.
The operation of the impactors requires extreme care to assure
that meaningful data are collected. The impactor substrates must
be selected to minimize any reentrainment of previously collected
particulate. Reentrained material would be transported by the
gas stream to the next sequential collection stage. This
phenomenon would cause errors in the measured size distribution.
The substrate.material has the potential for chemical reaction
with gas phase constituents. The material must be tested for
gas phase reactions prior to their utilization in tests. The
substrate material must be evaluated for gas phase reactions
prior to use. This is described in more detail.
RESISTIVITY MEASUREMENTS
In-situ resistivity measurements are made with a point-to-plane
electrostatic collection instrument. The device is inserted
into the flue gas environment and allowed to reach near thermal
equilibrium with the gas stream. The dust thickness gage is
reset to zero and the measurement cell positioned for collection.
A clean electrode voltage vs current characteristic is recorded.
The current density for collection is selected and a dust layer
is precipitated electrostatically. After collection, a second
voltage vs current characteristic is recorded. This provides one
measure of resistivity. The measurement electrode is then lowered
to contact the dust layer and the layer thickness determined.
The resistance cf this known geometrical configuration (right
cylinder) is measured. The resistivity is then determined from
the measured resistance.
For the special case where the flue gas temperature exceeds
200°C, the resistivity is determined in the laboratory. A dust
sample is collected in the field and the resistivity is measured
according to the method described in the A.S.M.E. Power Test Code
Number 28.
GAS ANALYSIS
The exit flue gas composition is determined by standard chemical
techniques. The carbon dioxide and oxygen content are deter-
mined by standard Orsat techniques. The oxides of sulfur are
determined by chemical techniques utilizing a conversion of
sulfur dioxide to sulfur trioxide in a hydrogen perioxide solu-
tion and a condensation of the sulfur trioxide on the walls of a
condenser. The concentrations of dilute sulfuric acid are deter-
mined by an acid titration utilizing a thorin indicator for
the final determination. These measurements are conducted at
intervals during the testing period.
-------
The flue gas .chemistry measurements .are omitted in-the power
stations .where:the control device operates,at .temperatures in
excess of 200°C. The sulfur trioxide does not materially influ-
ence the particulate characteristics at these relatively high
temperatures.
PRECIPITATOR .ELECTRICAL CHARACTERISTICS
The power supply secondary voltage and-current-values are
recorded at intervals during the test program. If the pre-
cipitator is, equipped with indicating meters, the values are
recorded from these meters. If not, selected .power -sets are
equipped with voltage dividers such that the secondary voltages
will be known throughout the tests.
BOILER OPERATING DATA
The control room operating characteristics are noted at inter-
vals during .the ..test. period. .Such items as steam generation
rates, electrical generation rates, fuel feed rates,'etc. -are
recorded.
SECTION III
GORGAS POWER STATION - ALABAMA - POWER COMPANY
INTRODUCTION
A test program,was conducted at the Gorgas Power Station, Alabama
Power Company, .to evaluate-the performance of the electrostatic
precipitator installed on unit 110. This installation was selected
as being -representative of a well-designed conventional (cold side)
precipitator collecting fly ash from 'an',eastern coal. The primary
.objectives of this test program were to determine the overall
collection efficiency of the unit, to evaluate the collection
efficiency .as a function of particle 'size and to analyze the per-
formance of 'the .unit by the use of-the precipitator mathematical
model.
ELECTROSTATIC PRECIPITATOR DESCRIPTION
Figure 3-1 illustrates the gas flow and precipitator arrangement.
Some of the electrical sets were not operating on the B side
precipitator, apparently due to broken corona wires; therefore,
tests were conducted on the A side only. Each precipitator
consists of .two series section, each of which has 144 gas passages,
with 0.229 m plate to plate spacing (9 in.). Each precipitator
consists of 144 gas passages 9.14 m high (30 ft), 10.97 m long
(36 ft), for .a total collecting area of 28877 m2 (311,000 ft2
per precipitator. The precipitators each have twelve electrical
sections arranged .in series with the gas flow, such that the
.individual sections power 1/12 of the plate area and 1/12 of the
length. Gas flow at full load (^700 MW) for each precipitator is
about 520 m3/sec (l.lxlO6 cfm) at 149°C (300°F). The specific
collecting area at these conditions would be 55 mV(mVsec) or
283 ft2/1000 cfm.
RESULTS
The results from field measurements on this unit are given
below..
Mass Loadings
The overall mass efficiency measurements were conducted by
Scientific South, Inc., under contract with SRI. Figures 3-2
and 3-3 illustrate the velocity profiles obtained at the inlet
and outlet sampling locations with preliminary pitot tube trav-
erses performed on July 9, 1973. Inlet and outlet dust loading
-------
Figure 3-1. Precipitator Layout at Gorgas Unit 10.
"**
10
Figure 3-2. Velocity Traverse at Inlet.
11
-------
Figure 3-3. Velocity Traverse at Outlet.
measurements were conducted on July 10 and 11. The results of
this work are given in Table 3-1". During the time period that
the measurements were conducted, the generation rate was constant
at 710 MW. Sampling, was performed- with an EPA approved sampling
train manufactured by Research Appliance Corporation.
Fractional Efficiency Measurements
Tests using cascade irapactors for particulate mass efficiencies as
a function of particle diameter were conducted on July 10, 11, 12,
13, and 16. Inlet data were obtained with modified Brink impactors
on the first four days of testing and outlet data were obtained with
an Andersen impactor on all five days. Diffusional sizings with a
series of- diffusion batteries and two condensation nuclei counters
were used to provide concentration and size distributions by number
over the size range from abo.ut 0.005 yra to 0.3 vim. Relative con-
centrations on a number basis were measured- using a Climet particle
size analyzer, equipped with a scanning pulse height analyzer and
digital rate meter. Because of the high number concentration of
small particles in the stack, dilution of the sampled gas stream
by factors ranging from about 50:1 to about 1000:1 was necessary in
order to obtain data with both the condensation nuclei counters
and the optical particle counter. These data are given in Figures
3-4, 3-5, and 3-6.
Resistivity
The resistivity of the fly ash obtained in a previous test at a
temperature of 165°C (330°F) is approximately 2x1010 ohm-cm.
Gas Analysis, Chemical Analysis and Coal Analysis
The results of the gas and coal sulfur content analyses are
given below in Table 3-2.
Sulfur oxide analyses performed on July 10, 11, and 13 indicate
that the SO2 concentration dropped significantly, apparently as
a result of decreasing sulfur content of the coal. There is some
disagreement between the coal sulfur contents obtained from the plant
records with those obtained by SRI. The samples which were analyzed
by SRI were obtained after the coal was pulverized prior to injec-
tion into the furnace. Results from these analyses show proportion-
ate agreement with the measured variation in SO2 concentration.
The current density of the precipitator also dropped significantly
during the same time period, possibly as a result of the response
of the power supplies to an increased tendency to spark arising
13
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Diameter< urn
10
Figure 3-6. Measured and Computed Efficiency as a Function of Particle Size
for Precipitator Installation at the Gorgas Plant of Alabama
Power Company.
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TABLE 3-2
SUMMARY OF DATA FSOM GORGAS PLANT, UNIT 10, PREdlPITATOR A
Overall
Date
7/9/73
7/10/73
7/11/73
7/12/73
7/13/73
7/16/73
Flue GOB Composition
SCT, W7 .fi!?, . .6, ..
! t
'1433 ' '3.8 '10.5 3.1
3.3
'1153 '6.0 '11.4
» 885 '2.4 '10. 5*.
'
Overall
Eft;, %
99.59
99.69
Current
Density
nA/cro'
25;
20.
15.
16.
29.
«
1
e
9
0
Coal Sulfur
Content ,%
(dry DBBIBJ
1.
1,
1,
1
1
1
.19
.59
.84
.54
.10
.44
1.40
1.20
1.20
1.05
1.40
Load .
Heqawatti
710
710
710
720
720
1. Measured at precipitator outlet!
2. Measured at precipitator inlet.
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TABLE 3-3
pH and Soluble Sulfate of Ash Obtained From an Exit Hopper
and an Inlet Traverse
Hopper Sample
3 Traverse Sample
Date
7/10/73
7/10/73
7/10/73
7/11/73
7/11/73
7/11/73
7/12/73
7/12/73
7/13/73
Time
1315
1830
1130
1815
1040
1815
1615
1 PH
4.63
4.90
4.35
4.85
4.37
5.10
4.55
Soluble SO;2 % ' pH Soluble SOl2 %
1.1
1.1
8.0 0.4
1.0
0.94
8.5 0.5
0.92
0.87
1.1
1. Measurement taken after stirring for one hour a slurry of 30 ml distilled
HtO and 0.1000 g ash.
2. Obtained from a hopper near the outlet.
3. Obtained at inlet from traverse with sampling train.
-------
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Voltage, kv
36
Figure 3-7. Voltage-Current Relationships Obtained on
Precipitator "B".
22
SECTION IV
PERFORMANCE TESTS AT A HOT SIDE ELECTRIC UTILITY
BURNING WESTERN COAL
INTRODUCTION
The performance of an electrostatic precipitator was evaluated
during April and May 1974. This test is the first detailed
analysis of the performance of a precipitator located on the
hot gas side of the air preheater (hot side) that Southern
Research has conducted. This installation was selected as being
representative of a reasonably well designed hot side precipitator
collecting fly ash that resulted from the combustion of the class
of coals designated as low sulfur western coals.
In .general, the testing procedures -described in Section II of
this report were followed. However, some discrepancies in the
test results were observed. The first discrepancy that was
noted .was the difference in the volume flow rates as measured at
the inlet and outlet sampling points of the electrostatic pre-
cipitator. There was a consistent reduction in -the gas volume
sampled at the outlet of the device as compared to the inlet by
approximately twenty percent. At the time of testing these
differences were noted and 'the measurement equipment checked.
No obvious problems were noted in the test equipment or procedures.
At the conclusion of the tests, this problem was discussed with
a power company engineer.. He pointed out that a fire in the
air preheater required a modification to the air preheater such
that the pressure drop downstream from the test precipitator was
significantly greater than that in the adjacent unit. Since the
two units were not physically separated by a partition, the
excess gas in the inlet was traversing the demarcation line
between the units and passing through the adjacent air heater.
This fact was not known during the test program.
The total mass loadings as determined by the mass trains differ
from that determined by the impactors for -the initial tests.
The inlet mass loadings differed by as much as a factor of
six. An attempted analysis of this discrepancy led to a retest
to evaluate the causes of this variation. Southern Research
funded a second trip to the power station to investigate these
interferences. The results of these tests are discussed later
in the section describing substrate interference.
23
-------
TABLE 4-1A
EPA METHOD 5 INLET MASS CONCENTRATION TESTS.
APRIL-MAY 1974
Run No.
Date
Time
Duration (minutes)
Moisture content %
Gas Temperature °C
Gas Velocity ft/min
Gas Velocity m/sec
Sample Vol. DSCF
Sample Vol. DSCM
Mass Concentr. Gr/ACP
Mass Concentr Gm/AM9
1
4/29
15:45
90
6.0
309
2431
12.4 .
33.51
.95
3.69
8.44
2
4/30
15:00
150
9.8
314
925*
4.7*
21.14 .
0.6
8.15
18.65
3
4/30
20:00
90
5.0*
311
4353*
22.1*
53.87
1.53
2.10
4.80
4
5/1
10:25
258
8.5
320
2489
12.6*
100.91
2.86
3.85
8.81
5
5/2
10:00
108
7.9
284
2241
11.4
36.42
1.03
3.94
9.01
6
5/2
13:33
96
8.7
305
2547
13.0
37.87
1.07
3.02
6.91
7
5/3
08:00
240
8.1
305
1796
9.1
68.33
1.93
1.91
4.37
Suspect test error
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TABLE 4-IB
EPA METHOD 5 OUTLET MASS EMISSION TESTS
APRIL - MAY 1974
Run No.
Date
Time
Duration (minutes)
Moisture Content %
Avg. Temp. °C
Gas Velocity FPM
Gas Velocity M/sec.
s> Sample Vol. DSCF
0V
Mass Cone. Gr/ACF
Go/AM*
Vol Flo. ACFM
M^Sec
Specific Collection Area
' ft'/KCFM
rtftnVfec
Generation Rate Mw
Efficiency »
1
V29
16:10
150
5.$
30«
1618
8.22
34.14
.97
.05S
.13
318095
150
460
94.5
220
98.5
2
4/30
15:04
123
8.4
305
1516
7.7
93.01
2.63
.022
.05
297960*
141
490
'96.4.
220
99.73
3
4/30
20:03
120
9.2
311
1627
8.3
96.01
2.72
.0244
.06
319700
151
457
89.9
220
98.84
4
5/1
10:19
300
8.7
290
1530
7.8
229.21
6.49
.0115
.03
300710
142
486.5
95.8
220
99.70
5
5/2
10:00
108
9.0
283
1698
8.6
87.50
2.48
.0167
.04
333728
158
438
86.2
260
99.58
6
5/2
13:40
108
8.4
302
1809
9.2
92.05
2.61
.017
.04
355544
168
411
80.9
260
99.44
7
5/3
08:07
240
8.3
291
1450
7.4
176.03
4.98
.0127
.03
285000
135
513
101
260
99.11
"V6T. tio' corrected irori» inlet
-------
10
o
X
1.0
Q 0.5
O
-J
Ul
s <
a:
O.I
0.05
0.02
0.01
O.I 0.2
"I I I
I I I
0.5 1.0 2.0 5.0 10 20
MAX PARTICLE DIAMETER, (xm
11.44
4.58
2.288
1.144 n£
^
w
2
0.458
0.229
0.114
O.O46
50 100
Figure 4-1. Cumulative Particle Size Distribution of the
Inlet Particulate.
O.I
g 0.051
0.02
3 0.01
o
0.005
3 0.002
0.001
O.I
i I i r
O AVERAGE MASS TRAIN ME AS.
0.012
0.007
I I
0.114
0.046
10
E
0.023
0.01 1
0.0046
0.2 0.5 I.O 2 5 10
MAX PARTICLE DIAMETER, («n
Figure 4-2. Cumulative Outlet Particle Size Distribution-
29
28
-------
to correlate the optical diameter with the inertial behavior of
the particles (i.e., Stoke's diameters). The optical and diffusional
data represent single point samples at both the inlet and outlet
of the precipitator. Extractive sampling and extensive dilution
at the sample gas stream was required in obtaining the optical
and diffusional data. Figure 4-3 shows the results of the measure-
ments. The data in Figure 4-3 are presented in terms of cumulative
concentration by number density (t/cra3) of particles having
diameters larger than or equal to the indicated'diameters.
Figure 4-4 shows the fractional efficiencies of the precipitator
as calculated from these data.
Laboratory Particulate Resistivity
The laboratory resistivity was determined for samples one and two
that represented the extremes in sodium oxide concentration. The
results of these tests are shown in Figure 4-5. The difference
in resistivity at temperatures greater than 300°F are as expected
for.the observed variation in_chemical composition.
' "-»-*-
Coal Analyses and Chemical Analyses
Coal sables were analyzed for each test during the series. The
proximate analysis for each sample is given in Table 4-3.
TABLE 4-3
PROXIMATE COAL ANALYSIS
108
Item
Moisture %
Ash »
Sulfur t
Beating value
(thou BtU/lb)
Test 1
4.8
22.4
0.85
9.9
2
4.3
24.7
1.07
10.1
3
4.3
24.5
1.02
9.8
4 5
4.1 3.9
24.36 23.3
0.87 1.13
9.7 10.0
6
4.2
23.45
9.98
The coal was considered to be essentially constant during this
test program. The coal samples were taken downstream from the
pulverizer. Thus the moisture content may be low and the other
values correspondingly high in comparison to raw coal samples.
Fly Ash Chemical Analysis
Fly ash samples were collected during the test program for
laboratory analysis. The results of these determinations are
given in Table 4-4.
10'
z I06
I05
(E
S
.0
3
(J
10*
DIFFUSIONAL DATA
I I
OPTICAL DATA
SEDIMENTATION SIZES
o.oi o.oa 0.05 o.i °-2
MINIMUM PARTICLE DIAMETER, fi
0.5
1.0
Figure 4-3. Cumulative Particle Number Concentration
30
31
-------
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