&EPA
United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
EPA-600/7-78-096
June 1978
Preliminary D oign
and Initial Testing
of a Mobile
Electrostatic
Precipitator
Interagency
Energy/Environment
R&D Program Report
-------
Research reports of the Office of Research and Development, U.S. Environmental Protec-
tion Agency, have been grouped into nine series. These nine broad categories were
established to facilitate further development and application of environmental tech-
nology. Elimination of traditional grouping was consciously planned to foster technology
transfer and a maximum interface in related fields. The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the ENVIRONMENTAL PROTECTION TECHNOLOGY
series. This series describes research performed to develop and demonstrate instrumen-
tation, equipment, and methodology to repair or prevent environmental degradation from
point and non-point sources of pollution. This work provides the new or improved tech-
nology required for the control and treatment of pollution sources to meet environmental
quality standards.
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 policy of the Agency, nor does mention of trade
names or commercial products constitute endorsement or
recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/7-78-096
June 1978
Preliminary Design and Initial Testing
of a Mobile Electrostatic Precipitator
by
Grady B. Nichols
Southern Research Institute
2000 Ninth Avenue, South
Birmingham, Alabama 35205
Contract No. 68-02-1860
Program Element No. EHE624A
EPA Project Officer: Dale L. Harmon
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
-------
DISCLAIMER
This report has been reviewed by the Industrial Environ-
mental Research Laboratory, U. S. Environmental Protection
Agency, and approved for publication. Approval does not signify
that the contents necessarily reflect the views and policies of
the U. S. Environmental Protection Agency, nor does mention of
trade names or commercial products constitute endorsement or
recommendation for use.
11
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ABSTRACT
This report describes the factors considered and the
general design concepts of a mobile electrostatic precipitator.
This pilot scale device is one of a family of laboratory scale
control deivces utilized by the Industrial Envirpnmental Research
Laboraoty of the U. S. Environmental Protection Agency located
at Research Triangle Park, N. C. The final design and construc-
tion of the unit was provided by the Naval Surface Weapons Center
at Dahlgren, Virginia.
111
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TABLE OF CONTENTS
Figures ill
Tables iv
Section I
Introduction 1
Section II
Discussion 2
Section III
Field Evaluation 10
Section IV
Design Of Additional Items 11
Appendix I
Design Drawings For Use By -
Naval Surface Weapons Center for the
Mobile Electrostatic Precipitator 14-26
Appendix II
Pilot Electrostatic Precipitator
Operating Guide 27-31
iv
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FIGURES
Number Paqe
Sodium carbonate injection system
for E.P.A. pilot E.S.P 12
300 cfm cyclone with a D 50
of 5 microns 13
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TABLES
Number Page
I Comparison Of Pilot And Full
Scale Electrostatic Precipitator
Parameters 4
II Mobile Pilot Electrostatic Precipitator
Shakedown Tests NERC Laboratories 7
III Mobile Electrostatic Precipitator Tests 8
VI
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SECTION I
INTRODUCTION
This report summarizes the work performed under Contract
68-02-1860 to provide the general design and assistance in the
evaluation of a mobile electrostatic precipitator. This test
facility was constructed for the Industrial Environmental Research
Laboratory of the U. S. Environmental Protection Agency at Research
Triangle Park, North Carolina, by the Environmental Sciences Branch,
of the Naval Surface Weapons Center at Dahlgren, Virginia.
The mobile electrostatic precipitator test facility was de-
signed to assist the Industrial Environmental Research Laboratory
in evaluating the applicability of the E.S.P. to a variety of in-
dustrial applications. The test facility design included both a
pilot scale electrostatic precipitator and a laboratory van. The
two units comprise a self sufficient facility with the exception of
the requirements for external sources of electrical energy and
water.
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SECTION II
DISCUSSION
Southern Research Institute was directed to supply a conceptual
design for the mobile test facility and to provide assistance to the
E.P.A. during the construction and test of the unit. These services
were provided as needed during the period of time that the contract
was active. The guidelines for this contract specified in the scope
of work were:
1. Mobile unit mounted on trailer suitable for highway
t rave1
2. Three inlet and outlet sampling sites included
3. Minimum of four independent electrical sections
4. Secondary voltage and current meters required
5. Operation up to temperature of 480°C
6. Fans and strip heaters to be included
7. Variable intensity rappers required
8. Include optical instrumentation port
9. Provide guidance in design of data sheet
10. Design 300 cfm cyclone with a DSO of 5 microns
11. Include gas flow control devices.
In addition the following items were to be considered for inclusion
if practical:
1. Lighted view ports in outlet section
2. Utilize standard E.S.P. electrical insulators
3. Wet and dry operation
4. Variable collection electrode spacing
5. Use precipitator vehicle for laboratory van.
2
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The items in the second group were to serve as suggestions for
the Naval Surface Weapons Center in the design of the unit, of these,
only the view ports were actually incorporated into the final de-
sign of the unit.
The initial design for the electrostatic precipitator was trans-
mitted to the Environmental Protection Agency and the Naval Surface
Weapon Center on September 24, 1974. The drawings, reduced and in-
cluded as Appendix I of the report, served as a conceptual design for
the pilot precipitator. The Naval Surface Weapon Center developed
the final design of the mobile E.S.P. from these suggestions. Meet-
ings were held between the individual parties at Research Triangle
Park, Naval Surface Weapons Center and Southern Research Institute,
during the design phase for this mobile test facility.
A number of problems were encountered during the development of
the device. Electrical sparkover between the corona wire support
system and grounded portion of the system occurred. Similarly, elec-
trical sparking occurred from the point that the high voltage connect-
ing is made to the corona frame. These problems were solved during
visits to the Naval Surface Weapon Center.
The power supplies that were delivered from Peschel Instruments
also required some modifications. Even though the required voltage
and current were stated to meet the specified values when connected
to a resistive load, they did not when connected to the corona frame.
These problems were corrected by the manufacturer when the transform-
ers were returned.
The design conditions selected for the mobile electrostatic pre-
cipitator were intended to include typical operating conditions for
full scale installations as near as was practical. A comparision be-
tween these conditions for the pilot unit and the majority of field
installations are given below in Table I.
It is to be noted that the only significant departure from full
scale conditions lies in the electrical sectionalization. It is im-
practical to duplicate this parameter in pilot units because of size
and weight requirements. This departure from comparable conditions
generally leads to the ability to operate the pilot unit at voltages
and average current densities that are somewhat greater in the pilot
unit than is possible in a comparable full scale unit. This factor
places a constraint on the permissible operating conditions for the
pilot unit when attempting to simulate full scale behavior.
A second departure from full scale conditions is related to gas
sneakage past electrified regions. It is difficult to estimate the
amount by which this differs between pilot and full scale devices.
In general, the relative quantity of dust laden gas that bypasses the
electrified region is significantly greater in pilot scale devices
than in full scale units. Care was exercised in the design of the
pilot scale unit to minimize the effect of gas sneakage.
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TABLE I
COMPARISON OF PILOT AND FULL SCALE
E.S.P. PARAMETERS
ITEM PILOT FULL SCALE
Specific collection area M2sec/M3 20-100 20-150
Wire to plate spacing - cm 13 10-15
Wire to wire spacing - cm 18 10-30
Electrical fields in direction
of gas flow 2-5 2-12
Gas velocity M/sec 0.5-2.0 1-2.5
Current density nA/cm2 5-100 5-80
Plate area per T.R. Set M2 9 50-750
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The mobile E.S.P. and laboratory vans were delivered to the
Environmental Protection Agency for final checkout. Tests were
conducted to verify the performance of the delivered items. The
results of these tests and a discussion of the design of the mobile
unit were discussed in a paper1 given in an E.P.A. sponsored sym-
posium in Denver, Colorado, "Particulate Collection Problems Using
Electrostatic Precipitators in the Metallurgical Industry."
Southern Research Institute provided the Environmental Pro-
tection Agency with a suggested measurement program and sampling
port requirements as a part of this contract. The items required
to be measured in the mobile pilot scale precipitator are described
below. It is desirable to provide sufficient sampling ports such
that all measurements can be made simultaneously. The sampling lo-
cations for mass loading and particle size distribution measurement
should be in a region where a reasonably uniform gas velocity dis-
tribution exists. The other measurements may be made in regions of
non-uniform flow without significantly deleterious effects. The
following measurements must be made at both the inlet and outlet
breechings to the precipitator:
1. Mass loading
2.. Particle size 0.3 ym and greater
3. Particle size 0.5 um and smaller
4. Gas velocity and temperature distribution
(can use mass and/or particle size ports)
5. Isokinetic ash sample (dry collection)
6. Particulate resistivity
7. Gas composition
8. Operating temperature
The mass loadings should be made with an EPA Method 5 appara-
tus. It is desirable to provide for a permanent installation for
the control console with semi-permanent sampling rails to support
the sampling case and probe.
The sampling ports for the impactors and fine particle sampling
should be located at a point that provides for a minimum of inter-
ference with the mass train sampling equipment.
The gas velocity distribution can be measured in the sampling
points provided for the mass train and size distribution measure-
ments .
Footnote 1. Brumfield, J.L. and Crowson, Fred. "Design and Fabrica-
tion of a Mobile Electrostatic Precipitator." Paper #11,
Proceedings: Particulate Collection Problems Using ESP's
in the Mettalurgical Industry EPA-600/2-77-208, Oct. 1977
-------
The sampling points for isokinetic dry ash samples, particulate
resistivity, and gas composition can be located at almost any point,
since the gas velocity distribution, turbulence, and gas velocity
are not critical to these measurements. The dry isokinetic ash col-
lection is necessary for providing a sample of ash for chemical anal-
ysis and laboratory resistivity measurements. Since the Method 5
system utilizes washings and dry filter collection, the dry sample
is required. The gas composition sampling point is not critical
since the high diffusivity gas components readily maintain good mix-
ing throughout the ducts.
A temperature measurement should be provided in both the inlet
and outlet duct with recording capability. These measurements pro-
vide information about the stability of the source as well as giving
an indication of any gas leakage into the precipitator.
A total gas volume measurement on the outlet duct or stack is
desirable because it does not include errors inherent in the velocity
traverses. A venturi type meter or a calibrated orifice with pres-
sure drop readout is recommended.
It is also necessary to provide ready access to the secondary
voltage and current readings from the precipitator power supplies.
These readings should be recorded at regular intervals during the
test period.
A follow-up to the initial recommendations were submitted as a
report to the Environmental Protection Agency on November 24, 1976.
This report described a test plan that should serve to both evaluate
the performance of the mobile E.S.P. as well as answer some specific
questions about the performance of an electrostatic precipitator ex-
periencing some difficulties in operation. This particular field
test was not conducted because of some contractual problems between
the utility and the E.S.P. supplier.
This test program included base line tests with the normal coal
and a test to evaluate the addition of sodium carbonate to improve
the performance. The test program summarized below does not include
the tests to evaluate the sodium conditioning but rather represents
a two week's test period to evaluate the pilot E.S.P.
The two weeks of field tests were designed to characterize the
behavior of the E.S.P. pilot plant under actual field test conditions.
This includes tests over a range of gas velocities (SCA's) and a range
of applied voltages and current densities.
In each field test condition, coal samples, inlet and hopper fly
ash samples, Orsat and sulfur oxide samples, and representative im-
pactor substrate samples should be preserved for later analysis.
-------
Flue gas temperatures and flow rates should be recorded together
with individual power supply readings.
The electrostatic precipitator tests recommended are as fol-
lows:
TABLE II
MOBILE PILOT ELECTROSTATIC PRECIPITATOR
SHAKEDOWN TESTS NERC LABORATORIES
Pretest
Day 1. Calibrate power supply meters. Prepare gas
velocity distribution sampling access.
2-3. Gas velocity distribution inlet, Field 1, inlet;
Field 5, o.utlet
4. Volt-ampere curves - cold gas - hot gas no
particulate
S. Make-up day and determine range of velocities
available.
Particulate tests - two weeks - two tests at each condition
Current density, na/cm2 15, 40, 15 with high resistivity
Gas velocity, m/sec 0.6, 1.0
Specific collection area
ftVkcfm 400, 240
Note: The above tests should be conducted at a temperature
on the order of 140-160°C (280-300°F).
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TABLE III
MOBILE ELECTROSTATIC PRECIPITATOR TESTS
Day 1-2
Day 4
Connect unit to access port
Check electrical supply
Check meters and instrumenta-
tion
Obtain V-I curves - cold gas
Operate fan
Run hot gas V-I curves
Check mass load in pilot with
main duct single point
Check gas temperature-pilot
with main duct
Measure gas velocity distribu-
tion - inlet and outlet
Inspect through view ports Day
Obtain two complete tests -
gas velocity 1.5 m/sec (5 fps)
S.C.A. = 160 ft2/kcfm - maxi-
mum current density
Select run times and sampling
rates
Mass loadings, inlet and outlet
Impactors, inlet and outlet
Resistivity
Gas analysis
Optical density
Ash and coal samples
Day 3
Day 6
Stabilize system at flue gas
operating temperature
Set gas velocity
Obtain V-I curves
Select operating points for
tests . Day
Select run times and sampling
rates
Run one complete test
Mass loadings - inlet and
outlet
Impactors - inlet and
outlet
Resistivity
Gas analysis
Repeat Day 4. With current den-
sity set at maximum for the in-
let field in all sets
Repeat Day 5 with current den-
sity set at 60% of inlet
Reduce data and display for re-
view. Determine if a repeat
test is required.
Day 8
Conduct tests at gas velocity of
1 m/sec (SCA = 240)
Day 9
Repeat Day 8 at reduced current
density
Day 10
Conduct tests at 0.6 m/sec
(SCA) = 400)
Maximum current density
Day 11
Repeat Day 10 at reduced current
density.
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Southern Research Institute next prepared a Pilot Electrosta-
tic Precipitation Operating Guide for the Environmental Protection
Agency. This document is included as Appendix II of this report.
This guide describes our approach to the philosophy and operational
techniques necessary to conduct an effective pilot electrostatic
precipitator research program.
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SECTION III
FIELD EVALUATIONS
The mobile electrostatic precipitator test facility was exer-
cised in two field tests. The first test was conducted at a stoker
fired steam generation system at the State of Maryland Correctional
Institution at Hagarstown, Maryland and the second at the Colstrip
Power Station, Montana Power Company, Colstrip, Montana. The re-
sults of tnese two tests were reported to the Industrial Environmen-
tal Research Laboratory by the respective contractor-operators Mon-
santo Research and Aerotherm Division of Acurex.
The Maryland tests were conducted to evaluate the collectabil-
ity of fly ash resulting from the combustion of a combination of
pelletized refuse and coal in the stoker fired boiler. This test
also served as the initial field test for the pilot E.S.P. as well
as a training exercise for their operating personnel. Southern Re-
search Institute provided assistance in developing the test plan as
well as operating suggestions during the test period. The tests in-
cluded a comparison between the operation of the control device while
utilizing coal only and coal plus refuse. Southern Research Institute
did not review this report.
The tests at Colstrip, Montana were designed to evaluate the
utility of sodium carbonate injection as a means for improving the
collection characterics of fly ash resulting from the combustion of
Western low sulfur, low sodium coals. This test consisted of a series
of base-line and conditioned tests where the electrical conditioning
was provided by the injection of dry sodium carbonate into the par-
ticulate laden gas streams at temperatures well below furnace tem-
peratures. The results of the test reported by Aerotherm Division
of Acurex Corporation indicate a significant increase in the electri-
cal conditions with a concommitant improvement in the collection ef-
ficiency of the pilot precipitator with the injection of the finely
divided sodium carbonate into the gas stream.
10
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SECTION IV
DESIGN OF ADDITIONAL ITEMS
Southern Research Institute was also requested to supply de-
signs for a sodium carbonate injection system and a 300 cfm cy-
clone collector with a Dso of five microns. These items were de-
signed as requested. The sodium carbonate injection system was
designed according to the sketch shown in Figure 1. Southern
Research Institute also supplied to the Environmental Protection
Agency a material metering system, a vibra-screw feeder model
SCR-20. This system was delivered to the Environmental Protection
Agency for use in the shakedown tests at Raleigh-Durham and in the
field test at the Colstrip Power Station.
A design for the 300 cfm cyclone was provided to the Environ-
mental Protection Agency as shown in the sketch in Figure 2. We
did no fabrication for this cyclone.
11
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WEATHER PROTECTION REQUIRED
SOME AIR WILL BE
DRAWN IN BY JET
/.
1. VIBRASCREW FEEDER SCR-20, 3/8 SCREW, 0-0.1 CFH
2. FABRICATED CONNECTION BETWEEN FEEDER & INJECTOR
3. JET INJECTOR, McMASTER-CARR -
P.O. BOX 4355, CHICAGO , CAT. 4977K-11
4. FABRICATED PIPE
5. COVER PLATE APPROX. 6" DIAM., WELDED TO BENT PIPE
6. COMPRESSED AIR SUPPLY LINE, APPROX. 100 PSIG
Figure 1. Sodium carbonate injection system for
E.P.A. pilot E.S.P.
12
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APPENDIX I
Design Drawings For Use
by
NAVAL SURFACE WEAPONS CENTER
for the
MOBILE ELECTROSTATIC PRECIPITATOR
14
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APPENDIX II
PILOT ELECTROSTATIC PRECIPITATOR
OPERATING GUIDE
27
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SORI-EAS-77-040
PILOT ELECTROSTATIC PRECIPITATOR
OPERATING GUIDE
by
Grady B. Nichols
Southern Research Institute
2000 Ninth Avenue South
Birmingham, Alabama 35205
Project No. 3419
EPA Project Officer: Dale Harmon
Environmental Protection Agency
Industrial Environmental Research Laboratory
Research Triangle Park, N. C. 27711
Prepared For
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
ENVIRONMENTAL PROTECTION AGENCY
RESEARCH TRIANGLE PARK, N. C. 27711
January 18, 1977
28
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PILOT ELECTROSTATIC PRECIPITATOR OPERATING GUIDE
Introduction. The operating techniques for utilizing the pilot
E.S.P. will be developed as the test personnel become more
familiar with the individual characteristics of the particular
unit. This document was prepared as a guide for use in the
early checkout and performance stages of the device.
Initial Installation and Checkout
The test location should be surveyed prior to moving the
test facility to the test site. A sketch of the available
space should be prepared and access ports installed. Arrange-
ments for electrical power should be made with plant personnel.
A plant contact should be established at this time.
The particulate and gas extraction ports should be located
and an acceptable sample extraction nozzle designed. This design
should provide for near isokinetic extraction at the mid-range
of the anticipated operating volume flow rate.
In some instances, it may be desirable to provide for a
sample extraction array and plenum to provide for a more repre-
sentative sample extraction. In those instances where signifi-
cant temperature or dust concentration variations occur within the
ductwork this alternative should be considered. This plenum
design may be equipped with variable cross sections for the sample
extraction as a means for maintaining isokinetic sampling over
an acceptable range of gas volume flow rates. This variable
throat sampling need not always be provided; only in those cases
where the fundamental purposes for the test program dictates the
need.
The pilot electrostatic precipitator and laboratory trailers
should be moved to the test site and located on the predetermined
positions. The ductwork should be checked and positioned
29
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to determine if the connections are adequate. The internals of
the pilot unit should be inspected and corrected while the
electrical connections and ductwork are being installed.
After the electrical connections are complete, the test
facility fan should be tested. Air load voltage vs current
data should be recorded and compared with previous curves. The
ash removal system and other auxiliary equipment should be checked,
Initial Tests
At the completion of the installation, inspection and check-
out portion, the system should be activated to pull hot particu-
late laden gas through the test unit. The test unit should be
allowed to thermally equilibrate; after which gas velocity
distributions and hot gas voltage vs current data should be
recorded and analyzed.
If the gas velocity distribution is inadequate, corrections
should be made to the inlet system to obtain an acceptable gas
flow quality. The V-I data should be provided in order to select
an operating point for the power supplies for the tests.
Initial mass, resistivity and gas analysis tests should be
performed on the pilot plant. Parallel tests should generally
be conducted in the main flue to assure that representative con-
ditions exist in the test unit. These data should be evaluated
prior to the initiation of the main test program.
Experimental Test Program
A test plan should be prepared for the main test program
prior to moving the equipment to the test site. This test plan
should be reviewed for the test crew and task assignments made.
At the beginning of the field experimental program, a shake-
down test should be conducted. This evaluates the adequacy of
equipment, space and port allowances and smoothness of operation.
At the completion of the shakedown test, the results should be
compiled and the adequacy of the test plan reviewed. A daily
test log should of course be maintained for the test.
30
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The complete test program should now be conducted. It is
advisable to conduct review meetings between key test personnel
at intervals during the actual tests. At these times the
adequacy of the tests and any required modifications to the
test plan can be discussed.
At the completion of the test program, each key test person
should review his data to ascertain that adequate samples have
been collected and preserved. These samples should be carefully
labeled and packaged for shipment. The daily test log should be
reviewed prior to concluding the tests.
Equipment Preparation
The test facility should be carefully disconnected from the
test site and prepared for moving to a new location. Specific
packing assignments should be prepared with one person responsible
for checking prior to departure.
31
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-78-096
3. RECIPIENT'S ACCESSION NO.
PITLE AND SUBTITLE
*. I I I I_C AAI1LJ OUO I I I I_C
Preliminary Design and Initial Testing of a Mobile
Electrostatic Precipitator
5. REPORT DATE
June 1978
6. PERFORMING ORGANIZATION CODE
7. AUTHORl-S)
Grady B. Nichols
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Southern Research Institute
2000 Ninth Avenue, South
Birmingham, Alabama 35205
10. PROGRAM ELEMENT NO.
EHE624A
11. CONTRACT/GRANT NO.
68-02-1860
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF RJEPORT AND
Final; 11/74-1/78
PERIOD COVERED
14. SPONSORING AGENCY CODE
EPA/600/13
,5 SUPPLEMENTARY NOTES i£RL-RTP project officer is Dale L. Harmon, Mail Drop 61, 919/
541-2925.
16. ABSTRACT
The report summarizes work done to provide the general design and
assistance in evaluating a mobile electrostatic precipitator (ESP) built for the
EPA by the Naval Surface Weapons Center, Dahlgren, Virginia. The mobile test
facility was designed to aid IERL-RTP in evaluating ESPs in a variety of industrial
applications. The test facility design included both a pilot scale ESP and a laboratory
van. The two units comprise a self sufficient facility, except for external sources
of electricity and water.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COS AT I Field/Croup
Air Pollution
Electrostatic Precipitators
Mobile Equipment
Laboratories
Design
Tests
Dust
Air Pollution Control
Stationary Sources
Particulate
13B
131
15E
14B
11G
3. D:STRIEUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
38
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
32
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