Experimental study of cross-flow wet electrostatic precipitator

Experimental study of a string-based counterflow wet electrostatic precipitator for collection of fine and ultrafine particles

Wet electrostatic precipitators (WESP) have been widely studied for collecting fine and ultrafine particles, such as diesel particulate matter (DPM), which have deleterious effects on human health. Here, we report an experimental and numerical simulation study on a novel string-based two-stage WESP. Our new design incorporates grounded vertically aligned polymer strings, along which thin films of water flow down. The water beads, generated by intrinsic flow instability, travel down the strings and collect charged particles in the counterflowing gas stream. We performed experiments using two different geometric configurations of WESP: rectangular and cylindrical. We examined the effects of the WESP electrode bias voltage, air stream velocity, and water flow rate on the number-based fractional collection efficiency for particles of diameters ranging from 10 nm to 2.5 μm. The collection efficiency improves with increasing bias voltages or decreasing airflow rates. At liquid-to-gas (L/G) as low as approximately 0.0066, our design delivers a collection efficiency over 70% even for fine and ultrafine particles. The rectangular and cylindrical configurations exhibit similar collection efficiencies under nominally identical experimental conditions. We also compare the water-to-air mass flow rate ratio, air flow rate per unit collector volume, and collection efficiency of our string-based design with those of previously reported WESPs. The present work demonstrates a promising design for a highly efficient, compact, and scalable two-stage WESPs with minimal water consumption.Implications: Wet Electrostatic Precipitators (WESPs) are highly effective for collecting fine particles in exhaust air streams from various sources such as diesel engines, power plants, and oil refineries. However, their large-scale adoption has been limited by high water usage and reduced collection efficiencies for ultrafine particles. We perform experimental and numerical investigation to characterize the collection efficiency and water flow rate-dependence of a new design of WESP. The string-based counterflow WESP reported in this study offers number-based collection efficiencies >70% at air flow rates per collector volume as high as 4.36 (m³/s)/m³ for particles of diameters ranging from 10 nm - 2.5 μm, while significantly reducing water usage. Our work provides a basis for the design of more compact and water-efficient WESPs.

Novel cross-flow electrostatic precipitator: Numerical and experimental study

Electrostatic precipitators (ESP) are used extensively for removing particulates from a gas flow by charging the particles and then removing them in the presence of an electric field. Traditional ESP designs use the walls of the flow channel as the grounded collection surface. The objective of this present study is to evaluate a novel ESP configuration, recently patented by Ohio University's Electrostatic Laboratory, in which an array of vertical surfaces of cylindrical geometry are placed in a crossflow configuration and used as grounded collection surfaces. A numerical approach was adopted by developing and implementing User-Defined Functions (UDFs) in ANSYS Fluent computational fluid dynamics (CFD) software to build a two-dimensional cross-flow ESP model, for the first time, for the gas flow and particulate capture. The two-dimensional numerical models proved useful in shedding light on the basics of the collection process in the novel cross-flow ESP. In the studied configuration, the collection of the particles on the collector surface was limited to the anterior and posterior surfaces of the first and second collection rows, respectively. The collection at the posterior surface of the second row presented interesting behavior, with the particles becoming entrained in the wake of the collectors and the electric field from the discharge electrode located downstream that was opposite to the fluid flow direction. The output of the simulation underestimated the experimental data. The lower efficiency prediction of the model could have been due to the vibration of the collection electrodes, collection by the mist formed in the wet system, and particle agglomeration in the experiments. The results of this study provide critical information in improving the particulate efficiency of novel cross-flow ESP and other similar cross-flow ESP systems.Implications: A novel Electrostatic precipitator (ESP) configuration (recently patented) was evaluated. A numerical approach was adopted to build a cross-flow ESP model, for the first time, for the gas flow and particulate capture. The collection of the particles on the collector surface was limited to the anterior and posterior surfaces of the first and second collection rows. Also, the particles were entrained in the wake of the collectors. The output of the simulation underestimated the experimental data. The results of this study provide critical information in improving the particulate efficiency of novel cross-flow ESP and other similar cross-flow systems.

Structure and arrangement of perforated plates for uniform flow distribution in an electrostatic precipitator

A wide-angle diffuser installed at the entrance of an electrostatic precipitator (ESP) causes a non-uniform flow distribution due to the boundary layer separation. Because a non-uniform flow pattern decreases the particulate matter control efficiency of an ESP, it is important to maintain a uniform flow distribution. The objective of this study is therefore to understand flow distribution with the conditions of perforated plates placed in the diffuser and then to design an ESP to obtain uniform flow. Discharge coefficients were determined varying the porosity, thickness, and number of holes of the perforated plate inside the lab-scale duct system. The test results suggest that the perforated plate with a porosity of 50%, a thickness of 5 mm, and 0.104 hole/m² perforated plate is most acceptable. This perforated plate was placed in the diffuser of the lab-scale ESP system. Velocity profiles in the body of the ESP were obtained depending on the number and arrangement of perforated plates in the diffuser. One perforated plate placed in the diffuser did not improve the flow distribution. Although more uniform flow distribution was found with two perforated plates, stalled flow regions still existed at the top and bottom of the ESP body. When three perforated plates were placed in the diffuser, the 2nd and 3rd perforated plates were important to obtain uniform flow distribution. When the 2nd and 3rd perforated plates were placed at the inlet side and outlet of the diffuser, respectively, the most uniform flow distribution was obtained in the body of the ESP.Implications: In order to determine the optimal perforated plate for Electrostatic Precipitator (ESP), we investigated the discharge coefficient depending on the structure of the perforated plate in a square duct. We measured the velocity distribution in a laboratory ESP with perforated plates and found the effect of the number and arrangement of perforated plates on the flow distribution in the collection region. Based on the test results, we found the configuration of perforated plates for uniform flow distribution in the body of the ESP.

Performance evaluation of novel wet vibrational precipitator

This study reports the development, construction, and initial testing of a novel vibrational precipitator (VP), patented at Ohio University in 2016, that uses vibrating metal cables with water running over them to capture particulate matter in an exhaust stream. Unlike traditional electrostatic precipitators relying on electric energy to capture particles, this new system uses the concept of vortex shedding to produce vibrations in vertical cables running perpendicular to an exhaust stream. Collisions between particles in the exhaust stream and these vibrating cables cause the particles to land onto a thin film of flowing water around the cables, which carries the particles downward for collection and removal. Initial tests with air containing particulates of 3 micron average particle size show capture efficiencies up to 54% using U.S. Environmental Protection Agency (EPA) Method 5 to measure the particulate concentrations at the upstream and downstream of a VP comprising 8 cells. These results show that this system, without consuming any electric energy, has a significant potential to be a simple and cost-effective way to treat particle-laden exhaust gases. Implications: In this work, for the first time, a novel precipitator is investigated that captures particles without using any particle charging and (hence) any electricity. The capture mechanism is governed by vibrations of collection electrodes, which are vertical steel cables wetted through continuous flow of water. Without any discharge electrodes, electrode suspension mechanism, and ability of the system to be installed in existing ducts, the novel precipitator becomes a simple chamber housing containing multiple collection electrode cells. The preliminary results show that this new technology can achieve net particulate matter capture efficiency of 54%. This paves a pathway forward for reducing capital and operating cost of air pollution control systems.

Integration of novel hybrid composite discharge electrode with semi-pilot novel cross-flow electrostatic precipitator

Wet electrostatic precipitators (WESPs) are modern-era pollution control systems specifically designed to capture ultrafine particles as well as acid mist, highly resistive and sticky particles; however, this requires the use of expensive corrosion-resistant metal alloys. The work presented here is part of a continuing study at Ohio University aimed at reducing the cost of WESPs by using a novel combination of a polymer collector surfaces with a hybrid composite discharge electrode. In this study, a hybrid composite discharge electrode was tested, for the first time, inside a semi-pilot-scale experimental setup, with collection surfaces consists of a vertical array of strands. Particle laden gases were passed through this array of polymer ropes, which were kept wet by a small flow of water. The discharge electrodes were composite laminates of carbon fibers in a polymer matrix enclosing a metal mesh. The preliminary results showed that this new integrated system of composite discharge electrode and polymer collector surfaces can match or exceed the performance of a conventional metal alloy electrostatic precipitator (ESP) with metal discharge electrodes. There are additional advantages due to the system being compact, lightweight, and highly corrosion resistant. Implications: This study focused on integrating and assessing performance of a novel hybrid composite electrode (HCE) inside semi-pilot novel cross-flow electrostatic precipitator at conditions typically observed in coal-fired power plant exhausts. The results were collected for particulate collection efficiencies and were compared with a rigid metal electrode. The HCE outperformed metal electrode by showing higher particulate collection efficiency. This result showcases substantial potential for these two new technologies (HCE and cross-flow system) as a substitute for conventional metal based wet ESPs.

Novel hybrid composite discharge electrode for electrostatic precipitator

Over the last few decades, electrostatic precipitators (ESPs) have emerged as effective air pollution control devices for treating coal-fired power plant exhausts. Among the components of the ESP, the discharge electrodes are extremely important in determining the collection efficiency of the ESP. Typically, in wet ESPs, the discharge electrodes used must be made of corrosion-resistant alloys, which makes them extremely expensive and heavy. Hybrid composite discharge electrodes have the potential to be lightweight and corrosion-resistant substitute for traditional metal alloy electrodes used in wet ESPs. In this experimental study, a novel hybrid composite electrode (recently patented at Ohio University) is presented as a substitute for traditional metal electrodes in wet ESPs. The samples of hybrid electrodes were fabricated by using carbon fiber composites, combined with metal mesh, in the shape of a long and thin tape. The electrode's electrical response was evaluated in open atmospheric conditions, while connected to a transformer-rectifier unit to generate a corona current at voltages exceeding 50 kV. Results of these hybrid electrodes were compared with traditional metal electrodes. The hybrid composite discharge electrode produced a uniform corona at comparable power levels to that of metal electrodes, with additional advantages of being compact, lightweight, and highly corrosion resistant. In addition, hybrid composite electrodes exhibited lower corona onset voltage as compared with metal electrodes. The preliminary experimental data are encouraging and show significant potential for this new inexpensive hybrid electrode to replace metal electrodes in wet ESPs, providing comparable (and in some cases exceeding) collection efficiencies with lower ozone generation.

IMPLICATIONS

The newly invented hybrid composite electrode (HCE) performance was evaluated through experimentation with conventional metal electrodes. The HCE performance was comparable to the metal electrodes. The HCE also exhibited uniform corona fields and steady power while maintaining similar and in some cases superior electrical performance as compared with metal electrodes and thus shows a significant potential to substitute metal electrodes in wet ESP systems.