Electrostatic Precipitator Services - TAPC · Electrostatic Precipitator Services We’re there to...
8
Product DescripƟon ‐ ESP Services T otal Air PolluƟon Control Rebuilds, Upgrades and Conversions Maintenance and Repairs Electrostatic Precipitator Services We’re there to help when you need us. No matter what industry you’re in, your precipitator can be one of the most misunderstood pieces of equipment in your plant. And if it isn’t operating well, your production can be limited. TAPC’s Precipitator division has one goal….to help you keep your precipitator working so well that you can main- tain or increase production levels. To achieve this goal, TAPC has assembled a skilled team of knowledgeable professionals in all disciplines related to precipitator maintenance and upgrading. When you contact TAPC, you have instant access to the best engineers, construction managers, site engineers, and inspection service experts in the industry. No other air pollution control company has this depth of expertise. Over the past decade, TAPC has become widely known for innovative, imaginative solutions to the problems en- countered by precipitator operators around the world. We specialize in customized remedies for the emission control challenges faced by our customers, regardless of what brand of equipment they own. New Units InspecƟons and Audits Spare Parts Total Air PolluƟon Control Pty. Ltd. Toll free (Australia only): 1800 269 424 InternaƟonal: +61 2 4272 5233 Email: [email protected] www.tapc.com.au TroubleshooƟng Brochure ESP01 rev 0
Transcript of Electrostatic Precipitator Services - TAPC · Electrostatic Precipitator Services We’re there to...
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Rebuilds, Upgrades
and Conversions
Maintenance
and Repairs
Electrostatic Precipitator Services
We’re there to help when you need us.
No matter what industry you’re in, your precipitator can be one of the most misunderstood pieces of equipment in
your plant. And if it isn’t operating well, your production can be limited.
TAPC’s Precipitator division has one goal….to help you keep your precipitator working so well that you can main-
tain or increase production levels. To achieve this goal, TAPC has assembled a skilled team of knowledgeable
professionals in all disciplines related to precipitator maintenance and upgrading. When you contact TAPC, you
have instant access to the best engineers, construction managers, site engineers, and inspection service experts
in the industry.
No other air pollution control company has this depth of expertise.
Over the past decade, TAPC has become widely known for innovative, imaginative solutions to the problems en-
countered by precipitator operators around the world. We specialize in customized remedies for the emission
control challenges faced by our customers, regardless of what brand of equipment they own.
New Units
Inspec ons
and Audits
Spare Parts
Total Air Pollu on Control Pty. Ltd.
Toll free (Australia only): 1800 269 424
Interna onal: +61 2 4272 5233
Email: [email protected]
www.tapc.com.au
Troubleshoo ng
Brochure ESP01 rev 0
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Technical Assistance
Inspec ons and Audits
Many of our clients need assistance to evaluate their ESP performance, to iden fy issues
and to provide recommenda ons for maintenance and performance improvements.
TAPC have un‐matched specialist exper se and knowledge to assist in these areas and
have undertaken hundreds of ESP inspec ons and audits over the years throughout Aus‐
tralia, New Zealand and SE Asia.
A thorough inspec on is the first essen al step in maximizing precipitator performance.
TAPC inspec on personnel are trained to examine your unit and report their findings
using comprehensive guidelines. A er the inspec on of your precipitator, our repre‐
senta ve will discuss with you their ini al findings. The report is then subjected to a
thorough TAPC engineering review to ensure that our final wri en recommenda ons
are in line with your long term objec ves and meet your sa sfac on.
We have designed our inspec on report to specifically iden fy those areas which are reducing the opera onal efficiency
of your electrosta c precipitator. Condi ons requiring immediate repair are iden fied, along with iden fica on of fu‐
ture issues and upgrade op ons for improved performance.
Experienced, Professional, Thorough.
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Case Study
Loca on: Australia
Applica on: Coal Fired Boiler ESP
Descrip on: A customer was no cing poor ESP performance
even though mechanically and electrically the ESP was oper‐
a ng well. It was determined that poor gas distribu on may be
the issue.
Stage 1 ‐ Gas Distribu on Analysis: TAPC performed a full inter‐
nal gas distribu on analysis which determined that
there was indeed poor flow distribu on within the
ESP (see top graph opposite). Darker areas show re‐
gions of high velocity and white areas show regions of
very low velocity.
Stage 2 ‐ CFD Modelling: TAPC then created a 3‐D
Computa onal Fluid Dynamics (CFD) model to simu‐
late the effect of various flow pa ern modifica ons.
Stage 3 ‐ Flow pa ern changes and retes ng: A turning vane
system and gas distribu on screen change was implemented and
the flow pa ern re‐analysed to vindicate the CFD model. The
bo om graph opposite shows the resul ng flow pa ern with
large areas of even flow and no areas of extremely high or low
flow.
Outcome: The customer saw significant improvement in emis‐
sions and a much reduced amount of wear due to erosion.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
1.90
1.77
1.70
1.63
1.50
1.58
1.65
1.73
1.80
1.88
1.95
2.03
2.10
1.84
1.58
1.31
1.05
0.79
0.53
0.26
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.43
0.45
0.48
0.50
0.53
0.55
0.58
0.60
0.53
0.45
0.38
0.30
0.23
0.15
0.08
0.00
0.28
0.55
0.83
1.10
1.38
1.65
1.93
2.20
2.11
2.03
1.94
1.85
1.76
1.68
1.59
1.50
1.63
1.75
1.88
2.00
2.13
2.25
2.38
2.50
1.43
1.43
1.44
1.44
1.45
1.52
1.58
1.65
1.71
1.78
1.84
1.91
1.98
1.79
1.60
1.41
1.23
1.04
0.85
0.66
0.48
0.52
0.56
0.60
0.64
0.68
0.72
0.76
0.80
0.78
0.76
0.73
0.71
0.69
0.67
0.65
0.63
0.56
0.50
0.44
0.38
0.31
0.25
0.19
0.13
0.35
0.58
0.80
1.03
1.25
1.48
1.70
1.93
1.87
1.82
1.77
1.71
1.66
1.61
1.55
1.50
1.59
1.68
1.77
1.86
1.95
2.04
2.13
2.23
0.95
1.10
1.18
1.25
1.40
1.46
1.51
1.57
1.63
1.68
1.74
1.79
1.85
1.74
1.63
1.51
1.40
1.29
1.18
1.06
0.95
0.98
1.01
1.04
1.08
1.11
1.14
1.17
1.20
1.13
1.06
0.99
0.93
0.86
0.79
0.72
0.65
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.43
0.60
0.78
0.95
1.13
1.30
1.48
1.65
1.63
1.61
1.59
1.58
1.56
1.54
1.52
1.50
1.56
1.61
1.67
1.73
1.78
1.84
1.89
1.95
0.95
1.10
1.18
1.25
1.40
1.46
1.51
1.57
1.63
1.68
1.74
1.79
1.85
1.74
1.63
1.51
1.40
1.29
1.18
1.06
0.95
0.98
1.01
1.04
1.08
1.11
1.14
1.17
1.20
1.13
1.06
0.99
0.93
0.86
0.79
0.72
0.65
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.43
0.60
0.78
0.95
1.13
1.30
1.48
1.65
1.63
1.61
1.59
1.58
1.56
1.54
1.52
1.50
1.56
1.61
1.67
1.73
1.78
1.84
1.89
1.95
0.48
0.77
0.91
1.06
1.35
1.40
1.44
1.49
1.54
1.58
1.63
1.68
1.73
1.69
1.65
1.61
1.58
1.54
1.50
1.46
1.43
1.45
1.47
1.49
1.51
1.53
1.56
1.58
1.60
1.48
1.37
1.25
1.14
1.02
0.91
0.79
0.68
0.64
0.60
0.56
0.53
0.49
0.45
0.41
0.38
0.50
0.63
0.75
0.88
1.00
1.13
1.25
1.38
1.39
1.41
1.42
1.44
1.45
1.47
1.48
1.50
1.52
1.54
1.57
1.59
1.61
1.63
1.65
1.68
0.00
0.43
0.65
0.87
1.30
1.34
1.38
1.41
1.45
1.49
1.53
1.56
1.60
1.64
1.68
1.71
1.75
1.79
1.83
1.86
1.90
1.91
1.93
1.94
1.95
1.96
1.98
1.99
2.00
1.84
1.68
1.51
1.35
1.19
1.03
0.86
0.70
0.68
0.65
0.63
0.60
0.58
0.55
0.53
0.50
0.58
0.65
0.73
0.80
0.88
0.95
1.03
1.10
1.15
1.20
1.25
1.30
1.35
1.40
1.45
1.50
1.49
1.48
1.46
1.45
1.44
1.43
1.41
1.40
0.15
0.55
0.75
0.95
1.35
1.39
1.43
1.46
1.50
1.54
1.58
1.61
1.65
1.65
1.64
1.64
1.64
1.63
1.63
1.63
1.63
1.65
1.67
1.69
1.71
1.73
1.76
1.78
1.80
1.68
1.56
1.43
1.31
1.19
1.07
0.95
0.83
0.80
0.77
0.74
0.71
0.68
0.66
0.63
0.60
0.65
0.69
0.74
0.79
0.83
0.88
0.93
0.98
1.03
1.08
1.13
1.18
1.23
1.28
1.33
1.38
1.40
1.42
1.44
1.46
1.48
1.51
1.53
1.55
0.30
0.67
0.85
1.03
1.40
1.44
1.48
1.51
1.55
1.59
1.63
1.66
1.70
1.66
1.61
1.57
1.53
1.48
1.44
1.39
1.35
1.38
1.41
1.44
1.48
1.51
1.54
1.57
1.60
1.52
1.44
1.36
1.28
1.19
1.11
1.03
0.95
0.92
0.89
0.86
0.83
0.79
0.76
0.73
0.70
0.72
0.74
0.76
0.78
0.79
0.81
0.83
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.25
1.31
1.36
1.42
1.48
1.53
1.59
1.64
1.70
0.30
0.67
0.85
1.03
1.40
1.44
1.48
1.51
1.55
1.59
1.63
1.66
1.70
1.66
1.61
1.57
1.53
1.48
1.44
1.39
1.35
1.38
1.41
1.44
1.48
1.51
1.54
1.57
1.60
1.52
1.44
1.36
1.28
1.19
1.11
1.03
0.95
0.92
0.89
0.86
0.83
0.79
0.76
0.73
0.70
0.72
0.74
0.76
0.78
0.79
0.81
0.83
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.25
1.31
1.36
1.42
1.48
1.53
1.59
1.64
1.70
0.45
0.78
0.95
1.12
1.45
1.49
1.53
1.56
1.60
1.64
1.68
1.71
1.75
1.67
1.58
1.50
1.41
1.33
1.24
1.16
1.08
1.12
1.16
1.20
1.24
1.28
1.32
1.36
1.40
1.36
1.32
1.28
1.24
1.20
1.16
1.12
1.08
1.04
1.01
0.97
0.94
0.90
0.87
0.83
0.80
0.79
0.78
0.77
0.76
0.75
0.74
0.73
0.73
0.78
0.83
0.88
0.93
0.98
1.03
1.08
1.13
1.22
1.31
1.40
1.49
1.58
1.67
1.76
1.85
0.60
0.90
1.05
1.20
1.50
1.54
1.58
1.61
1.65
1.69
1.73
1.76
1.80
1.68
1.55
1.43
1.30
1.18
1.05
0.93
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.16
1.13
1.09
1.05
1.01
0.98
0.94
0.90
0.86
0.83
0.79
0.75
0.71
0.68
0.64
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.13
1.25
1.38
1.50
1.63
1.75
1.88
2.00
0.80
0.95
1.03
1.10
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.57
1.48
1.40
1.31
1.23
1.14
1.06
0.98
1.03
1.09
1.14
1.20
1.26
1.31
1.37
1.43
1.39
1.36
1.32
1.29
1.25
1.22
1.18
1.15
1.12
1.08
1.05
1.01
0.98
0.94
0.91
0.88
0.85
0.83
0.81
0.79
0.77
0.74
0.72
0.70
0.75
0.79
0.84
0.89
0.93
0.98
1.03
1.08
1.17
1.26
1.36
1.45
1.54
1.64
1.73
1.83
1.00
1.00
1.00
1.00
1.00
1.06
1.13
1.19
1.25
1.31
1.38
1.44
1.50
1.46
1.41
1.37
1.33
1.28
1.24
1.19
1.15
1.21
1.28
1.34
1.40
1.46
1.53
1.59
1.65
1.58
1.51
1.44
1.38
1.31
1.24
1.17
1.10
1.07
1.04
1.01
0.98
0.94
0.91
0.88
0.85
0.84
0.84
0.83
0.83
0.82
0.81
0.81
0.80
0.84
0.89
0.93
0.98
1.02
1.06
1.11
1.15
1.21
1.28
1.34
1.40
1.46
1.53
1.59
1.65
1.00
1.00
1.00
1.00
1.00
1.06
1.13
1.19
1.25
1.31
1.38
1.44
1.50
1.46
1.41
1.37
1.33
1.28
1.24
1.19
1.15
1.21
1.28
1.34
1.40
1.46
1.53
1.59
1.65
1.58
1.51
1.44
1.38
1.31
1.24
1.17
1.10
1.07
1.04
1.01
0.98
0.94
0.91
0.88
0.85
0.84
0.84
0.83
0.83
0.82
0.81
0.81
0.80
0.84
0.89
0.93
0.98
1.02
1.06
1.11
1.15
1.21
1.28
1.34
1.40
1.46
1.53
1.59
1.65
1.20
1.05
0.98
0.90
0.75
0.83
0.90
0.98
1.05
1.13
1.20
1.28
1.35
1.35
1.34
1.34
1.34
1.33
1.33
1.33
1.33
1.39
1.46
1.53
1.60
1.67
1.74
1.81
1.88
1.77
1.67
1.57
1.46
1.36
1.26
1.15
1.05
1.02
0.99
0.97
0.94
0.91
0.88
0.85
0.83
0.83
0.84
0.85
0.86
0.87
0.88
0.89
0.90
0.94
0.98
1.02
1.06
1.10
1.14
1.18
1.23
1.26
1.29
1.32
1.35
1.38
1.41
1.44
1.48
1.40
1.10
0.95
0.80
0.50
0.59
0.68
0.76
0.85
0.94
1.03
1.11
1.20
1.24
1.28
1.31
1.35
1.39
1.43
1.46
1.50
1.58
1.65
1.73
1.80
1.88
1.95
2.03
2.10
1.96
1.83
1.69
1.55
1.41
1.28
1.14
1.00
0.98
0.95
0.93
0.90
0.88
0.85
0.83
0.80
0.83
0.85
0.88
0.90
0.93
0.95
0.98
1.00
1.04
1.08
1.11
1.15
1.19
1.23
1.26
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.35
1.08
0.95
0.82
0.55
0.65
0.75
0.85
0.95
1.05
1.15
1.25
1.35
1.33
1.30
1.28
1.25
1.23
1.20
1.18
1.15
1.21
1.28
1.34
1.40
1.46
1.53
1.59
1.65
1.55
1.46
1.36
1.26
1.17
1.07
0.97
0.88
0.86
0.85
0.84
0.83
0.81
0.80
0.79
0.78
0.79
0.81
0.83
0.85
0.87
0.89
0.91
0.93
0.94
0.96
0.98
1.00
1.02
1.04
1.06
1.08
1.08
1.09
1.09
1.10
1.11
1.11
1.12
1.13
1.30
1.07
0.95
0.83
0.60
0.71
0.83
0.94
1.05
1.16
1.28
1.39
1.50
1.41
1.33
1.24
1.15
1.06
0.98
0.89
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.14
1.09
1.03
0.98
0.92
0.86
0.81
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.76
0.78
0.79
0.80
0.81
0.83
0.84
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.86
0.88
0.89
0.90
0.91
0.93
0.94
0.95
1.30
1.07
0.95
0.83
0.60
0.71
0.83
0.94
1.05
1.16
1.28
1.39
1.50
1.41
1.33
1.24
1.15
1.06
0.98
0.89
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.14
1.09
1.03
0.98
0.92
0.86
0.81
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.76
0.78
0.79
0.80
0.81
0.83
0.84
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.86
0.88
0.89
0.90
0.91
0.93
0.94
0.95
1.25
1.05
0.95
0.85
0.65
0.78
0.90
1.03
1.15
1.28
1.40
1.53
1.65
1.50
1.35
1.20
1.05
0.90
0.75
0.60
0.45
0.49
0.53
0.56
0.60
0.64
0.68
0.71
0.75
0.73
0.72
0.70
0.69
0.67
0.66
0.64
0.63
0.64
0.65
0.66
0.68
0.69
0.70
0.71
0.73
0.73
0.74
0.74
0.75
0.76
0.76
0.77
0.78
0.76
0.74
0.72
0.70
0.68
0.66
0.64
0.63
0.64
0.66
0.68
0.70
0.72
0.74
0.76
0.78
1.20
1.03
0.95
0.87
0.70
0.84
0.98
1.11
1.25
1.39
1.53
1.66
1.80
1.59
1.38
1.16
0.95
0.74
0.53
0.31
0.10
0.13
0.15
0.18
0.20
0.23
0.25
0.28
0.30
0.33
0.35
0.38
0.40
0.43
0.45
0.48
0.50
0.53
0.55
0.58
0.60
0.63
0.65
0.68
0.70
0.70
0.70
0.70
0.70
0.70
0.70
0.70
0.70
0.66
0.63
0.59
0.55
0.51
0.48
0.44
0.40
0.43
0.45
0.48
0.50
0.53
0.55
0.58
0.60
Scale
:View is looking at the inlet to the first field (i.e. with back to gas distribution plate)
m/s 0
0.25 0.5
0.75 1
1.25 1.5
1.75 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74
1.03
1.02
1.01
1.01
0.99
0.98
0.99
1.01
1.01
1.02
1.03
0.95
0.88
0.88
0.80
0.72
1.01
1.31
1.31
1.60
1.89
1.97
2.06
2.06
2.14
2.22
2.43
2.63
2.63
2.84
3.04
3.10
3.34
3.15
3.21
3.64
3.28
3.09
2.93
2.57
2.54
2.51
2.51
2.47
2.44
2.38
2.33
2.33
2.27
2.21
1.95
1.69
1.69
1.42
1.16
1.18
1.20
1.20
1.22
1.24
1.23
1.22
1.22
1.21
1.20
1.17
1.14
1.14
1.10
1.07
1.03
1.03
1.02
1.02
1.02
1.01
1.03
1.04
1.04
1.05
1.06
0.97
0.88
0.88
0.78
0.69
0.95
1.21
1.21
1.47
1.73
1.77
1.82
1.82
1.86
1.91
2.08
2.25
2.25
2.41
2.58
2.62
2.79
2.66
2.70
3.01
2.78
2.63
2.55
2.32
2.24
2.17
2.17
2.10
2.03
2.01
1.98
1.98
1.96
1.94
1.72
1.51
1.51
1.30
1.09
1.12
1.16
1.16
1.19
1.23
1.21
1.19
1.19
1.18
1.16
1.14
1.13
1.13
1.11
1.09
1.03
1.03
1.04
1.04
1.04
1.05
1.06
1.07
1.07
1.08
1.10
0.99
0.88
0.88
0.77
0.66
0.89
1.11
1.11
1.34
1.57
1.57
1.58
1.58
1.59
1.60
1.73
1.86
1.86
1.99
2.12
2.14
2.25
2.16
2.19
2.38
2.27
2.16
2.17
2.06
1.95
1.84
1.84
1.73
1.63
1.63
1.64
1.64
1.65
1.66
1.50
1.34
1.34
1.17
1.01
1.06
1.12
1.12
1.17
1.22
1.19
1.17
1.17
1.14
1.12
1.12
1.12
1.12
1.12
1.12
1.03
1.03
1.04
1.04
1.04
1.05
1.06
1.07
1.07
1.08
1.10
0.99
0.88
0.88
0.77
0.66
0.89
1.11
1.11
1.34
1.57
1.57
1.58
1.58
1.59
1.60
1.73
1.86
1.86
1.99
2.12
2.14
2.25
2.16
2.19
2.38
2.27
2.16
2.17
2.06
1.95
1.84
1.84
1.73
1.63
1.63
1.64
1.64
1.65
1.66
1.50
1.34
1.34
1.17
1.01
1.06
1.12
1.12
1.17
1.22
1.19
1.17
1.17
1.14
1.12
1.12
1.12
1.12
1.12
1.12
1.03
1.04
1.05
1.05
1.07
1.08
1.09
1.10
1.10
1.12
1.13
1.00
0.88
0.88
0.75
0.63
0.82
1.02
1.02
1.21
1.40
1.37
1.35
1.35
1.32
1.29
1.38
1.48
1.48
1.57
1.66
1.66
1.70
1.67
1.67
1.74
1.76
1.70
1.78
1.81
1.66
1.51
1.51
1.36
1.22
1.26
1.30
1.30
1.34
1.39
1.27
1.16
1.16
1.05
0.94
1.00
1.07
1.07
1.14
1.21
1.18
1.14
1.14
1.11
1.07
1.09
1.11
1.11
1.12
1.14
1.03
1.05
1.07
1.07
1.09
1.11
1.12
1.14
1.14
1.15
1.16
1.02
0.88
0.88
0.74
0.60
0.76
0.92
0.92
1.08
1.24
1.18
1.11
1.11
1.05
0.98
1.04
1.09
1.09
1.15
1.20
1.19
1.16
1.17
1.16
1.11
1.26
1.24
1.40
1.55
1.37
1.18
1.18
1.00
0.81
0.89
0.96
0.96
1.04
1.11
1.05
0.99
0.99
0.92
0.86
0.95
1.03
1.03
1.12
1.20
1.16
1.12
1.12
1.07
1.03
1.06
1.10
1.10
1.13
1.16
1.06
1.07
1.08
1.08
1.09
1.10
1.12
1.13
1.13
1.15
1.16
1.06
0.96
0.96
0.85
0.75
0.90
1.05
1.05
1.20
1.35
1.30
1.25
1.25
1.20
1.15
1.23
1.31
1.31
1.39
1.47
1.50
1.44
1.53
1.57
1.41
1.50
1.47
1.58
1.67
1.53
1.40
1.40
1.26
1.13
1.19
1.24
1.24
1.30
1.36
1.25
1.15
1.15
1.05
0.95
1.02
1.10
1.10
1.18
1.26
1.22
1.19
1.19
1.15
1.12
1.13
1.15
1.15
1.16
1.18
1.10
1.09
1.09
1.09
1.09
1.09
1.11
1.13
1.13
1.14
1.16
1.10
1.03
1.03
0.97
0.90
1.04
1.18
1.18
1.32
1.46
1.42
1.39
1.39
1.35
1.32
1.42
1.52
1.52
1.63
1.73
1.81
1.72
1.89
1.97
1.71
1.73
1.70
1.76
1.78
1.70
1.62
1.62
1.53
1.45
1.49
1.53
1.53
1.56
1.60
1.46
1.32
1.32
1.17
1.03
1.10
1.17
1.17
1.24
1.31
1.28
1.26
1.26
1.23
1.20
1.20
1.20
1.20
1.20
1.20
1.10
1.09
1.09
1.09
1.09
1.09
1.11
1.13
1.13
1.14
1.16
1.10
1.03
1.03
0.97
0.90
1.04
1.18
1.18
1.32
1.46
1.42
1.39
1.39
1.35
1.32
1.42
1.52
1.52
1.63
1.73
1.81
1.72
1.89
1.97
1.71
1.73
1.70
1.76
1.78
1.70
1.62
1.62
1.53
1.45
1.49
1.53
1.53
1.56
1.60
1.46
1.32
1.32
1.17
1.03
1.10
1.17
1.17
1.24
1.31
1.28
1.26
1.26
1.23
1.20
1.20
1.20
1.20
1.20
1.20
1.13
1.12
1.10
1.10
1.09
1.08
1.10
1.12
1.12
1.14
1.16
1.13
1.11
1.11
1.08
1.05
1.18
1.31
1.31
1.43
1.56
1.54
1.52
1.52
1.50
1.48
1.61
1.74
1.74
1.87
2.00
2.12
2.00
2.25
2.38
2.01
1.97
1.94
1.93
1.90
1.86
1.83
1.83
1.80
1.77
1.79
1.81
1.81
1.83
1.85
1.66
1.48
1.48
1.30
1.12
1.18
1.24
1.24
1.30
1.37
1.35
1.33
1.33
1.31
1.29
1.27
1.25
1.25
1.24
1.22
1.16
1.14
1.12
1.12
1.09
1.07
1.09
1.12
1.12
1.14
1.16
1.17
1.18
1.18
1.19
1.20
1.32
1.44
1.44
1.55
1.67
1.67
1.66
1.66
1.66
1.65
1.80
1.96
1.96
2.11
2.26
2.43
2.29
2.61
2.78
2.31
2.21
2.17
2.11
2.01
2.03
2.05
2.05
2.07
2.09
2.09
2.09
2.09
2.09
2.09
1.87
1.65
1.65
1.42
1.20
1.26
1.31
1.31
1.37
1.42
1.41
1.40
1.40
1.38
1.37
1.34
1.31
1.31
1.27
1.24
1.09
1.06
1.04
1.04
1.02
1.00
1.03
1.06
1.06
1.09
1.12
1.11
1.11
1.11
1.11
1.10
1.20
1.31
1.31
1.41
1.51
1.50
1.48
1.48
1.47
1.46
1.59
1.73
1.73
1.87
2.01
2.12
2.03
2.24
2.36
2.06
1.95
1.95
1.84
1.73
1.85
1.96
1.96
2.07
2.19
2.11
2.03
2.03
1.94
1.86
1.69
1.52
1.52
1.35
1.18
1.23
1.28
1.28
1.33
1.38
1.36
1.35
1.35
1.34
1.33
1.31
1.30
1.30
1.28
1.26
1.01
0.99
0.97
0.97
0.95
0.93
0.96
1.00
1.00
1.03
1.07
1.05
1.04
1.04
1.02
1.01
1.09
1.18
1.18
1.26
1.35
1.33
1.31
1.31
1.28
1.26
1.38
1.51
1.51
1.63
1.75
1.82
1.78
1.88
1.95
1.80
1.69
1.73
1.57
1.46
1.66
1.87
1.87
2.08
2.29
2.12
1.96
1.96
1.80
1.64
1.52
1.40
1.40
1.28
1.16
1.20
1.24
1.24
1.29
1.33
1.32
1.31
1.31
1.30
1.29
1.29
1.29
1.29
1.29
1.29
1.01
0.99
0.97
0.97
0.95
0.93
0.96
1.00
1.00
1.03
1.07
1.05
1.04
1.04
1.02
1.01
1.09
1.18
1.18
1.26
1.35
1.33
1.31
1.31
1.28
1.26
1.38
1.51
1.51
1.63
1.75
1.82
1.78
1.88
1.95
1.80
1.69
1.73
1.57
1.46
1.66
1.87
1.87
2.08
2.29
2.12
1.96
1.96
1.80
1.64
1.52
1.40
1.40
1.28
1.16
1.20
1.24
1.24
1.29
1.33
1.32
1.31
1.31
1.30
1.29
1.29
1.29
1.29
1.29
1.29
0.94
0.91
0.89
0.89
0.87
0.85
0.90
0.94
0.94
0.98
1.03
1.00
0.97
0.97
0.94
0.91
0.98
1.05
1.05
1.12
1.19
1.16
1.13
1.13
1.10
1.07
1.17
1.28
1.28
1.39
1.50
1.51
1.52
1.52
1.53
1.55
1.42
1.51
1.30
1.18
1.48
1.78
1.78
2.08
2.38
2.14
1.90
1.90
1.65
1.41
1.34
1.27
1.27
1.20
1.13
1.17
1.21
1.21
1.25
1.29
1.27
1.26
1.26
1.25
1.24
1.26
1.28
1.28
1.29
1.31
0.86
0.84
0.82
0.82
0.80
0.78
0.83
0.88
0.88
0.93
0.98
0.94
0.90
0.90
0.85
0.81
0.87
0.92
0.92
0.98
1.03
0.99
0.95
0.95
0.91
0.87
0.96
1.06
1.06
1.15
1.24
1.20
1.27
1.15
1.11
1.29
1.16
1.29
1.03
0.90
1.30
1.69
1.69
2.09
2.48
2.16
1.83
1.83
1.51
1.18
1.16
1.15
1.15
1.13
1.11
1.14
1.18
1.18
1.21
1.24
1.23
1.22
1.22
1.21
1.20
1.23
1.27
1.27
1.30
1.33
0.65
0.63
0.62
0.62
0.60
0.59
0.64
0.69
0.69
0.74
0.79
0.76
0.73
0.73
0.70
0.68
0.70
0.72
0.72
0.75
0.77
0.76
0.74
0.74
0.72
0.71
0.80
0.89
0.89
0.99
1.08
1.02
1.10
0.96
0.90
1.12
0.97
1.05
0.82
0.68
0.99
1.30
1.30
1.61
1.92
1.70
1.49
1.49
1.28
1.06
1.02
0.98
0.98
0.93
0.89
0.93
0.97
0.97
1.00
1.04
1.05
1.06
1.06
1.07
1.08
1.07
1.07
1.07
1.06
1.05
0.43
0.42
0.41
0.41
0.40
0.39
0.44
0.50
0.50
0.55
0.60
0.59
0.57
0.57
0.56
0.54
0.53
0.53
0.53
0.52
0.52
0.52
0.53
0.53
0.54
0.55
0.64
0.73
0.73
0.83
0.92
0.84
0.93
0.77
0.69
0.95
0.78
0.81
0.62
0.45
0.68
0.90
0.90
1.13
1.35
1.25
1.15
1.15
1.05
0.95
0.88
0.81
0.81
0.74
0.67
0.71
0.76
0.76
0.80
0.85
0.87
0.90
0.90
0.93
0.96
0.91
0.87
0.87
0.82
0.78
0.43
0.42
0.41
0.41
0.40
0.39
0.44
0.50
0.50
0.55
0.60
0.59
0.57
0.57
0.56
0.54
0.53
0.53
0.53
0.52
0.52
0.52
0.53
0.53
0.54
0.55
0.64
0.73
0.73
0.83
0.92
0.84
0.93
0.77
0.69
0.95
0.78
0.81
0.62
0.45
0.68
0.90
0.90
1.13
1.35
1.25
1.15
1.15
1.05
0.95
0.88
0.81
0.81
0.74
0.67
0.71
0.76
0.76
0.80
0.85
0.87
0.90
0.90
0.93
0.96
0.91
0.87
0.87
0.82
0.78
0.22
0.21
0.21
0.21
0.20
0.20
0.25
0.30
0.30
0.36
0.41
0.41
0.41
0.41
0.41
0.41
0.37
0.33
0.33
0.29
0.26
0.29
0.32
0.32
0.35
0.38
0.48
0.57
0.57
0.67
0.76
0.67
0.77
0.57
0.48
0.77
0.59
0.57
0.41
0.23
0.37
0.51
0.51
0.65
0.79
0.80
0.81
0.81
0.82
0.83
0.73
0.64
0.64
0.54
0.44
0.49
0.55
0.55
0.60
0.65
0.69
0.74
0.74
0.79
0.83
0.75
0.67
0.67
0.58
0.50
0.00
0.00
0.00
0.00
0.00
0.00
0.06
0.11
0.11
0.17
0.22
0.23
0.25
0.25
0.26
0.27
0.20
0.14
0.14
0.07
0.00
0.06
0.11
0.11
0.17
0.22
0.32
0.41
0.41
0.51
0.60
0.49
0.60
0.38
0.27
0.60
0.40
0.33
0.20
0.00
0.06
0.11
0.11
0.17
0.22
0.34
0.47
0.47
0.59
0.71
0.59
0.47
0.47
0.34
0.22
0.28
0.34
0.34
0.39
0.45
0.52
0.58
0.58
0.65
0.71
0.59
0.47
0.47
0.34
0.22
Scale
:View is looking at the inlet to the first field (i.e. with back to gas distribution plate)
m/s 0 0.5 1 1.5 2 2.5 3 3.5 4
Gas Distribu on Analysis (before modifica ons)
CFD modelling with modifica ons
Gas Distribu on Analysis (a er modifica ons)
Gas Distribu on Studies
Gas Distribu on is an o en overlooked area of an electrosta c precipitator with
people tending to focus more on mechanical and electrical issues. However, poor
gas distribu on can have a large detrimental effect on performance even though
the ESP electrical readings may appear fine. At TAPC we have many years of experi‐
ence in determining gas distribu on issues and rec fying them. We have the latest
in 3‐D design so ware and CFD analysis tools.
Technical Assistance
Remote Troubleshoo ng
TAPC Engineers are available to assist either online or via phone free of charge. Please email us
at [email protected] or call us on the numbers on the back of this brochure. Also, you can
visit the troubleshoo ng area of our web site 24 hours a day ‐ the answers you’re a er may al‐
ready be there.
Resis vity Tes ng
Are there other factors causing your ESP to underperform? Do you know the resis vity of your dust? Resis vity is a meas‐
ure of the capability of your dust to accept electrical charge. The resis vity of the dust varies with factors like temperature
and gas composi on, so knowing the temperatures and process condi ons that cause the ESP to underperform can be in‐
valuable in fine tuning your process to op mise performance and produc on. With a dust sample size of around 500mL
we can provide resis vity curves spanning all possible temperature condi ons.
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Spare Parts - Direct Replacement and Upgrade
Collec ng plates
Collec ng plates are vital to the opera on of the electrosta c precipitator. If
they become damaged, they can degrade the performance of the ESP signifi‐
cantly. Collec ng plates are typically made from specialty plate steel between
1.2 and 1.8mm thick. Each manufacturer has their own unique profile design,
requiring special tooling to make each. If you require collec ng plates for your
ESP, please note that these are not held in stock and require special set‐ups and
mill runs to produce. This means that leads mes for collec ng plates can be
the longest of all ESP parts.
Discharge Electrodes, Weights and Frames
Whether you have weighted‐wire discharge
electrode systems, spring electrodes, rigid
electrodes or ribbons we can supply replace‐
ment versions for your unit. Broken wires
mean shorted fields and reduced ESP perfor‐
mance. To achieve the highest reliability and
extended plant runs, discharge electrodes
should be replaced once failures start to oc‐
cur.
As an alterna ve, we design and manufacture
our own line of reliable and versa le RDEs,
with a wide variety of available emi er pin
spacings and configura ons, including stag‐
gered, opposed and V‐pin styles.
Insulators
When an insulator fails in a precipitator, there can be disastrous consequences. Electrical
fields can be shorted out, lower guide frames can start swaying, discharge electrode rap‐
ping can be lost, or high voltage conductors can contact ground. If a support insulator fails,
the high voltage frame in that field can fall. Time is of the es‐
sence when an insulator needs to be replaced. We not only
stock most common ESP insulators but we also supply 85%
alumina versions which have vastly superior strength and
electrical proper es over standard porcelain.
Contact us today for all your insulator needs.
WHY NOT UPGRADE?
For improved reliability and
greater performance why
not try TAPC’s Rigid Dis‐
charge Electrodes (RDEs)?
Spring
TAPC offers a full range of discharge electrodes and weights. Our ESP products meet or exceed the
requirements of any OEM specifica on for quality and design.
Ribbon
WHY NOT UPGRADE?
For improved electrical
resistance and greater
strength why not try our
range of 85% Alumina Insu‐
lators?
TAPC offers a full range of collec ng plate profiles
from all OEMs. Our ESP products meet or exceed
the requirements of any OEM specifica on for
quality and design.
Including CS, CSV, CSH, ZT24 and many more.
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l Original Manufacturer
Discharge
System
Dis
char
ge E
lect
rod
es
Dis
char
ge F
ram
es
Rap
pin
g an
vils
, ham
mer
s
Rap
pin
g m
ech
anis
m
Sup
po
rt In
sula
tors
Rap
per
Insu
lato
rs
Thro
ugh
‐Bu
sh In
sula
tors
Collecting System
Co
llect
ing
Pla
tes
Sho
ck B
ars
and
An
vils
Rap
pin
g H
amm
ers
Rap
pin
g M
ech
anis
m
Fast
ener
s
Gas Distribution
Scre
en P
late
s
Rap
pin
g A
nvi
ls
Rap
pin
g H
amm
ers
Rap
pin
g M
ech
anis
m
Electrical
Tran
sfo
rmer
Rec
tifi
ers
Au
tom
atic
Vo
ltag
e C
on
tro
llers
SCR
an
d M
CC
Rap
pin
g C
on
tro
l
ABB
Alstom
Elex
Flakt
FLS
Fowlerex / Rheem
Furukawa
Humboldt
Joy (Western Precipitation)
Korea Cottrell
Lodge Cottrell (Sturdevant)
Lurgi
Mitsubishi
Noell
Outokumpu
Research Cottrell
SF (Svenska Fabrika)
Walther
Rapping Systems
Rapping systems come in many varied and different configura ons. Gener‐
ally, these can be divided into two main categories: tumbling hammer sys‐
tems and impact rapper systems. Every manufacturer has their own meth‐
od of rapping the accumulated dust from the discharge electrodes (DE rap‐
ping), the collec ng plates (CE Rapping) and the gas distribu on screen (GD
rapping).
As the rapping system is a mechanical device, they wear and ul mately fail
over me. They typically need the highest maintenance of any component
on the ESP. Likewise, the parts that make up the rapping mechanisms need
replacing o en. At TAPC, we stock or supply most parts associated with
ESP rapping.
Spare Parts - Direct Replacement and Upgrade
Supply Matrix
Electrical
TAPC offers the world’s finest precipitator electrical com‐
ponents from industry leading voltage controllers (B&W
SQ300i) to rapper controls, monitoring so ware, and high
efficiency transformer rec fiers. All designed to directly
integrate with any exis ng opera ng ESP.
But that’s just the beginning of the story.
High frequency transformer rec fiers can drama cally im‐
prove performance by delivering a true DC supply to the
ESP field. Contact us today to see if this will work for you.
WHY NOT UPGRADE?
In many cases, modernising
your electrical system can
be the best bang‐for‐your‐
buck op on.
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Service and Maintenance
Experienced, Professional, Safe, and Reliable
TAPC have an expert crew of skilled site managers and tradesmen with
many years of detailed experience in all types of electrosta c precipita‐
tors. Behind our service crews are a full team of project managers and engi‐
neers who can determine and resolve any issue that you may be having.
Currently TAPC services and maintains many electrosta c precipitators
across Australia and SE Asia ‐ many under long term maintenance contracts
with the region's largest customers. If we're not currently servicing your
ESP, why not give us a call and give yourself peace of mind.
Par al Reference List
Adelaide Brighton Cement
Alcan
Alcoa
Alinta Energy
Australian Paper
BHP Billiton
Boral
Boyne Island Smelter
BlueScope Steel
Carter Holt Harvey
Cement Australia
Cockburn Cement
CS Energy
Delta Electricity
Energy Brix
Eraring Energy
Fletcher Challenge
Genesis
Golden Bay Cement
Hazelwood Power
Holcim
Iluka
Incitec
Interna onal Power
KCGM
Macquarie Genera on
Norske Skog
NRG
Nyrstar
Onesteel
Orica
QAL
QCL
QNI
Rio Tinto
Stanwell Power
Tarong Energy
Temco
Visy Paper
Verve Energy
Worsley
Xstrata
Yallourn Energy
Professional Planning
Site Works completed mely and
with a strong fo‐cus on Safe‐ty and Quality.
Expert Project Management
TAPC Advantages
Hundreds of completed projects
Specialised tooling and jigs for fast
and accurate installa on of collec ng
plates and discharge electrodes.
Highly accurate alignment systems
A portable site container stocked
with specialised tools, jigs, safety equip‐
ment, and fasteners.
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Rebuilds, Upgrades and Conversions
Case History ‐ Rebuild
Steel Manufacturer, Australia ‐ Steelmak‐
ing furnace ven la on (2010).
Background:
This customer had substan al problems
with corrosion damage leading to poor
performance of the exis ng ESP. As the
exis ng performance was adequate prior
to the corrosion damage, it was decided to
rebuild the ESP in its original style.
Outcomes:
The ESP was returned to its original condi‐
on and once again performed as per de‐
sign. TAPC was awarded a further unit to rebuild in 2013.
Case History ‐ Upgrade
Nickel Refinery, Australia ‐ Dryer ven la‐
on (2011)
Background:
Poor performance and poor reliability lead
this customer to require a complete re‐
build of one of their ESPs. It was decided
to upgrade the collec ng plates to ESP1™
plates and the old weighted wire elec‐
trodes to TAPC RDEs™.
Outcomes:
The performance increase was substan al
with emissions below 50mg/Nm3 (well below EPA requirements). TAPC was
awarded the upgrade of a further unit.
Case History ‐ Conversion to Fabric Filter
Cement Manufacturer, Australia ‐ Cement Grinding Mill
(1999)
Background:
This customer wanted to increase their mill produc on
capacity. In doing so they would have pushed the old elec‐
trosta c precipitator well beyond it EPA emission require‐
ments. In this instance it was not going to be possible to
just upgrade the ESP technology as the exis ng casing was
too small. It was decided to convert the ESP casing to a
TAPC PowerJet™ fabric filter using the latest technology GE
PulsePleats™ with GE Prevail™ ePTFE membrane.
Outcomes:
The new fabric filter performed so well that for the first me since the plant started, there were
zero visible emissions. Due to the low pressure loss and high air flow of these filter elements,
the new mill performed well above its design produc on rate.
Is your plant failing to meet higher produc‐
on targets due to emissions from your ESP?
Has the performance of your ESP deteriorated
over me?
Maybe we can help in one of the following
ways:
Rebuilding your unit to bring it back to
it’s original performance.
Upgrading your unit with modern tech‐
nology including advanced TAPC rigid
discharge electrodes, wider plate spac‐
ings and high powered electronics to
improve performance.
Conver ng your ESP to a TAPC Power‐
Jet™ fabric filter to improve perfor‐
mance.
At TAPC we have mul ple op ons to help you
achieve your produc on and
emission goals.
Pro
du
ct Descrip
on
‐ ESP Services
Total A
ir Pollu
on Contro
l
Total Air Pollu on Control Pty. Ltd. ACN 097 531 416
HEAD OFFICE: 4 Prince of Wales Avenue
UNANDERRA, NSW, 2526
Tel: +61 2 4272 5233
Fax: +61 2 4272 5633
E‐mail: [email protected]
Toll free: 1800 269 424
www.tapc.com.au
1960s 1970s 1980s 1990s 2000s Today
Air Pollution Control Experts since 1968
History
In 1968 Ceilcote Tasmania was formed as a specialist producer of fibreglass packed bed scrubbers based on Tellere e packing. Ceilcote
became Transfield RPC in the 1980s and Horizon APC in the 1990s. In 1998 the Environmental Group (EGL) acquired Horizon APC to
augment its exis ng air pollu on control business that included ac vated carbon systems and flares. From 1998 un l 2012, the busi‐
ness grew to become the largest in Australia at removing gaseous pollutants from industrial processes.
In 2001 TAPC was formed as the Australasian representa ve for BHA Group Inc (now GE Energy). TAPC quickly established itself as one
of the region's leading industrial air pollu on control companies in the field of par culate capture using electrosta c precipitators and
fabric filters.
In 2007 the Environmental Group (EGL) acquired TAPC to add par culate capture technologies to its already substan al gaseous pollu‐
tant technologies. In 2012 it was decided to merge the two business units into one en ty; Total Air Pollu on Control (TAPC). In so
doing, forming Australia's largest and most comprehensive air pollu on control company. No ma er what the pollutant, TAPC has the
technology, experience and capability to capture it.
EGL is listed on the Australian stock exchange under the code "EGL". TAPC is a wholly owned subsidiary of EGL.
Gas Scrubbing Fabric Filters Electrosta c Precipitators
Australia’s Leading Air Pollution Control Company.
