Electrostatic Precipitators

The advanced technology of FLSmidth’s electrostatic precipitators delivers highly reliable dust emission control down to 5mg/Nm³.

ESP
  • Overview
  • Pulp and paper
  • Iron & steel
  • Cement
  • Metallurgical

Designed for lower operational cost

With more than 4,000 electrostatic precipitator (ESP) installations worldwide, FLSmidth Airtech has the proven experience to understand your individual process requirements. We design the optimal ESP configuration for your plant, adhering to the most stringent particulate emissions regulations.

Our ESP solutions offer the lowest cost of ownership and have been engineered to deliver the best efficiency and performance. We are continuously improving our flexible designs and features to stay ahead of future particulate emission requirements. Our solutions are designed to:

  • Ensure a minimal footprint
  • Reduce energy consumption
  • Simplify maintenance requirements
  • Lower operating costs

ESP AUCC

Features and benefits

ESP high-voltage control
The PIACS® DC4 enables the ESP to react efficiently to process variations, minimizing outlet emissions even in challenging conditions.

Coromax® pulse system
The Coromax® pulse system reduces particulate emissions under difficult operating conditions, such as high resistivity and in the presence of very fine particles.

100% utilised
Computational Fluid Dynamics (CFD) – is used in our design for optimal gas and dust distribution, enabling us to achieve 100% utilisation of the collection area and a reduced equipment footprint.

Customer service
Our global presence means we can help customers with upgrading existing equipment, service and spare parts.

Pulp and paper

Productivity is an important parameter for owners and operators of pulp and paper mills. ESPs from FLSmidth Airtech are constructed to secure trouble-free operation in collecting the chemicals recirculated in the kraft process, while minimising dust emissions to the environment.

The unique design of our high-voltage Fibulax® electrodes secures 100% utilisation of the collecting plate area, providing a cost-effective solution.

The fast-reacting PIACS® DC4 high-voltage controller ensures optimal power input under varying plant operating conditions.

We select the best combination of rated current (mA), voltage (kV) and high-voltage transformer type (single phase or three phase) to ensure optimal operating conditions.

Applications

Pulp & Paper industry ESP

Soda recovery boilers
Our market-leading ESP technology is tailor-made to your specifications with multiple casings in steel, concrete or stainless steel.

Lime reburning kilns
With design temperatures up to 400°C, our ESPs can operate under most conditions while maintaining internal alignment and low emission during normal operation.

Power boilers
We design our ESPs for circulating fluid bed, bubbling fluid bed or grate-type boilers operating with all fuel types (bark, wood waste, sludge and coal) at all mixing ratios.

Iron & steel

Operating conditions for ESPs in the iron and steel industry vary significantly. We design our ESPs to ensure minimum maintenance and maximum annual operational hours, while meeting all dust emission requirements.

Our mechanical design typically withstands operating temperatures from 50° to 300°C and suction from +50 to -3000 mmWG for sinter strands. We adjust the design to manage abrasive dust (for example, in pelletizers & sinter coolers) or sticky dust (sinter strands).

We select the best combination of high-voltage transformer type – either traditional DC or Coromax® Pulse – depending on the dust type and operating conditions.

Applications

Iron & Steel ESP

Sinter strand
FLSmidth Airtech’s specialists have deep process knowledge of dust behaviour related to sinter strands, including how to return dust to the process. We design the most cost-effective combination of ESP size and application of Coromax® Pulse high-voltage supply for removing fine particulate, while also saving power.

Room dedusting
We collect and mix gases from hoods, conveyors, coolers and more to reduce dust emissions in one common ESP.

Pelletizer
We design ESPs for pelletizers typically for 80-300°C for dust removal. In combination with our semi-dry FLS-GSA® we can also reduce SO2 emissions by up to 97%.

Cement

The priority in the cement industry is maintaining high productivity while ensuring ambient particulate levels and collection and recycling of dust.

ESPs from FLSmidth Airtech are constructed to secure trouble-free operation in collecting recirculated dust and to minimise dust emissions.

The unique design of high-voltage Fibulax® electrodes secures 100% utilisation of the collecting plate area. The fast-reacting PIACS DC4 high voltage controller ensures optimal power input even as plant operating conditions change.

The uniquely designed anti-sneakage plates provide optimal gas distribution in the ESP and ensure no dust passes through the active high-voltage system.

Cement industry ESP

Clinker cooler ESP
FLSmidth Airtech designs ESPs for use with clinker coolers with or without waste heat recovery in the circuit for a temperature range of 90-400°C.

Kiln/Raw mill ESP
FLSmidth Airtech offers deep process knowledge of dust behaviour associated with kilns and raw mills, including how to return dust to the process. The highly compact ESP design, which minimises footprint, is based on our top-rapping design.

Bypass ESP
Increasing the amount of alternative fuel in the kiln/calciner can increase the presence of unwanted chemical components in the kiln system. We work with you to design the optimal solution for using alternative fuels.

Cement mill ESP
The ESP inlet dust load can exceed 700 g/Nm3. Our ESP includes a pre-separator hopper to separate coarser dust and maximise overall efficiency.

Coal mill ESP
FLSmidth Airtech’s coal mill ESP can be designed with a N2 or CO2 purging system. Explosion flaps can be added to the roof to meet ATEX/NFPA standards requirement for vent pressure clearance.

Metallurgical

In the metallurgical industry, processes typically occur at high temperatures and with high SO2 concentrations. To withstand changing temperatures, the ESP design needs to allow the collecting plates to expand and to be efficiently cleaned when the dust becomes sticky – for example, during cooling.

To protect the insulators, we have designed an effective purge-air system, which keeps them dust-free and prevents acid and moisture condensation. Our rapping system for collecting plates and high voltage electrodes and drag chains on the hopper are designed to remove heavy, sticky dust.

Applications

Metals industry ESP

FLSmidth Airtech’s ESP is designed for use within a variety of metallurgical applications, including:

  • Copper converter
  • Copper roaster
  • Copper dryer
  • Ferro/nickel kiln
  • Ferro/nickel dryer
  • Zinc roaster
  • Molybdenum roaster