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Key Benefits

  • Reduce dust emissions
  • Minimise footprint
  • Reduce energy consumption
  • Simplify maintenance requirements
  • Lower operating costs

Reliable, trouble-free dust emission control for all industries

Our ESP solutions offer the lowest cost of ownership and are engineered to deliver industry-leading efficiency and performance. They match fabric filters in efficiency, delivering reliable dust emission control down to 5mg/Nm3

With more than 4,000 ESPs installed in a wide range of applications, FLSmidth provides ESP solutions for processes within cement, pulp and paper, iron and steel, and metallurgical production. We have the proven experience to understand your individual process requirements. This means we can design the optimal ESP configuration, while adhering to the most stringent dust emissions regulations.

 

We continuously develop the design and the technology of our ESPs to meet increasingly stringent dust emission requirements through optimal gas distribution, greater particulate capture and reduced energy consumption.

 

Our electrostatic precipitators make use of several important technologies:

  • A proprietary power supply system (Coromax®), which ensures energy savings, increased efficiency and reduced emissions for challenging processes with high-resistivity dust, such as coal-fired power boilers
  • Proprietary microprocessor controls (PIACS®) enabling the ESP to react efficiently to process variations, ensuring outlet emissions remain low even under challenging conditions
  • High-voltage Fibulax® electrodes for specific process and operating conditions – maximising utilisation of power input and increasing efficiency

 

Thanks to their high quality and flexible design based on extensive process experience, our ESPs minimise wear and tear and require only minimal maintenance. Wear parts are placed outside the dust-stream, allowing trouble-free operation and easy access to the parts

Computational Fluid Dynamics (CFD)

With the help of Computational Fluid Dynamics (CFD), we determine the optimal gas and dust distribution, enabling optimal utilisation of the installed collection area and reduced equipment footprint.


Thanks to their high quality and flexible design based on extensive process experience, our ESPs minimise wear and tear and require only minimal maintenance. Wear parts are placed outside the dust-stream, allowing trouble-free operation and easy access to the parts


computational fluid dynamics illustration showing air flow speed inside electrostatic precipitator
Pulp and paper

FLSmidth’s ESPs secure trouble-free operation in collecting the chemicals recirculated in the kraft process, while minimising dust emissions. 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.

 

For soda recovery boilers, our electrostatic precipitators are tailor-made to your specifications with multiple casings in steel, concrete or stainless steel.

 

In lime reburning kilns, our ESPs can operate under most conditions, including up to 400°C, while maintaining internal alignment and low emission during normal operation.

 

For power boilers, FLSmidth’s ESPs are ideal for circulating fluid bed, bubbling fluid bed or grate-type boilers. They operate with all fuel types (bark, wood waste, sludge and coal) at all mixing ratios.


Recovery boiler ESP
Iron and steel

The mechanical design of the ESP 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 emission type and operating conditions.

 

FLSmidth’s specialists have deep process knowledge of dust emission behaviour related to sinter strands, including how to return dust to the process. We design the most cost-

effective combination of ESP size and high-voltage supply for removing fine particulate, while also saving power.

 

Gases are collected and mixed from hoods, conveyors, coolers and more to reduce dust emissions in one common ESP.

 

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 percent.

Pelletizing plant ESP
Cement

We design electrostatic precipitators for use with clinker coolers with or without waste heat recovery in the circuit for a temperature range of 90-400°C.

 

Our deep process knowledge of dust behaviour associated with kilns and raw mills, including how to return dust to the process, has resulted in an effective, highly compact ESP design, which minimises footprint.

 

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.

 

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

 

FLSmidth’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.

Mining (Metallurgical)

Our ESP solutions are 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

 

To withstand changing temperatures, our ESP design allows the collecting plates to expand and to be efficiently cleaned when the dust becomes sticky – for example, during cooling.

 

We have designed an effective purge-air system that protects the insulators, keeping them dust-free and preventing 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.

Reduce dust emissions with low-energy ESPs

Reduce dust emissions

Our ESPs are engineered to reduce dust emissions down to 5mg/Nm3 based on optimal gas distribution, greater particulate capture and reduced energy consumption.

 

Minimise footprint

We have optimised gas and dust distribution in the ESP, enabled 100% utilisation of the installed collection area. This has enabled us to minimise the equipment footprint.

 

Reduce energy consumption

FLSmidth ESPs consume less energy thanks to innovative developments, including the proprietary power supply system, Coromax®, and microprocessor controls (PIACS®), and the high-voltage Fibulax® electrodes.

 

Simplify maintenance requirements

The high quality and flexible design ensure minimal wear and tear and require only minimal maintenance. Wear parts are placed outside the dust-stream, allowing trouble-free operation and easy access to the parts.

 

Lower operating costs

The combination of reliable technology, low power consumption and ease of maintenance ensure that you keep your cost of operation to a minimum level.

Principles of ESP operations

for dust emissions

Precipitator casing

The FLSmidth ESP is designed for horizontal flue gas flow. The precipitator casing is an all-welded steel construction, made of prefabricated plate sections, welded to a rigid frame.

 

Depending on the process and the ambient conditions, the electrostatic precipitator is designed to withstand a variety of conditions, including high temperatures, under or over-pressure, and naturally occurring forces, such as wind, snow, and earthquakes.

 

Hoppers

The precipitator is provided with longitudinal bottom hoppers or with pyramidal hoppers. For special processes, the precipitator can be supplied with a flat bottom and the hoppers provided with heating elements.

 

Supports

Due to the high working temperatures, the precipitator is mounted on a support to ensure minimum forces on the precipitator casing and support during repeated thermal expansions and contractions. If a rigid support of concrete or steel is used, the precipitator is placed on roller bearings or slide bearings.

 

An alternative to the use of roller or slide bearings is a pendular support (column support), in which heat expansion is absorbed as angular movement of the individual supporting columns.

 

Insulation

The precipitator casing, inclusive of bottom hoppers and inlet and outlet transition pieces, is insulated with mineral wool to avoid harmful condensation, which causes corrosion and reduces lifetime. The insulation also prevents uncontrollable heat expansion, which may cause dangerous tension in the structure. One or more electrically independent fields are arranged in the precipitator casing.

 

Gas distribution

The precipitator casing includes inlet and outlet transition pieces. Their design varies according to the specific process and plant layout. Gas distribution devices are installed in the inlet and outlet transition pieces to ensure optimal gas distribution over the cross-section of the precipitator.

 

Collecting and discharge system

In special cases, each field may be further divided into more electrically independent, so-called “bus” sections. Each precipitator field can be inspected through inspection doors both from the side of the precipitator and from the roof. Each field consists of a grounded collecting system and a high-voltage discharge system. Both systems are provided with independent rapping devices.

 

The collecting system consists of long, specially designed collecting plates, which are suspended from the roof of the precipitator. These form several rows, each consisting of several plates, depending on the length of the field. Each row of collecting plates is connected at the top or bottom to the rapping bars. The distance between the individual rows of plates is called the duct spacing, which may vary according to the specific process.

 

The discharge system is a rigid electrode system carried by support insulators placed on the roof in insulator compartments.

Reducing emissions far below target

LKAB pelletizing plant in Svappavaara, Sweden. For LKAB to increase production, local authorities demanded that they also reduce emissions – all made possible by a turnkey solution from FLSmidth.

Reducing emissions far below target

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