Enhancing Electrostatic Precipitators with Custom Air Preheaters from Hotfoil-EHS

Air preheaters enhance the efficiency and longevity of electrostatic precipitators (ESPs) installed in industrial plants. By maintaining optimal flue gas temperatures, reducing corrosion, and improving particulate collection efficiency, these devices significantly boost ESPs' overall performance. 

In an industrial setting, maintaining the flue gas temperature within a specific range is essential for the efficient operation of an ESP. Air preheaters achieve this by raising the temperature of the incoming flue gas before it enters the precipitator. This temperature increase reduces the moisture content in the gas, preventing condensation that could otherwise interfere with the electrostatic process. The gas's electrical resistivity improves with less moisture, facilitating better particle charging and collection. Consequently, the ESP can more effectively capture particulate matter, resulting in cleaner emissions and compliance with environmental regulations.

Another critical benefit provided by air preheaters is reducing corrosion. Acidic condensation forms when the flue gas temperature falls below the acid dew point, leading to corrosion and fouling of ESP components. By keeping the flue gas temperature above this threshold, air preheaters prevent the formation of corrosive acids, thereby protecting the ESP from damage. This not only extends the lifespan of the equipment but also provides significant relief from maintenance needs and associated costs, giving you peace of mind and confidence in the financial benefits of air preheaters.

Improving particulate collection efficiency represents a significant advantage of using air preheaters with ESPs. Elevated gas temperatures lower the flue gas's viscosity, making it easier for the ESP to capture fine particles. Additionally, higher temperatures increase the electrostatic process's overall effectiveness, ensuring that the ESP operates at its peak efficiency. This leads to more efficient removal of particulates from the flue gas, enhancing air quality and meeting stringent emission standards.

For industrial plants seeking to maximize the benefits of air preheaters, custom fabrication offers tailored solutions to meet specific operational requirements. Companies like Hotfoil-EHS of Hamilton, NJ, specialize in designing and manufacturing custom air preheaters that address different industries' unique challenges. By opting for custom fabrication, plant operators can ensure that their air preheaters precisely match the demands of their ESP systems, leading to optimal performance and efficiency.

Hotfoil-EHS stands out in the industry with its commitment to quality and innovation. Their custom air preheaters incorporate the latest technologies and materials, ensuring reliable and efficient operation under the harshest conditions. With a focus on customer satisfaction, Hotfoil-EHS provides comprehensive support from design to installation, ensuring that each air preheater meets the highest standards of performance and durability. This level of support ensures that you feel confident and supported in your investment in air preheaters.

Air preheaters significantly enhance the efficiency and longevity of electrostatic precipitators by maintaining optimal flue gas temperatures, reducing corrosion, and improving particulate collection efficiency. Custom fabrication from companies like Hotfoil-EHS ensures that these devices meet the specific needs of each industrial plant, delivering superior performance and long-term reliability. Investing in custom air preheaters not only boosts operational efficiency but also leads to substantial cost savings and, importantly, environmental benefits. This contribution to a cleaner environment is something to be proud of and a testament to the responsible operation of your industrial plant.

Hotfoil-EHS
https://hotfoilehs.com
609-588-0900

Prevent Electrostatic Precipitator and Baghouse Hopper Blockage with Hopper Heaters

Coal-fired power plants in the U.S. require the use of electrostatic precipitators or bag houses to filter out very fine fly ash particles incorporated into flow gas. The ash is collected while the flue gas passes through filter bags or large electrodes and then falls into hoppers. As the hot fly ash cools, it may condense on the hopper walls. The mixture of dry, sulfur-rich fly ash and water is very problematic, so it is very important that there is no condensation in the collection hoppers.

The mixture of water and fly ash can cause the hopper to block up (or "pluggage "), and most importantly, residual sulfur in the flue gas will combine with condensate to form sulfuric acid. The sulfuric acid attacks the inside of the hopper walls, causing corrosion, weakening walls and generating significant (and costly) maintenance problems over time.

Efficient and continuous removal of fly ash is essential for all coal-fired power plants. Collection hoppers are an integral part of the removal process. Plugging or inoperable hoppers are a known problem for engineers and maintenance crews. Constant maintenance and excess downtime seriously prevent a plant's ability to manage the production rate of fly ash. Slower fly ash production means a reduction in energy production and efficiency. The power generation of a power station is directly proportional to its rate of combustion of coal, which in turn directly affects the production of fly ash. The maintenance personnel usually attempt to remedy ash system failures in real time by disabling the affected hopper, while continually generating electricity and ash. In some situations (to prevent shutdowns of boilers), ash will be dumped on the floor, requiring costly cleaning.

Evacuation and management of fly ash is much easier if the ash is kept warm. One of the most common ways of maintaining high fly ash and hopper temperatures is by connecting electric hopper heaters to the outside hopper walls. Hopper heaters play a very important role in removing the fly ash from precipitators and bag filter walls by keeping the hopper temperatures over the flue gas acid dew point. The only function of the hopper heater is to preheat the hopper and the internal environment to prevent the formation of moisture, fly ash clumping and the development of sulphuric acid.

Hopper heaters are designed for a dirty, high-vibration power plant environment. They provide the optimum watt density for proper thermal transfer through the hopper wall and uniform heating. They are available in square, rectangular and trapezoidal shapes for any hopper design. For poke tubes, man-ways and cylindrical throats, ancillary flexible heating cloths are available. The use of electric hopper heaters in electrostatic precipitator and bag house fly ash collection systems is an effective time-tested way to prevent condensation and the resulting clumping and corrosive acids in hopper products, thus providing better opportunities for continuous production of fly ash.

Hopper, Tank & Chute Heaters plus Control Systems

Hotfoil-EHS specializes in electric surface heating systems. Applications include fly-ash hoppers on electrostatic precipitators, baghouses, coal and material handling systems, tanks, and pipes.

For more information, contact Hotfoil-EHS by calling 609.588.0900 or visit https://hotfoilehs.com.

Electric Process Heaters & Controls

Hotfoil specializes in electric surface heating systems for fly ash hoppers on electrostatic precipitators or baghouses, coal and material handling systems, tanks, pipes, etc. in all types of industry.

For more information, visit http://www.hotfoilehs.com or call 609.588.0900.

Electric Heating and Control Solutions for Power Generation

Hotfoil-EHS specializes in electric surface heating systems in power plants for fly ash hoppers on electrostatic precipitators or baghouses, coal and material handling systems, tanks, and pipes.

For more information, visit http://www.hotfoilehs.com.

Eliminate Costly Hopper Pluggage with Electric Hopper Heaters

Modular, metal-clad hopper heaters
installed on large hopper.

Fly ash is a by-product of coal fired and waste-to-energy fired electrical generating facilities. Fly ash is a combination of dust and fine particles produced during combustion. Environmental laws require fly ash to be collected and not released in to the atmosphere. Large collectors called electrostatic precipitators combined with a system of filters extract fly ash from the flue gas and dispense the fly ash in large steel hoppers prior to being dumped in to containers and transported.

Due to the temperature differential between the hot internal temperature of the hopper and the cooler exterior, condensation forms on the internal wall surfaces, The condensation, combined with the fly ash, creates a concrete-like material that bonds to the hopper walls. The accumulation of this material eventually clogs the hopper to the extent it cannot be emptied. At this point, the only way to free the clogged material is with sledge hammers and pneumatic tools and long periods of downtime and the related expense.

To prevent the fly ash and condensate mixture from forming,

electric heaters are bonded or clamped to the exterior walls and throat of the hopper. Because the environment is normally very dirty with high vibration, “hopper heaters” are designed to withstand to meet these mechanical and environmental stresses.

Hopper heaters come in a variety of physical sizes, voltages, and wattages. Most often, hopper heaters come in pre-engineered sets that have been specified and configured by an applications engineer.

For more information on any hopper heating application, contact Hotfoil-EHS for a free consultation. Visit http://www.hotfoilehs.com or call 609.588.0900.

Electrostatic Precipitator and Bag House Hopper Heaters Prevent Fly Ash Production Problems

Coal fired power plants must manage fly ash properly.

Coal fired power plants in the United States require the use of electrostatic precipitators or bag houses to filter out very fine fly ash particulate incorporated in the flue gas. The ash is collected as the flue gas passes through filter bags or by large electrodes, and then falls into collection hoppers.

As the hot fly ash cools, condensate on the hopper walls can form. The mixture of dry, sulfur rich fly ash and water is very problematic, so it's very important to keep condensation from forming in the collection hoppers. The mixture of water and fly ash can cause clogging (or “pluggage”) in the throat of the hopper,  and more importantly, the residual sulphur in the flue gas will combine with the condensate to form sulphuric acid. The suluric acid attacks the hopper walls from the inside causing corrosion, weakening the walls and creating significant (and costly) maintenance issues over time.

Fly ash hopper with heaters.

Efficient and continuous fly ash removal is critical for all coal fired power plants. Collection hoppers are an integral part of the removal process. Pluggage or inoperable hoppers are a known issue to engineers and maintenance crews. The constant maintenance and excess of down time seriously hinder a plant’s ability to manage the fly ash production rate. Slower fly ash production means limiting energy production and efficiency. A power plant’s electricity production is directly proportional with its coal combustion rate which, in turn, directly effects the fly ash production rate. Plant maintenance personnel usually attempt to remedy ash system failures in real time by deactivating the affected hopper while continuing to generate power and ash. In some situations (to prevent boilers shutdowns) ash will be dumped on the floor, requiring costly clean up.

The evacuation and management of fly ash is much easier when the ash is kept hot. One of the most common ways to maintain elevated fly ash and hopper temperature are electric hopper heaters attached to the external hopper walls. Hopper heaters play a very important role in the removal of fly ash from precipitators and bag filter hoppers by keeping the hopper temperatures operating above the flue gas acid dew point. The hopper heater’s sole function is to preheat the hopper and the internal environment to prevent the formation of moisture and the resulting clumping of fly ash and development of sulphuric acid.

Flexible heating element used on hopper throat.

Hopper heaters are designed for the dirty, high vibration environment of a power plant. They provide the optimum watt density for proper conduction through the hopper wall and for uniform heating. The are available in square, rectangular, and trapezoidal shapes to accommodate any hopper design. Ancillary flexible heating blankets are available for poke tubes, man-ways, and cylindrical throats.

The use of electric hopper heaters on electrostatic precipitator and bag house fly ash collection systems is a time proven, effective way to prevent condensate formation and the resulting clumping and corrosive acids in hoppers, thus facilitating a better opportunity for uninterrupted fly ash production.

For more information, contact:

Hotfoil-EHS, Inc.
2960 East State Street Ext.
Hamilton, NJ 08619
Phone # 609.588.0900
Fax # 609.588.8333

Email: dap@hotfoilehs.com

www.hotfoilehs.com