Collecting Electrode & Discharge Electrode Retrofit in a Cement Plant

Application

Industry: Cement

Capacity: 1,600TPD

ESP OEM / Information:

OEM: Korea Cottrell

Process: Raw Mill / Kiln

Start of Operation: 1995

Original Type of Electrodes: CE (Sword type), DE (Dura-Trode)

Rapping Design: MIGI Rapper for both CE and DE

Country: Philippines

Problem

Past inspections in the Kiln ESP revealed a major issue as the unit showed signs of aging parts. Collecting Electrode (CE) and Discharge Electrode (DE) systems had started to deteriorate resulting in poor collecting efficiency. Furthermore, such CE and DE designs were obsolete and not anymore available in the market.

Torn CE
Torn CE
Welding failure on CE anvil beam
Welding failure on CE anvil beam
Bent DEs
Bent DEs
Welding failure on CE carrier beam
Welding failure on CE carrier beam
Deformed CE spacers
Deformed CE spacers
Dust build-up on DE
Dust build-up on DE

Solution

Due to design obsolescence, Tai & Chyun proposed to retrofit Dura-Trode DE to Pipe and Spike type and CE to a more improved design. Pipe and Spike DE design provides more aggressive corona current generation particularly at high dust loading. The installation was carried out at the inlet field to handle the heavier dust load.

New design of CE and DE
New design of CE and DE

New design of CE and DE

Benefit

The retrofit to Rigid DE and new CE design allowed the ESP to operate reliably thus preventing emergent or unnecessary shutdowns due to broken / damaged internal parts. Such retrofit also helped the plant keep their emission level below regulation limits and so continuous smooth production could be achieved.

Readings before the retrofit
Readings before the retrofit
Readings after the retrofit
Readings after the retrofit
Emission maintained at 50mg/Nm3
Emission maintained at 50mg/Nm3

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