Technical Tips
ESP Technical Tip
Optimizing Your Precipitator: Power Circuits
In our previous ESP Technical Tip , the first in a series about optimizing your precipitator, we explained why troubleshooting should always start inside the box with a look at plates, discharge electrodes and other internal components. Building on this, your next step is to consider electrical components and how they inter-relate to efficiently feed power into the precipitator--or not.
The two main electrical components to consider are Current Limiting Reactors (CLRs) and T/R sets. The CLR is the primary component that shapes electrical waveforms being fed into the precipitator; it does this by opposing rapid changes in current, using an electromotive force. CLRs also limit current during overload (sparking) conditions. The T/R set is a high voltage transformer and rectifier that converts A/C power to D/C and feeds it into the precipitator.
To efficiently get power into the precipitator, both CLRs and T/R sets need to be appropriate sized in relation to one another and to the ESP field. It takes two to tango, a T/R set and a CLR. If these components are mismatched, the precipitator can't run at peak efficiency.
Ideally, CLRs should be matched with T/R sets in such a way as to provide full primary current at a target conduction angle of between 120 degrees and 150 degrees. For most precipitators, if the conduction angle falls below 100 degrees or so, some losses in collection efficiency will occur. Conversely, conduction angles above 150 degrees have no added benefit.
At many power plants, ESPs were originally built with equally sized (or rated) T/R sets on all the fields. The rating was probably chosen to best suit the outlet collecting fields, since those sections draw the most current. But, this is not an efficient way to distribute power; it creates an immediate power circuit mismatch.
Because of high particulate loading, the inlet fields typically draw 80% less current than the outlet fields. T/R set sizes/ratings should progress from front to back of the ESP, getting increasingly larger.
Matching the size of T/R sets and CLRs to each field's power demands is key to optimizing the power circuit. Result: improved particulate charging, boosted field strength and enhanced overall ESP collection efficiency.
Visit our website to learn more about optimizing the performance of ESP electrical components. Or, call us anytime for advice: (440) 942-8990.
Fabric Filter (Baghouse)Technical Tip
Use Sonic Horns to Enhance R/A and Shaker Cleaning
During the past 25 years, sonic horns--also known as acoustic horns--have been used successfully for supplemental cleaning energy in reverse air and shaker baghouses. The keyword here is "supplemental;" these horns are high-intensity, low-frequency generators that act on dust particles to break their adhesion/bond. Without added energy from other cleaning sources (reverse air, shaking), horns alone cannot effectively clean a baghouse over the long term.
That being said, supplemental acoustic energy can have a significantly positive effect on R/A baghouse and/or shaker cleaning. It's not uncommon to see over three inches of differential pressure improvement just by adding horns.
Not all acoustic horns are the same, and some work better in certain settings than others. The two most important factors to look for when choosing and installing horns: concentrated, low fundamental output frequency, and engineered placement within the collector so that the low tones are not canceled out.
If your baghouse already has horns installed but they don't seem to be having much of an effect, you'll want to make sure they are functioning properly. If the horns have been in place for many years, consider an upgrade. Newer models have a much more focused, low fundamental frequency (around 60 Hz compared with 125 Hz for older models). The supplemental energy from one newer horn is equivalent to about two older ones.
Acoustic horns can also be installed in pulse jet baghouse hoppers to help prevent ash buildup. If wet ash is a common problem, or hoppers aren't deep/steep enough to handle typical ash load without plugging, adding acoustic horns is often a smart move. For this application, the horns are placed into a cylinder which is mounted on the hopper sidewalls. The head of the horn sticks out the side, and the bell protrudes inside.
Visit our website to learn more about using acoustic horns for supplemental cleaning power in baghouses. Or, call us anytime for advice: (440) 942-8990.
Management Change
Steve Ostanek Promoted to New Role at Neundorfer
Neundorfer recently made a noteworthy change to its management team: Steve Ostanek, formerly Vice President of Sales and Marketing, is now President and Chief Operating Officer. Mike Neundorfer, owner and founder, is now Chairman and Chief Executive Officer.
"Steve's new title reflects that fact that he's been with Neundorfer for more than 25 years, and has been taking on more management responsibilities for a while," Mike says. "Steve and I will both continue working directly with customers, and supporting our consulting and training activities. Our work schedules will not substantially change."
In reflecting on his new title, Steve stressed that he got to where he is now with guidance from customers and co-workers.
"I've been successful personally and professional because of lessons learned from those I work with here at Neundorfer, and from our customers," Steve says. "I'll continue drawing on these lessons, and future learning experiences, as I help maintain and enhance our positive company culture, excellent products, and world-class customer service."
He adds: "I am grateful for the opportunity to expand my leadership role."
Steve joined Neundorfer in 1982, and in the years since has contributed to the company's success in many ways: customer relations, process and equipment analysis, training, consulting, strategic planning and personnel development. He holds a Bachelor of Science degree in International Marketing from University of Akron. Steve and his wife, Karen, have been married for 19 years and have two girls, ages 8 and 14. A fitness enthusiast with a passion for running, Steve is also a railroad buff and model train collector.
To learn more about Steve, Mike, and others on the Neundorfer team, visit the neundorfer.com Our People page.
Learning Opportunities
Close Your Knowledge Gaps...
Design a Custom Neundorfer Training Workshop!
If your plant is feeling the pinch of a reduced knowledgebase related to maintaining and troubleshooting air pollution control equipment, call Steve Ostanek (440) 942-8990 x120, or fill out a training needs worksheet and send it to Maggie Zeller, maggiez@neundorfer.com.
Together, we can design a custom, hands-on training workshop to fill your specific knowledge gaps, presented by our experts who have decades of experience with everything from gas flow distribution problems to short fabric filter bag life to ash resistivity issues. These training sessions can be held at your facility or at our headquarters in Willoughby, Ohio.
Learn more about custom training options here.