Engineering & Execution of
Electrostatic Precipitators
Guaranteeing 99.9%+ Particulate Capture. Optimizing Plant OPEX.
From greenfield sizing and turnkey mechanical erection to brownfield retrofits. We build and upgrade high-efficiency ESP systems that secure strict environmental compliance without bottlenecking your induced draft (ID) systems.
Precise
System Sizing & Process Engineering
An under-sized ESP risks emission violations; an over-sized one wastes CAPEX. Our engineering team designs precipitators based on exact flue gas chemistry, particulate resistivity, and thermal dynamics.
- Precise Specific Collection Area (SCA) Modeling: We calculate exact migration velocities and SCA requirements tailored to your boiler, kiln, or furnace output.
- Gas Flow Distribution Optimization: Using advanced fluid dynamics principles, we design gas distribution (GD) screens and flow baffles to ensure uniform velocity across the ESP fields.
- The Business Advantage: Prevents localized gas channeling, which causes heavy plate erosion and drastically reduces collection efficiency.
- Structural & Thermal Engineering: We design casings and support structures to withstand high differential temperatures and heavy wind/seismic loads, preventing structural warping over the asset’s lifecycle.
Turnkey
Mechanical Erection & Commissioning
Executing an ESP build requires balancing heavy structural lifting with extreme internal precision. We deliver turnkey erection with a focus on safety, speed, and strict mechanical tolerances.
- High-Precision Internal Alignment: The core of ESP efficiency is the alignment between emitting electrodes and collecting plates. We enforce strict mechanical tolerances during erection to ensure uniform corona generation.
- The Operator Advantage: Misaligned internals cause localized sparking, which wastes TR set power and physically degrades the electrodes. Our alignment protocols prevent this.
- Heavy Lifting & Structural Assembly: Expert site mobilization for the erection of support structures, hoppers, casings, and internal roof frames.
- Integration & Commissioning: Complete mechanical, electrical, and pneumatic integration. We conduct comprehensive dry runs, TR set high-voltage testing, and air-load tests to ensure immediate operational readiness and Performance Guarantee (PG) clearance.
Critical
ESP Spares
& Lifecycle Support
We operate a rapid-response supply chain for high-wear internal and electrical components, ensuring your ESP maintains peak efficiency over a 20+ year lifespan.
- Mechanical Internals: Rigid discharge electrodes, collecting plates (multiple profiles), tumbling hammers, anvil beams, and inner/outer bearings.
- Electrical & Control Hardware: Support and shaft insulators, conventional TR sets, hopper heaters, and advanced microprocessor-based ESP controllers.
Brownfield Retrofits & Capacity Upgrades
Emission limits are tightening globally. We specialize in upgrading legacy, underperforming ESPs during scheduled plant shutdowns to restore or exceed original design efficiencies.
- Internal Component Upgrades: Replacing outdated wire-type electrodes with rigid discharge electrodes (RDE) for higher corona current and improved reliability.
- Field Additions: Engineering and erecting series or parallel field extensions to increase total collection area without bottlenecking existing plant infrastructure.
- Power Supply Modernization: Upgrading conventional Transformer Rectifier (TR) sets to High-Frequency/Three-Phase power supplies for superior voltage control and reduced energy consumption.
- Rapping System Optimization: Re-calibrating or replacing mechanical rapping systems to deliver the exact G-force required to dislodge sticky dust without causing dust re-entrainment.
