U.S. patent number 3,650,092 [Application Number 05/064,243] was granted by the patent office on 1972-03-21 for electrogasdynamic precipitator utilizing retarding fields.
This patent grant is currently assigned to Gourdine Systems, Inc.. Invention is credited to Ta Kuan Chiang, Meredith C. Gourdine, Geza Von Voros.
United States Patent |
3,650,092 |
Gourdine , et al. |
March 21, 1972 |
ELECTROGASDYNAMIC PRECIPITATOR UTILIZING RETARDING FIELDS
Abstract
Electrostatic precipitating apparatus in which particles
entrained in a gas stream are charged in an ionization zone
established between one or more ionizer electrodes and a movable
attractor electrode and collected, by reaction with a transverse
precipitation field, in an adjacent downstream zone including a
movable dielectric collection surface. The dielectric collection
surface may be carried by the same conductive member constituting
the attractor electrode. Electric fields that are non-attractive to
the charged particles, and that have components directed against
gas flow, are established in the vicinity of the ionization
zone-collection zone interface, thus increasing collection
efficiency by retarding downstream movement of the particles,
including turbulence in the gas stream, and creating non-linear
precipitation field conditions. A series of such collection zones
or of additional ionization zones and associated collection zones
may be spaced along the gas stream to further enhance precipitation
efficiency and to reduce re-entrainment of particles in the gas
stream. The ionizer and attractor electrodes and the dielectric
collection surfaces are movable to a cleaning zone remote from the
gas stream where collected particles are neutralized and
removed.
Inventors: |
Gourdine; Meredith C. (West
Orange, NJ), Von Voros; Geza (Glen Rock, NJ), Chiang; Ta
Kuan (Berkeley Heights, NJ) |
Assignee: |
Gourdine Systems, Inc.
(Livingston, NJ)
|
Family
ID: |
22054559 |
Appl.
No.: |
05/064,243 |
Filed: |
August 17, 1970 |
Current U.S.
Class: |
96/40;
310/11 |
Current CPC
Class: |
B03C
3/10 (20130101); B03C 3/12 (20130101) |
Current International
Class: |
B03C
3/12 (20060101); B03C 3/10 (20060101); B03C
3/04 (20060101); B03c 003/10 () |
Field of
Search: |
;55/2,12,13,14,108,109,110,111,112,113,114,115,116,121,136,137,138,139,141,142 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
1,130,602 |
|
Oct 1956 |
|
FR |
|
365,018 |
|
Jan 1932 |
|
GB |
|
716,868 |
|
Oct 1954 |
|
GB |
|
Primary Examiner: Talbert, Jr.; Dennis E.
Claims
We claim:
1. Apparatus for electrostatically precipitating particles
entrained in a gas stream comprising:
means defining at least one surface adjacent to and movable along
the gas stream boundary;
means, including at least one ionizer electrode, defining an
ionization zone at an upstream region of the movable surface for
imparting unipolarity electric charges to the entrained
particles;
means defining a collection zone at an adjacent downstream region
of the movable surface; and
means for establishing electric fields in the gas stream in the
vicinity of the ionization zone-collection zone interface that are
non-attractive to the charged particles and that have components in
opposition to the gas flow thereby to retard particle flow
downstream, the field establishing means including the region of
the movable surface within the collection zone being constructed of
dielectric material and the region within the ionization zone being
constructed of electrically conductive material, and further
including high-potential electrode means, of like polarity as the
ionizer electrode, located within the collection zone in spaced
relation to the downstream edge of the electrically conductive
region of the surface to establish with the electrically conductive
region an electric field extending in the upstream direction.
2. Apparatus according to claim 1 further comprising:
means for moving the surface to a cleaning zone remote from the gas
stream; and
means at the cleaning zone for removing particles from the
conductive and dielectric regions of the surface.
3. Apparatus according to claim 2 in which the movable surface
comprises an endless belt structure, and in which the means for
moving the surface includes drive means for successively moving the
conductive and dielectric regions of the surface through the
ionization and collection zones, respectively, and the cleaning
zone.
4. Apparatus according to claim 2 in which the cleaning means
includes means for neutralizing the charges remaining on the
collected particles to facilitate the removal thereof from the
surface.
5. Apparatus according to claim 4 in which the cleaning means
comprises at least one electrically conductive brush and the means
for neutralizing the charges comprises a conductor connecting the
brush to electrical ground.
6. Apparatus according to claim 1 further comprising means for
retaining charged particles collected on the dielectric region of
the surface against forces tending to re-entrain them in the gas
stream.
7. Apparatus according to claim 6 in which the particle retaining
means comprises an electrically conductive member located closely
adjacent the dielectric region and exterior to the gas stream.
8. Apparatus according to claim 7 in which the upstream portion of
the electrically conductive member forms the conductive region of
the movable surface.
9. Apparatus according to claim 8 in which the dielectric region of
the surface comprises a dielectric layer on the electrically
conductive member.
10. Apparatus according to claim 1 in which the means for defining
the ionization zone includes a plurality of ionizer electrodes
spaced along the conductive region of the surface in the direction
of gas flow and arranged in the same plane relative to the
conductive region.
11. Apparatus according to claim 10 in which the spacing between
adjacent electrodes is at least as great as 1 1/4 the distance from
the plane of the ionizer electrodes to the plane of the conductive
region of the surface.
12. Apparatus according to claim 1 further comprising a plurality
of collection zones spaced along the movable surface downstream
from the ionization zone.
13. Apparatus according to claim 1 in which the means defining the
collection zone includes a high-potential passive electrode, of
like polarity as the ionizer electrode, located in spaced, parallel
relation to the dielectric region of the movable surface, and in
which the high-potential electrode means comprises the upstream end
of the passive electrode.
14. Apparatus according to claim 13 in which the upstream end of
the passive electrode is spaced at least no farther upstream than
the upstream edge of the dielectric region of the surface.
15. Apparatus according to claim 14 in which the upstream end of
the passive electrode is located downstream of the upstream end of
the dielectric region a distance no greater than fifteen-sixteenths
the distance between the plane of the electrode and the plane of
the conductive region of the surface.
16. Apparatus according to claim 13 in which the means defining the
ionization zone includes a plurality of electrodes spaced along the
conductive region of the surface in the direction of gas flow, and
in which the ionizer electrode nearest to the passive electrode is
spaced from the upstream end of the passive electrode a distance at
least as great as 1 1/4 the distance between the plane of the
ionizer electrodes and the plane of the conductive region of the
surface.
17. Apparatus according to claim 16 in which the ionizer electrodes
and passive electrode are aligned in the direction of gas flow.
18. Apparatus according to claim 1 in which the high-potential
electrode means comprises a precharging ionizer electrode located
within the collection zone in overlying relation to the upstream
portion of the dielectric region of the surface, thereby to
maintain the charge level on the upstream portion of the dielectric
region independent of the charges carried to the dielectric surface
by the collected particles.
19. Apparatus according to claim 18 in which an air gap is formed
in the movable surface between the upstream edge of the dielectric
region and the downstream edge of the conductive region.
20. Apparatus according to claim 19 in which the width of the air
gap is at least 0.063 inches per kilovolt per inch of the average
field strength between the plane of the precharging electrode and
the plane of the conductive region of the surface, but not less
than 0.125 inches.
21. Apparatus according to claim 19 in which the precharging
electrode is spaced downstream from the upstream edge of the
dielectric region by a distance no greater than five-sixteenths the
distance between the plane of the precharging electrode and the
plane of the conductive region of the surface.
22. Apparatus according to claim 18 in which the collection zone
defining means includes a high-potential passive electrode, of like
polarity as the precharging electrode, located in spaced, parallel
relation to the dielectric region of the surface.
23. Apparatus according to claim 22 in which the upstream end of
the passive electrode is spaced from the precharging electrode a
distance at least as great as 1 1/4 the distance between the plane
of the precharging electrode and the plane of the conductive region
of the surface.
24. Apparatus according to claim 23 in which the passive electrode
and the precharging electrode are aligned in the direction of gas
flow.
25. Apparatus for electrostatically precipitating particles
entrained in a gas stream comprising:
means defining at least one surface adjacent to and movable along
the gas stream boundary;
means, including at least one ionizer electrode, defining an
ionization zone at an upstream region of the movable surface for
imparting unipolarity electric charges to the entrained
particles;
means defining a plurality of collection zones at spaced downstream
regions of the movable surface;
means defining a termination zone between adjacent collection
zones; and
means for establishing electric fields in the gas stream in the
vicinity of the ionization zone-collection zone interface, and at
the interface of each termination zone and collector zone, that are
non-attractive to the charged particles and that have components in
opposition to the gas flow thereby to retard particle flow
downstream, the field establishing means including the region of
the movable surface within each collection zone being constructed
of dielectric material and the regions within the ionization zone
and each termination zone being constructed of electrically
conductive material, and further including a high-potential passive
electrode, of like polarity as the ionizer electrode, located
within each collection zone in spaced relation to the downstream
edge of the preceding electrically conductive region of the surface
to establish between the upstream end of the passive electrode and
the electrically conductive region an electric field extending in
the upstream direction.
26. Apparatus according to claim 25 in which the downstream end of
the passive electrode of each collection zone in advance of the
trailing collection zone is located downstream of the downstream
edge of the dielectric region of the zone.
27. Apparatus according to claim 26 in which the downstream end of
each passive electrode in advance of the trailing zone is located
downstream of the downstream edge of the associated dielectric
region a distance at least as great as five-sixteenths the distance
between the plane of the electrode and the plane of the associated
conductive region of the surface.
28. Apparatus according to claim 26 in which the upstream end of
each succeeding passive electrode is spaced from the downstream end
of the next preceding passive electrode a distance at least as
great as 1 1/4 the distance between the plane of the electrode and
the plane of the associated conductive region of the surface.
29. Apparatus for electrostatically precipitating particles
entrained in a gas stream comprising:
means defining at least one surface adjacent to and movable along
the gas stream boundary;
means defining with the movable surface a plurality of ionization
zones spaced along the surface in the direction of gas flow for
imparting unipolarity electrical charges to the entrained
particles, at least the foremost ionization zone including at least
one ionizer electrode;
means defining with the movable surface a collection zone
downstream of and adjacent to each ionization zone; and
means for establishing electric fields in the gas stream in the
vicinity of each ionization zone-collection zone interface that are
non-attractive to the charged particles and that have components in
opposition to the gas flow thereby to retard particle flow
downstream, the field establishing means including the region of
the movable surface within each collection zone being constructed
of dielectric material and the region within each ionization zone
being constructed of electrically conductive material, and further
including high-potential electrode means, of like polarity as each
ionizer electrode, located within each collection zone in spaced
relation to the downstream edge of the electrically conductive
region of the preceding ionization zone to establish with said
electrically conductive region an electric field extending in the
upstream direction.
30. Apparatus according to claim 29 further comprising:
means for moving the surface to a cleaning zone remote from the gas
stream; and
means at the cleaning zone for removing particles from the
conductive and dielectric regions of the surface.
31. Apparatus according to claim 29 further comprising means for
retaining charged particles collected on the dielectric regions of
the surface against forces tending to re-entrain them in the gas
stream.
32. Apparatus according to claim 31 in which the particle retaining
means includes an electrically conductive member located closely
adjacent each dielectric region and exterior to the gas stream.
33. Apparatus according to claim 32 in which the conductive member
is coextensive with the movable surface and forms the conductive
regions of the surface.
34. Apparatus according to claim 33 in which the dielectric regions
of the surface comprise spaced dielectric layers on the
electrically conductive member.
35. Apparatus according to claim 29 in which the means defining the
collection zones includes in each collection zone a high-potential
passive electrode, of like polarity as the ionizer electrode,
located in spaced, parallel relation to the dielectric region of
the zone, and in which the high-potential electrode means in each
zone comprises the upstream end of the passive electrode.
36. Apparatus according to claim 35 in which the upstream end of
each passive electrode is spaced at least no farther upstream than
the upstream edge of the dielectric region of the zone.
37. Apparatus according to claim 36 in which the upstream end of
each passive electrode is located downstream of the upstream edge
of the dielectric region a distance no greater than
fifteen-sixteenths the distance between the plane of the electrode
and the plane of the associated conductive region of the
surface.
38. Apparatus according to claim 37 in which each ionization zone
includes at least one ionizer electrode.
39. Apparatus according to claim 38 in which the foremost ionizer
electrode of each successive ionization zone is spaced from the
downstream end of the next preceding passive electrode a distance
at least as great as 1 1/4 the distance between the plane of the
ionizer electrodes and the plane of the associated conductive
region of the movable surface.
40. Apparatus according to claim 39 in which the upstream edge of
the dielectric region of each succeeding collection zone is spaced
downstream from the downstream end of the next preceding passive
electrode by a distance at least as great as twenty-five sixteenths
the distance between the plane of the electrode and the plane of
the associated conductive region of the surface.
41. Apparatus according to claim 29 in which the high-potential
electrode means in each collection zone comprises a precharging
ionizer electrode located within the collection zone in overlying
relation to the upstream portion of the dielectric region of the
zone, thereby to maintain the charge level on the upstream portion
of the dielectric region independent of the charges carried to the
dielectric surface by the collected particles.
42. Apparatus according to claim 41 in which an air gap is formed
in the movable surface between the upstream edge of the dielectric
region of each collection zone and the downstream edge of the
conductive region of the adjacent ionization zone.
43. Apparatus according to claim 42 in which the width of each air
gap is at least 0.063 inches per kilovolt per inch of the average
field strength between the plane of the precharging electrode and
the plane of the associated conductive region of the surface, but
not less than 0.125 inches.
44. Apparatus according to claim 42 in which each precharging
electrode is spaced downstream from the upstream edge of the
dielectric region of the zone by a distance no greater than
five-sixteenths the distance between the plane of the precharging
electrode and the plane of the associated conductive region of the
surface.
45. Apparatus according to claim 41 further comprising a
high-potential passive electrode, of like polarity as the
precharging electrode, in each collection zone located in spaced,
parallel relation to the dielectric region of the zone.
46. Apparatus according to claim 45 in which each precharging
electrode is spaced downstream from the downstream end of the next
preceding passive electrode by a distance at least as great as 1
1/4 the distance between the plane of the precharging electrode and
the plane of the associated conductive region of the surface.
47. Apparatus according to claim 1 further comprising:
means for moving each ionizer electrode to a cleaning zone remote
from the gas stream; and
means at the cleaning zone for removing particles collected on each
ionizer electrode.
48. Apparatus according to claim 29 further comprising:
means for moving each ionizer electrode to a cleaning zone remote
from the gas stream; and
means at the cleaning zone for removing particles collected on each
ionizer electrode.
Description
BACKGROUND OF THE INVENTION
The present invention relates to the electro-static precipitation
of particles entrained in a gas stream and, in particular, to
apparatus for achieving high precipitating efficiency, while
affording significant reductions in the size of precipitator units,
through the establishment of electric fields tending to retard
movement of the entrained particles through the precipitator.
Conventional practice in the electrostatic precipitator technology
has been to precipitate particles carried by a gas stream by
passing the particles through a transverse electric field in which
the particles both acquire electrical charges and are caused to be
brought into contact with a collection surface. This is the
familiar single-stage or Cottrell precipitator. Alternatively, the
particles may be charged and collected in a two-stage operation,
including an upstream charging field and a separate precipitation
field located in a downstream region of the stream. A precipitator
of this type is, for example, disclosed in U.S. Pat. No. 2,318,093,
issued to Penney on May 4, 1943.
Both foregoing types of precipitators, however, utilize charging
and precipitation fields in which the chief component is directed
transverse to the gas stream, with little or no component oriented
parallel to the gas flow. Moreover, such parallel components as do
occur are generally balanced in both the upstream and downstream
directions, so that no net electric repelling force exists to
retard downstream movement of the charged particles. Accordingly,
the particles move through the precipitators at virtually the speed
of the gas stream. The residence time of any given particle within
the precipitation field is thus determined by the gas stream
velocity. Hence to increase residence time in such precipitators,
with the object of increasing efficiency of collection by
prolonging particle exposure in the precipitation field, it is
necessary to decrease the velocity of the gas stream or enlarge,
usually by lengthening, the collection zone. Neither of these steps
is desirable, however, as the former requires a reduction in
throughput capacity and the latter an increase in the size of the
precipitating unit.
Typically, the removal of particles deposited on the collection
surfaces of the foregoing prior art precipitation systems is
accomplished by vibrating or rapping the surfaces, which may be in
the form of plates positioned along the gas stream, to dislodge the
particles. However, this causes a substantial amount of
re-entrainment of the particles in the gas stream. These
re-entrained particles must be recharged and again collected for
efficient cleaning of the gas stream. The prior art solution has
been to lengthen the collection zone to compensate for such
re-entrainment of particles during the cleaning operation. Attempts
to produce high efficiency, on the order of 99%, for example, units
by this approach have resulted in significant increases in the
overall size and complexity of the precipitation system.
Manufacturing costs, of course, are correspondingly increased.
A further difficulty associated with known precipitation techniques
is that the operative elements of the particle charging and
precipitation zones, e.g., the ionizer and attractor electrodes and
the particle collection surfaces, in time become saturated with
precipitated particles, so that the charging or precipitation
fields, or both, are quenched to the point that further particle
collection is impeded. Such quenching of the charging and
precipitating fields results in reduced collection efficiencies
since, on the one hand, the electric charge imparted to each
particle will drop in value as the charging field becomes weaker
and, on the other, the electrostatic forces tending to move the
particles to the collection surface will also be of a lower
magnitude by virtue of the combined effect of the lower particle
charge and the decreased field strength of the precipitation field.
This situation is aggravated, and collection efficiency still
further reduced, when particles of low conductivity are being
precipitated, a common circumstance in many industrial and
environmental applications.
Efforts directed toward overcoming the foregoing difficulties
associated with cleaning of the collection surfaces and quenching
of the ionization and/or precipitation fields, have included the
use of moving electrodes that are cleaned at quiescent locations so
as to minimize re-entrainment and to avoid field deterioration.
Some measure of improvement in performance has been achieved in
this way. But current technology has failed to recognize that
important advantages are obtainable through the appropriate
utilization of such cleaning and field maintenance procedures in
combination with and complementary to the establishment of particle
retarding electric fields in the gas stream.
These and other disadvantages of prior art precipitation systems
are overcome by the present invention.
SUMMARY OF THE INVENTION
In accordance with the invention, a movable surface having one or a
series of associated conductive regions and dielectric regions,
spaced alternately in the direction of gas flow, is located along a
boundary of the gas stream. Particles entrained in the gas stream
are charged electrically in an ionization zone or zones established
with one or more of the conductive regions of the movable surface
and are thereafter precipitated in a collection zone or zones
established with the downstream dielectric regions of the surface.
Movement of the charged particles through the precipitator is
retarded, and the residence time of the particles within the
precipitator increased, by electric fields set up in the gas stream
in the vicinity of each ionization zone-collection zone interface.
For this purpose, the geometries of adjacent ionization zones and
collection zones are such that electric fields that are
non-attractive to the charged particles and that have components in
opposition to the gas flow are established across the zone
interfaces.
Significant advantages contributing to increased collection
efficiency are realized by the use of particle retarding fields.
Notably, increased residence time in the ionization and
precipitation fields yields more effective movement of the
particles to the collectors; eddy currents induced in the gas
stream by rearwardly directed force lines lead to an increased
incidence of collision between particles and thus to agglomeration
of the particles and a consequent increase in electrostatic
mobility; and the average precipitation field strength is elevated
due to the creation of a non-linear field at the area of transition
between ionization and collection zones.
In preferred embodiments, the movable surface is constituted by a
single conductive member, with each dielectric region of the
surface being formed by a layer of dielectric material on the
surface of the member facing the gas stream. The region of the
conductive member immediately upstream of the respective dielectric
layers then forms the associated conductive region of the surface.
Other constructions of the movable surface may be used, including
the use of a dielectric member having one or more strips of
conductive material provided on the facing surface.
Each ionization zone preferably is formed by a plurality of ionizer
electrodes positioned in opposed spaced relation to a conductive
region of the surface, which functions as an attractor electrode
for corona discharges emanating from the ionizer electrodes. A
transverse precipitation field extending from a high-potential
passive electrode, desirably in the plane of the ionizer
electrodes, is established in each collection zone normal to the
corresponding dielectric region of the surface.
During operation, charged particles and molecular ions are
collected rapidly at the upstream areas of each dielectric region,
where they set up electric fields terminating at the downstream
area of the preceding conductive region. These fields, being
non-attractive to the charged particles, have a repelling effect on
the charged particles and therefore slow downstream movement of the
particles. As a result, the particles remain within the influence
of the ionization and precipitation fields for a longer time,
acquire higher electric charges, and thus are moved in a shorter
trajectory to the dielectric collection surface. Particle movement
is most influenced by the retarding fields when laminar flow
conditions prevail in the gas stream, but improved collection
efficiency is obtained with turbulent flow as well since residence
time is thereby prolonged.
In one embodiment, additional particle retarding fields are
maintained in the gas stream by appropriate positioning of the
upstream end of the passive electrode in each collecting zone.
Preferably, the passive electrode is located so that the upstream
end is at least no farther upstream than the leading edge of the
associated dielectric region of the surface. By this configuration,
the change in the magnitudes and directions of the electric field
lines is created between the upstream end of the passive electrode
and the downstream area of the adjacent upstream conductive region.
As the polarity of each passive electrode is the same as that of
the charged particles, an electric force in opposition to particle
flow is thus set up in the gas stream, with the result that the
rate of particle flow relative to the gas stream is decreased.
In another embodiment, each passive electrode is spaced farther
downstream and a pre-charging ionizer electrode is located within
the collection zone in spaced relation to the upstream edge of the
associated dielectric region. A corona discharge occurs between the
pre-charging electrode and the adjacent conductive region, thereby
setting up an electrostatic force directed in opposition to
particle flow. A further advantage of this configuration is that it
enhances the retarding field set up by the particles and ions
deposited on the upstream area of the dielectric region. This
results by virtue of a field being established between the
precharging ionizer and the upstream area of the dielectric region,
so that a significant portion of the charges generated by the
ionizer electrode is attracted to and retained on the dielectric
surface. Such "pre-charging" of the leading area of the collector
surface assures a high charge level irrespective of the rate at
which charges are carried to the surface by the collected
particles. The strength of the retarding fields is therefore
preserved at all times.
To prevent reverse corona conditions from arising at the ionization
zone-collection zone interface when a precharging ionizer is used,
particularly at high operating potentials, or when high resistivity
particulate materials are collected, an air gap is interposed
between the downstream edge of the attractor region and the leading
edge of the dielectric region. The air gap is sized to reduce
electrical stresses across the interface to below corona initiation
conditions.
According to still another aspect of the invention, particles
collected on the conductive regions and dielectric regions of the
movable surface are removed at a cleaning zone located remote from
the gas stream to avoid re-entrainment of the collected particles.
For greater cleaning efficiency, neutralization of the particle
charges accompanies the cleaning operation. If desired, the ionizer
electrodes, including the pre-charging ionizer, may also be movable
to a remote location for cleaning.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference may be made
to the following description of exemplary embodiments, taken in
conjunction with the figures of the accompanying drawings, in
which:
FIG. 1 is a sectional view of one embodiment of an electrostatic
precipitator constructed in accordance with the invention, showing
the distribution of the electric fields established within the
ionization and collection zones;
FIG. 2 is a sectional view of a second embodiment of the invention,
also showing electric field patterns within the precipitator;
FIG. 3 is a sectional view of a cascaded-zone precipitator unit
having the basic configuration of FIG. 1, but including an
additional collection zone;
FIG. 4 portrays still a further variation of the embodiment of FIG.
1, in which a series of associated ionization zones and collection
zones are spaced along the gas stream;
FIG. 5 is a sectional view of another plural-zone precipitator
according to the invention, showing the use of multi-point ionizer
electrodes, but with the field lines within the ionization and
collection zones omitted for clarity;
FIG. 6 is a sectional view of a further embodiment of the
invention, depicting the configuration of FIG. 3 incorporated into
a cascaded-zone precipitator;
FIG. 7 illustrates yet another embodiment of the invention, in
which an extended ionizer module is used in the collection
zone;
FIG. 8 is a pictorial illustration of a precipitator embodying
certain novel features of the invention, and in which the movable
surface constitutes an endless belt structure;
FIG. 9 is a graph depicting collection efficiency percentage
(.eta..sub.c) versus .lambda. for Cottrell precipitation systems;
and
FIG. 10 is a bar graph portraying collection area (in.sup.2) versus
collection efficiency percentage (.eta..sub.c).
DESCRIPTION OF AN EXEMPLARY EMBODIMENT
As illustrated in FIG. 1, a representative embodiment of the
invention includes a pair of spaced members 10 and 12 that define
the boundaries of a gas stream (indicated by the arrows) from which
dust particles, such as the fly ash entrained in the exhaust gases
of incinerator stacks or the like, are to be removed. Preferably,
the members 10 and 12 are electrically conductive and, as
illustrated, connected to electrical ground. They may, however, be
maintained at any appropriate reference potential.
In accordance with the invention, an upstream region 14 and 16 of
the members 10 and 12, respectively, is exposed to the gas stream.
Downstream from these conductive regions, the members 10 and 12 are
blocked from exposure to the gas flow by bodies 18 and 20 of
dielectric material, thus defining dielectric regions 22 and 24
along the downstream extent of the members 10 and 12. Preferably,
the dielectric bodies 18 and 20 constitute layers formed on the
surfaces of the members 10 and 12, but an independent construction
may be used and the members 10 and 12 may take the form of
conductive substrates located behind the dielectric bodies.
Similarly, the conductive and dielectric regions, for example, the
regions 14 and 22, respectively, of the member 10, need not be
carried by the same member, although for simplicity of construction
it is preferable that they are.
If desired, the members 10 and 12 may be constructed of dielectric
material and the conductive region of each member might then be
constituted by a conductive strip carried by the facing surface of
the member. With this arrangement, a conductive substrate would be
located adjacent to the dielectric region of each member and
external to the gas stream to provide a reference electrode to
maintain a strong electric field tending to hold the collected
particles on the dielectric surface.
Regardless of the specific construction used, however, the
conductive and dielectric regions together define a surface located
in proximity to the gas stream. As explained more fully
hereinafter, this surface is supported in a manner to be movable to
a quiescent location for cleaning.
One or more ionizer electrodes 26 are located centrally of the
members 10 and 12 opposite the conductive regions 14 and 16, and a
passive electrode 28 is disposed in spaced relation to the
dielectric regions 22 and 24. The ionizer electrodes 26 and the
passive electrode 28 desirably are located in the same plane
relative to the members 10 and 12.
As schematically illustrated in FIG. 1, the ionizer electrodes 26,
depicted as elongate wire-like elements, are connected to a power
source 30 to set up a corona discharge in the gas stream between
the wires 26 and the conductive regions 14 and 16 of the members 10
and 12. For clarity, only half of the field distribution lines are
shown in FIG. 1, but it will be apparent that the corona discharge
field surrounding each electrode 26 is symmetrical.
In a like manner, the passive electrode 28 is connected to a power
source 32 of the same polarity as the source 30 to establish a
precipitation field normal to the dielectric regions 22 and 24.
Again, the field lines in this respect are shown in FIG. 1 over
only one-half of the unit. Although a separate source 32 is
illustrated for driving the passive electrode 28, the electrode 28
may, if desired, be connected to the same source 30 used for the
ionizer electrodes 26. Also, while four ionizer electrodes are
depicted in FIG. 1, this is for illustrative purposes only and any
suitable number may be used.
Dust particles entering the precipitator are impressed with
unipolarity electrical charges upon traversing the ionization zone
defined by the ionizer electrodes 26 and the conductive regions 14
and 16, which function as attractor electrodes for the corona
discharge currents emanating from the ionizer electrodes.
Thereafter, the charged particles enter the collection zone, which
functionally may be considered as beginning at the upstream edges
of the dielectric regions 22 and 24, although some particle
collection does, of course, occur on the conductive regions 14 and
16 within the ionization zone. Most particles, however, pass
through the ionization zone and are deposited on the dielectric
surfaces of the collection zone.
It is a feature of this invention that, complementary to the
transverse ionization and precipitation fields, additional electric
fields are established in the vicinity of the interface, indicated
generally in FIG. 1 at 34, of the ionization and collection zones.
These fields are non-attractive to the charged particles and have
components directed in opposition to particle flow. The existence
of such non-attractive or repelling fields in the gas stream
results in electric repulsion forces being exerted against the
downstream movement of the charged particles, causing them to slow
down relative to the velocity of the gas stream. Accordingly, the
individual particles remain in the transverse ionization and
precipitation fields for a longer time, acquire higher electrical
charges, and hence are caused to be moved more effectively to the
collection surfaces. Thus, fewer particles escape through the
outlet end of the precipitator.
Other benefits are also derived from the presence of the retarding
fields. For instance, a certain degree of turbulence, i.e., eddy
currents, is generated in the gas stream by the upstream field
components. Such turbulence induces chaotic motion of the particles
within the stream, with the result that the incidence of collision
among the particles is increased. Since particles tend to
agglomerate upon colliding and because large particles acquire
charges more rapidly then do small particles, greater
electro-static mobility is therefore imparted to the particles. The
particles, as a consequence, drift toward the collection surfaces
at an increased rate. Collection efficiency is thereby further
enhanced.
Precipitation is still further aided by the retarding fields
inasmuch as a non-linear field condition is created in the vicinity
of transition from a conductive region to a dielectric region. The
effect is to increase the average precipitation field strength in
the transitional area. An obvious contribution to improved
collection performance results.
Referring to FIG. 1, one such electric retarding field is seen as
being established across the ionization zone-collection zone
interface between the leading area of the dielectric region 22 and
the adjacent downstream area of the conductive region 14. This
occurs because the charged particles and molecular ions collected
on the dielectric region 22 are prevented from leaking their
charges to the grounded member 10. Consequently, a high-strength
electrical disruption exists across the interface 34. Charged
particles entering the area of this disruption encounter a
repulsive force in the upstream direction and are accordingly
slowed in their downstream movement. This effect is especially
pronounced when gas flow is laminar.
A further electric field having a component in opposition to
particle flow is established in one embodiment of the invention by
appropriate positioning of the passive electrode 28. More
specifically, the passive electrode is located such that its
upstream end 36 extends no farther upstream than the upstream end
of the dielectric region 22. With the passive electrode thus
positioned, a high-strength electrical disruption is established
across the gas stream between the end 36 of the passive electrode
and the downstream area of the conductive region 14. A similar
disruption (not shown) is of course established with the conductive
region 16. Inasmuch as the passive electrode 28 extends across the
full width of the gas stream, that is to say, in a direction
perpendicular to the plane of FIG. 1, all charged particles in the
stream will be subjected to the retarding forces of this field.
The beneficial effects of these retarding fields on the collection
process may be further appreciated by consideration of the
following simplified analysis. The precipitating or collection
efficiency (.eta.c), assuming uniform charging in the ionization
zone and negligible re-entrainment of collected particles, may be
expressed as:
(1) .eta.c = 1-e.sup.-
and the coefficient .lambda. as:
(2) .lambda. = [v.sub.dy /v.sub.p ] [1/d] = k.sub.p E.sub.p
l/v.sub.p d
where:
v.sub.dy is the drift velocity of a particle perpendicular to the
collector surface (meters per second);
v.sub.dx is the particle drift velocity in the upstream direction
imparted by the retarding electric fields (meters/seconds);
v.sub.g is the gas velocity (meters/seconds);
v.sub.p = v.sub.g - v.sub.dx, i.e., the actual particle velocity
downstream (meters/seconds);
1 is the length of the precipitation zone (meters);
E.sub.p is the average precipitation field strength (volts per
meter);
d is a multiple of the distance between the plane of the passive
electrode and the plane of the surface (meters); and
k.sub.p is particle mobility in an electrostatic field
(meters.sup.2 /volt-second).
Typical values of collection efficiency (.eta..sub.c) for specific
values of .mu. are tabulated in Table I.
---------------------------------------------------------------------------
TABLE I
.lambda. .eta. c(%)
__________________________________________________________________________
0 0 2 86.5 3 95.0 4 98.0 7 99.0
__________________________________________________________________________
Analyzing equations (1) and (2), it is apparent that for a
precipitator having given values of 1 and d the magnitude of
.lambda., and hence the collection efficiency (.eta..sub.c), may be
increased by increasing k.sub.p and/or E.sub.p, or by decreasing
the value of v.sub.p. With this in mind, it is clear that
significant advantages in precipitator performance are attributable
to the presence of retarding fields within the gas stream, since
all three of these desired parameter changes are thereby
realized.
As previously described, k.sub.p is increased by the agglomeration
mechanism produced by the retarding fields, and E.sub.p is
increased by the creation of a non-linear precipitation field in
the area of transition between the ionization zone and the
collection zone, as is clearly depicted in FIG. 1. Also, as pointed
out above, the net particle velocity (v.sub.p) in the downstream
direction is lower than the gas velocity, due to the slowing
influence of the electric repulsion forces set up by the retarding
fields.
Conversely, for a given collection efficiency (.eta.c) reductions
in the size of the precipitator unit required to obtain that
particular efficiency may be achieved in accordance with the
present invention. Turning again to equations (1) and (2), it may
be seen that the length of the precipitation zone 1 may be
decreased if k.sub.p and/or E.sub.p is increased or if v.sub.p is
decreased, assuming a constant value of d. It has already been
shown that the values of all three parameters are improved through
the use of the retarding electric fields of the present invention.
Accordingly, it is obvious that the utilization of such fields
allows the reduction of precipitator size, through reduction in the
length of the precipitation zone required, without sacrifice of
collection efficiency.
A further benefit of the invention is that it allows optimization
of the parameters of equation (2) in order to obtain a high
.lambda. value, and accordingly a high collection efficiency
(.eta.c), while keeping 1 (collector size) as small as possible.
Experiments have established, for example, certain preferred values
of h (see FIG. 1) which give good ionizer performance without
unduly lengthening the ionization zone. An appropriate value of h,
which is measured from the emission surface of the electrode, in
this respect has been found to be 11/4 the distance between the
plane of the electrodes 26 and the plane of the conductive region
14. The term "plane of electrodes" refers to the plane containing
the emission surfaces of the electrodes nearest to the facing
conductive region. The ionizer electrodes 28 may be positioned
farther apart than the foregoing value of h at little or no loss in
charging efficiency, but with some sacrifice in compactness of the
ionization zone. On the other hand, some loss in ionizer
performance results if the electrodes are spaced closer together
than 11/4 the distance to the plane of the conductive regions 14 or
16.
To further optimize ionizer performance, the foremost ionizer
electrode should be located at least as far as 3/4 h (see FIG. 1)
downstream from the upstream edge of the conductive region 14 or
16. This assures that there will be no downstream distortion of the
ionization field due to unduly high current flow to the leading
ionizer electrode.
Similarly, for best results, the distance f in FIG. 1, i.e., the
distance between the upstream edge of the dielectric region 22 and
the leading end 36 of the passive electrode 28, should not exceed
fifteen-sixteenths the distance between the plane of the electrodes
26 and the plane of the conductive region 14. If the end 36 is more
distantly located from the upstream edge of the region 22, a
retarding field might still be created with the downstream areas of
the conductive regions 14 and 16, but the length of the
precipitation zone would be unnecessarily enlarged.
Other preferred dimensions are indicated in FIG. 1 and the other
figures of the drawings. It will be understood, of course, that
these are merely illustrative of preferred values and that other
configurations and locations of the various components may be used
without departing from the scope of the invention.
The above-described beneficial effects of the electric retarding
fields, and particularly those due to the buildup of charges on the
upstream areas of the dielectric regions, are further enhanced in
the embodiment of the invention represented in FIG. 2. It
incorporates generally the same overall organization as that of
FIG. 1, except for the location of the trailing ionizer electrode
38, the position of the passive electrode 40, and the formation of
an air gap 42 at the interface of the ionization and collection
zones.
As shown in FIG. 2, the trailing electrode 38 is positioned in
overlying relation to the upstream area of the dielectric regions
44 and 46 of the collection zone. So positioned, a corona discharge
is established in the upstream direction between the electrode 38
and the downstream area of the conductive regions 48 and 50, and a
strong electrical disruption terminating at the upstream area of
the dielectric regions 44 and 46 is also set up. Therefore, not
only is a retarding field maintained between the ionizer electrode
38 and the conductive regions 48 and 50, but the charge level on
the upstream areas of the dielectric regions leading to the
establishment of electric retarding fields between the dielectric
and conductive regions is maintained at a high order of magnitude
irrespective of the rate at which charges are carried to the
dielectric regions by collected particles. By thus "precharging"
the adjacent areas of regions 44 and 46, the electrode 38 assures
that substantial electrostatic forces will be maintained in
opposition to the gas stream at all stages of operation.
Although the ionizer electrode 38 is physically located within the
collection zone, some particle charging occurs by virtue of the
corona current between the electrode 38 and the conductive regions
48 and 50. In effect, therefore, the zone of ionization extends to
the upstream ends of the dielectric regions 44 and 46,
notwithstanding that an air gap 42 is formed between the conductive
and dielectric regions.
For optimum performance, the electrode 38 should be positioned
downstream from the upstream edges of the dielectric regions 44 and
46 at least as far as five-sixteenths the distance between the
plane of the ionizer electrodes, including, of course, the
precharging electrode 38, and the plane of the conductive region 48
or 50. In the same vein, superior operating conditions are achieved
when the upstream end of the passive electrode 40 is spaced from
the precharging electrode 38 by a distance at least as great as
11/4 the distance between the electrodes and the conductive
regions.
At high operating potentials, high charge levels are impressed on
the upstream areas of the dielectric regions 44 and 46 by the
precharging electrode 38. This gives rise to very high electrical
stresses across the ionization zone-collection zone interface,
tending to initiate reverse corona conditions in the vicinity of
particles collected on the grounded conductive regions 48 and 50.
Reverse corona conditions are especially likely to occur when
particulate materials having a resistivity greater than about
10.sup.9 ohm-centimeters are being collected. It is to avoid the
creation of such corona conditions that an air gap 42 is interposed
between the conductive and dielectric regions.
Desirably the size w (see FIG. 2) of the air gap is at least as
great as 0.063 inches per kilovolt per inch of the average field
strength between the precharge ionizer 38 and the planes of the
conductive regions 48 and 50. However, to assure that reverse
corona discharges will not occur even at low potentials, w should
not be less than 0.125 inches. An air gap sized in this manner
reduces the electrical stress between the conductive and dielectric
regions to below corona initiation levels.
Still further advantages of increased collection efficiency and
size reduction are obtainable if a plurality of collection zones or
a series of ionization zones followed by associated collection
zones are spaced along the gas stream. With such plural-zone, or
cascaded-zone, configurations, the extent of the individual
ionization zones, and particularly of the individual collection
zones, may be shortened considerably from those required in a unit
utilizing only a single ionization zone and a single collection
zone. In addition, particles which may become re-entrained at
upstream collection zones are again precipitated, since they retain
their charges by virtue of the dielectric collection surfaces
controlling charge leakage, at a downstream zone. In embodiments
utilizing a series of ionization zones as well as a plurality of
collection zones, still better performance is achieved inasmuch as
any particles not collected in an upstream collection zone are
further charged in the succeeding ionization zone or zones and thus
react strongly with the electric retarding fields at the zone
interfaces and the precipitation fields within the downstream
collection zones.
Since each collection zone is preceded by a conductive region,
constituting either a termination zone or an ionization zone
depending on whether additional ionizer electrodes are used, a
series or cascade of particle retarding fields is established along
the gas stream. Those particles not collected in the upstream
portions of the stream are therefore subjected to additional
retarding forces tending to further slow their downstream movement.
Of course, the agglomerating and precipitation field strengthening
effects of the retarding fields are similarly multiplied.
Consequently, precipitation efficiency is improved since even fewer
particles will escape collection.
Turning now to FIG. 3, one plural-zone arrangement includes at the
upstream end an ionization zone 52 and a collection zone 54
configured as in FIG. 1, followed by a second collection zone 56 of
similar configuration spaced downstream from the zone 54. As
illustrated in FIG. 3, the dimensional relationships between the
various components of the zones 52, 54 and 56 are the same as
described in connection with FIG. 1.
In order to establish an electric retarding field between the
upstream end of the passive electrode 58 of the second collection
zone 56, conductive regions 60 and 62 are provided between the
dielectric regions of the collection zones 54 and 56. The regions
60 and 62, therefore, function as termination zones for force lines
extending upstream from the passive electrode 58 and the leading
areas of the dielectric regions of the zone 56. For purposes of
clarity, the latter field lines are omitted from FIG. 3 as are the
lines for the equivalent fields extending across the interface of
the ionization zone 52 and the collection zone 54.
Electric fields will, of course, be set up between the downstream
end of the foremost passive electrode 64 and the adjacent
conductive regions 60 and 62. However, the component of these
fields in the downstream direction, and hence the propelling effect
of the fields on the particles, is minimized by positioning the
trailing end of the electrode 64 at least as far downstream as the
upstream edges of the regions 60 and 62, or, in other words, at
least as far as the downstream edges of the foremost dielectric
regions. In a preferred arrangement, the electrode 64 extends
beyond the downstream edge of the dielectric regions by a distance
at least as great as five-sixteenths the distance between the plane
of the electrodes and the plane of the conductive region 60 or 62.
Such spacing of the passive electrode 64 creates field
distributions between it and the adjacent conductive regions that
are substantially transverse to the gas stream, with negligible
downstream components. Accordingly, the electric field system
within the precipitator is maintained unbalanced in the upstream
direction to yield a net retarding influence on particle flow.
Optimally, the passive electrode 58 is spaced downstream from the
electrode 64 by a distance at least as great as 11/4 the distance
between the plane of the electrodes and the plane of the conductive
region 60 or 62.
As with the embodiment of FIG. 1 and as schematically represented
in FIG. 3, separate power sources 66 and 68 may be used to drive
the ionizer electrodes and the passive electrodes 58 and 64,
although a single source may be used. Alternatively, individual
power supplies may be used for each of the passive electrodes 58
and 64 as well as for the ionizer electrodes.
FIG. 4 depicts a further embodiment of a cascaded-zone precipitator
modeled after the basic configuration of FIG. 1, and including at
least one additional ionization zone 70 and associated collection
zone 72. Although only one ionizer electrode 74 is shown in the
ionization zone 70, any suitable number may be used. It will be
understood, also, that the spacing among the components of the
ionization zones and collection zones and between the respective
zones are as described above in connection with FIGS. 1 and 3.
In this respect, it need only be mentioned that the leading ionizer
electrode of each succeeding ionization zone, for example, the
electrode 74 in zone 70 of FIG. 4, preferably is spaced from the
trailing end of the preceding passive electrode by a distance at
least as great as the previously defined distance h. Also, any
additional ionizer electrodes provided in the successive ionization
zones should be spaced downstream from the foremost electrode by a
distance equally as great. For maximum compactness commensurate
with high performance, the minimum spacing would of course be
adopted.
Where only a single ionizer electrode is used in succeeding zones,
it is desirable that the upstream edges of the dielectric regions
of the collection zone associated therewith be located no closer to
the downstream end of the preceding passive electrode than twenty
five-sixteenths the distance between the plane of the electrodes
and the plane of the conductive regions at the gas stream
boundary.
Yet another version of a plural-zone precipitator constructed in
accordance with the invention is portrayed in FIG. 5. The field
distribution lines are omitted from FIG. 5 for clarity.
While wire-like ionizer electrodes have been illustrated and
described in connection with the embodiments of FIGS. 1 to 4, the
invention is not limited to the use of that particular type of
ionizer electrode. Indeed, any suitable configuration capable of
establishing a strong ionization current across the gas stream may
be used. One such configuration of ionizer electrode is depicted in
FIG. 5, where a plurality of electrodes 76, each having a
multiplicity of pointed discharge members 78, are shown. The
electrodes 76 may, for example, constitute pointed saw-tooth blades
in order to promote very high electrical stress on the discrete
corona points so as to burn off and prevent the accumulation of
particulate matter on the ionizer. This improves charging
efficiency since such accumulations reduce the local electrical
field intensity and thus seriously degrade ionization current. As
indicated in FIG. 5, the spacing between the individual ionizer
electrodes 76 preferably conforms to the dimensions earlier
described in connection with the wire-like electrodes.
Also illustrated with the embodiment of FIG. 5 is that the polarity
of the ionizer electrodes and the passive electrodes may be either
positive or negative so long as they are the same, though negative
is advantageous as it usually gives a higher charging efficiency.
Thus, the ionizer electrodes and passive electrodes of FIG. 5 are
shown connected to the positive terminals of the power
supplies.
A cascaded-zone precipitator having a representative arrangement of
the ionization and collection zone configurations of FIG. 2 is
shown in FIG. 6. In sequence, the precipitator includes an
ionization zone 80, a collection zone 82, a second ionization zone
84, and a second collection zone 86. Additional ionization zones
and collection zones may be added if desired.
With reference to the second ionization zone 84, as mentioned
previously although the precharging ionizer electrode 88 is located
within the collection zone 86, an ionization current is
nevertheless established between the electrode 88 and the
conductive wall regions of the zone 84. Accordingly, the zone 84 is
in fact an ionization zone in which particles carried by the gas
stream will receive electrical charges.
The embodiment of FIG. 7 represents still a further configuration
of ionization zones and collection zones in accordance with the
invention. In particular, an integral module 90 is shown as
incorporating both a passive electrode 92 and ionizer electrodes 94
of the multi-point type. This modular construction of the ionizer
and passive electrodes facilitates assembly and reduces costs by
minimizing the number of electrode supports and electrical
connectors required.
FIG. 7, in addition, illustrates the use of a multi-point
precharging ionizer electrode 96 within the collection zone. This
type ionizer electrode, or any other suitable type ionizer, may be
used as well as the precharging electrode in the embodiments of
FIGS. 2 and 6 in place of the wire-like electrodes there shown.
Since an air gap is not included in the FIG. 7 embodiment, despite
the use of a precharging electrode, it is especially adapted for
use in applications where conductive dust particles are to be
collected or where high operating potentials are not required.
Regardless of the type of precharging ionizer electrode used,
however, if highly resistive dust particles are being precipitated
or if operating potentials are elevated, an air gap is preferred to
avoid the creation of reverse corona conditions.
It is another feature of the invention that the establishment of
particle retarding electric fields within the gas stream, which
yield substantial benefits in improved precipitator performance as
described above, is complemented by providing for movement of the
member or members carrying the conductive and dielectric regions to
a location remote from the gas stream where particles collected on
the regions are removed without danger of re-entrainment. After
cleaning, the surface carrying the conductive and dielectric
regions is then available in a cleaned condition to be moved back
into operating position within the ionization and collection zones.
In this way, the buildup of saturation level charges on the
collection zones and the buildup of deposited particles on the
conductive, attractor electrode regions of the surface are avoided.
The high efficiency performance characteristics attributable to the
retarding fields of the present invention are thus preserved.
A pictorial representation of a movable wall, or "surface,"
precipitator is contained in FIG. 8. In FIG. 8, an endless belt 98
constructed of conductive material is carried by spaced rollers 100
and 102 for movement into and out of proximity to the gas stream. A
dielectric layer 104 is formed on the belt surface, leaving a bare
region 106 at the upstream portion of the belt exposed to the gas
stream. Corona discharges are established between the conductive
region 106 and one or more ionizer electrodes 108 extending
transverse to the direction of particle flow.
As schematically shown in FIG. 8, it is a further feature of the
invention that the ionizer electrodes 108 may also be mounted for
movement to a quiescent location for cleaning. A pair of spools 110
and 112 associated with each ionizer electrode 108 move the
electrode, either intermittently or continuously, through the gas
stream. A cleaning element 114, such as a brush, wiper, or the
like, is provided at a location outside of the gas stream to remove
particles adhering to the electrode.
Charged particles leaving the ionization zone are caused to be
precipitated on the dielectric surface 104 by precipitation fields
established between the grounded belt 98 and a high-potential
passive electrode 116. These particles are retained on the
dielectric surface 104 against forces tending to re-entrain them by
the electrostatic attraction of the charged particles for the metal
belt 98. Some particles collect on the conductive attractor 106 as
well.
However, as mentioned, it is desirable that the collected particles
be removed from the belt to prevent quenching of the charging and
precipitation fields. This is accomplished by contacting the belt
with a brush 118, or some other suitable cleaning device, at a
location remote from the gas stream. As the belt 98 is moved past
the brush 118, the particles adhering to the conductive region 106
and the dielectric region 104 of the belt are removed. Since those
particles collected on the dielectric region 104 retain electrical
charges, it is preferable that the brush 118 be constructed of an
electrically conductive material and be connected to ground so that
the particle charges may be neutralized to facilitate their
removal. Other techniques of discharging the charges carried by the
particles in advance of or simultaneously with the cleaning
operation may of course be used.
Where the dust particles are electrically conductive, either
brushes constructed of dielectric material or electrically isolated
brushes are preferred.
Movable or moving surfaces other than endless belts may be used in
accordance with the invention. Examples of these are discs or drums
which are rotated past the gas stream. Also, it is not necessary
that a surface susceptible of continuous movement be used. Instead,
the surface may be reciprocated between a position of proximity to
the gas stream, where particle charging and collection are carried
out, and a cleaning position outside of the stream. Similarly, the
ionizer electrodes, or the precharging ionizer electrode if one is
used, may be reciprocated into and out of the gas stream for
cleaning at a remote location.
Moreover, both surfaces of the movable member may be exposed to the
gas stream, notwithstanding that the description heretofore has
made reference to only one side of a movable member. For example,
in the figurative embodiment portrayed in FIG. 8, an additional
passive electrode 120 may be located in juxtaposition to the inner
surface of the belt 98. In this instance, the inner surface would
also be provided with a dielectric layer to define a collection
zone and an upstream ionization zone. Appropriate ionizer
electrodes would of course be located in particle charging relation
to the upstream conductive region on the inner surface of the belt.
A third passive electrode 122, and additional ionizer electrodes,
could be positioned to allow for collection on the outer surface of
the belt 98 on its return run after being cleaned by the brush 118.
If collection proceeds on both surfaces of a member, so should
cleaning. To that end, it is contemplated that a brush or the like
would be provided to engage each surface.
The substantial advantages flowing from the present invention will
become additionally apparent from a consideration of the following
test data, and upon analysis of the graphs of FIGS. 9 and 10.
TESTS OF RETARDING-FIELD UNIT
A cascaded-zone precipitator in the FIG. 4 configuration, with a
series of three ionization zones and three collection zones, was
tested. A movable surface was located on either side of the gas
stream. The surface was constituted by an endless Mylar belt having
strips of brass shim stock secured to its facing surface to define
the conductive regions of the surface. The belt speed was 1.33
inches per second, the air velocity 19 feet per second, and the
volumetric flow rate of the air stream 443 cubic feet per minute.
An absolute filter was connected across the exhaust end of the
precipitator to trap all particles not collected within the
unit.
Five ionizer electrodes were used in each ionization zone. Except
for the trailing electrode in each zone, the ionizers were
maintained at a voltage of -28 kv., and a current of approximately
3.5 to 4 milliamps. A separate power supply was used for the first
four electrodes in each ionization zone. Each trailing ionizer
electrode was energized by an independent power supply at a voltage
of -20 kv. and a current of one milliamp. The passive electrodes
were raised to a voltage of -19 kv., with negligible current. The
effective volume of the precipitating unit was 1.23 cubic feet.
The results obtained are listed below:
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TABLE II
D.sub.L .eta. c T
__________________________________________________________________________
(a) 12.8 99.2 57.2 (b) 13.1 98.6 56.7
where:
D.sub.L is the dust loading in grains per cubic foot of dry fly
ash;
.eta.c is the collection efficiency determined by weighing
collections at the absolute filter, i.e., .eta.c = (weight of fly
ash at entrance -- weight of fly ash at absolute filter) divided by
weight of fly ash at entrance; and
T is the time of the run in minutes.
TESTS OF COTTRELL UNITS
For purposes of comparison, a Cottrell-type precipitator was
tested, both with collection surfaces constituted by stationary
walls, as in the conventional Cottrell unit, and with a moving
dielectric wall but without the retarding fields of the present
invention.
A total of 35 ionizer wires spaced 1 inch apart were used. The
collection surfaces, one on each side of the gas chamber, were
constituted by brass shim stock and were grounded. Seven power
supplies ranging from voltages of -25 kv. to -19.5 kv., at a
current of approximately 4.6 milliamps to 1 milliamp, where used to
drive the ionizer electrodes. Belt speed (where applicable), gas
velocity, and volumetric flow rate were the same as for the
retarding-field unit.
The following results were obtained:
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TABLE III
D.sub.L .eta. c T (c) 10 93.85 67.33 (d) 12.3 95.46 61.7 (e) 11.1
74.2 67.2
(belt held stationary, collected particles removed by rapping the
walls)
The data in Table II verifies that a small (1.23 cubic feet
effective volume) precipitator with the moving dielectric surface
and retarding field features of the present invention is capable of
handling high dust mass loads (10 to 15 grains per cubic foot) at
high gas velocities (19.5 to 20 feet per second) while providing
collection efficiencies up to 99.2 percent, using the cascaded
triple ionization-collection zone geometry.
However, initially it might appear that the Cottrell units perform
nearly as well as the unit of the present invention. Comparing
lines (a) of Table II with lines (d) and (e) of Table III, there is
only approximately a 25 percent difference in efficiency between
the retarding-field unit (line (a)) and the stationary wall
Cottrell unit (line (e)) and only a 4 percent difference between
the retarding-field unit and the moving wall Cottrell unit (line
(d)). But this is illusory, as the following analysis of FIGS. 9
and 10 reveals.
Again considering equation (1), for sake of simplicity, the
collection efficiency (.eta.c) percentage becomes:
(1 a) .eta.c = 100 (1-e.sup.- )
where:
.lambda. may be expressed in an alternative version of equation (2)
as:
(2 a) .lambda. = k.sub.p E.sub.p .SIGMA.A/V.sub.g
where:
.SIGMA.A is the total collection surface area; and V.sub.g is the
volumetric rate of gas flow.
FIG. 9 depicts a graph of collection efficiency (.eta.c) percentage
versus .lambda.; i.e., equation (1a). Studying FIG. 9, it is
evident that the "cost" of improvement in collection efficiency
depends upon the efficiency range involved. For instance, an
improvement of 4 percent in collection efficiency from 70 percent
to 74 percent requires only a small change (.DELTA..lambda..sub.1
of FIG. 9) in .lambda., while approximately the same improvement
from 95 percent to 99.2 percent necessitates a very large change
(.DELTA..lambda..sub.3) in .lambda.. It is assumed here that
k.sub.p, .SIGMA.A, and V.sub.g are held constant.
Thus for the collection efficiency of the Cottrell units to be
raised to that of the retarding field unit, without sacrificing
throughput capacity by lowering the volumetric rate of flow
(V.sub.g), the area available for particle collection (.SIGMA.A)
must be increased. Turning again to the test data for the Cottrell
units and looking once more at FIG. 9, to improve the moving wall
Cottrell system from 94.6 percent (line (d) of Table III) to the
99.2 percent value (line (a) of Table I) of the retarding-field
precipitator, the size of the collector surface, and hence of the
precipitator, must be increased by a factor of at least 1.6.
Similarly, an improvement from 74.2 percent (line (e) of Table III)
to 99.2 percent requires that the collection surface area be
increased by a factor of approximately 3.5.
As the cost of manufacturing a precipitator is proportional to the
size of the collection surface, FIG. 9 indeed reflects that a high
"cost" must be paid for seemingly small improvements in collection
efficiency at the efficiency levels here involved.
FIG. 10 illustrates the relationship between collection efficiency
and the size of the collection area even more clearly. (FIG. 10 is
based on a dust loading of 15 grains per cubic foot, a gas velocity
of 20 feet per second, and a volumetric flow rate of 500 cubic feet
per minute.) It is obvious from FIG. 10 that substantial economies
in the size of the collection area, and, consequently, of the
precipitator unit as a whole, are obtainable at any given
collection efficiency by the techniques of the present invention.
Moreover, the Cottrell units were tested under conditions that must
be considered as ideal for that type of system. For example, the
buildup of a heavy dust layer on the collection surfaces was
eliminated by moving or frequently rapping the collectors, which in
turn eliminated the re-entrainment and field quenching problems
inherent in Cottrell systems. Therefore, in actual practice the
collection efficiency of a Cottrell unit might be significantly
less than those observed in the reported tests. If so, the factor
by which .lambda., i.e., the collection area, must be increased to
achieve collection efficiencies on the order of those of the
present invention would be raised substantially, and may go up as
high as 10 to 25. This would be especially true where highly
resistive dusts are collected since the buildup of charges on the
collection surfaces would greatly degrade the performance level of
the Cottrell type units.
Additional costs savings over the Cottrell systems are realized
with the present invention inasmuch as the Cottrell units require
nearly three times the number of corona wires as does the
retarding-field unit. The power requirements are therefore also
nearly tripled. Finally, an automatic voltage regulator is needed
for the stationary wall Cottrell system to compensate for charge
buildup on the collection surfaces. At the usual voltage of 60 kv.
to 100 kv., typically used in Cottrell units, such regulators are
very expensive.
It will be readily apparent to those skilled in the art that the
above-described embodiments are intended to be merely exemplary, in
that they are susceptible of modification and variation without
departing from the spirit and scope of the invention as defined in
the appended claims.
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