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AbstractAfter the revamp of DR FCC unit in 2005over the limit dust emission was measuredin the flue gas of the unit. Electrostaticprecipitator (ESP) equipment wasinstalled in the flue gas system in the frameof a project for decreasing the emissionbelow the environmental limit. This paperpresents the electrostatic precipitation

technology and the equipment overview,summarizes the basic design work. One-year operational experience is also sharedin this work.

ÖsszefoglalásElektrosztatikus porelválasztó beépítésea Dunai Finomító FCC üzemébenA Dunai Finomító FCC üzemének 2005évi nagyrevíziója után a környezetvédelmielôírást meghaladó poremissziót mértek

az üzemi füstgázban. A mérések aztmutatták, hogy a por szemcseméreteloszlása miatt annak leválasztása

mechanikai úton nem lehetséges. A14/2001 (V.9.) KöM-EüM-FVM ren-

deletben megengedett határérték(50 mg/Nm3) teljesítése érdekében aMOL 2006-ban projektet indított egyfüstgáztisztító berendezés beszerzésére,és installálására. A publikáció bemutatjaaz elektrosztatikus porleválasztás tech-nikáját, a készülék felépítését és ter-vezésének alapelveit. Összefoglaljuk azegy éves üzemeltetés tapasztalatait is.

IntroductionIn September, 2004 the Executive Board of MOLGroup approved the implementation of the Project“FCC Unit Upgrade in Duna Refinery”. One of themajor aims was to reduce Fluid Catalytic Cracking(FCC) unit flue gas particulate concentration belowlegislation limit set forth in 14/2001 (V.9.) KöM-EüM-FVM interministerial decree i.e.: 50 mg/Nm3

(on dry basis at 5 vol% oxygen) by additionalflue gas cleaning equipment. The project wasimplemented during the planned turnaround of theFCC unit, in September-October, 2005. After the starting up of the unit, when measuringof the dust emission became possible, it was

realized that the more efficient dust separationwas not achieved by the equipment modifications.Since then, several measures have been taken tofind the root cause of the non-compliance with theassistance of licensors, designers, contractors,manufacturers and vendor. This troubleshootingprocedure was detailed in a previous publicationby Dr. Fürcht [1]. At the end of this process MOLand the process licensor, UOP arrived at the sameconclusion in their evaluation reports:• The design was performed in line with licensors’

specifications.

• Every system, equipment, catalyst, etc. werefound to meet the design specifications andbeing in good shape.

Márk Bubálik, Dr. (33)Chemical engineer PhDMOL Plc. R&M Division Refining technology expert

E-mail: [email protected]

László Nagy (59)Chemical technicianMOL Plc. R&M Division RefiningOTS ExpertE-mail: [email protected]

Zsolt Császár (44)MOL Plc. R&M Division RefiningINA Adviser E-mail: [email protected]

Artur Thernesz (46)MOL Plc. R&M DivisionDirector, DS DevelopmentE-mail: [email protected]

Installation of an

in the FCC plant of Duna Refinery (DR)electrostatic precipitator

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• The root cause of the high emission is the highload of the fine particles in the flue gas whichseems to be inherent to this very unit andcould not be detected in the past in the lack ofappropriate sampling facilities.

Meeting the emission limit of solid pollutants canonly be achieved by the installation of new post-separation equipment in frame of a new project. Asit was described in Dr. Fürcht’s review [1] duringthe definition phase of the project electrostaticprecipitation (ESP) technology was chosen to meetthe stringent emission limit of solid pollutants.Installations of an electrostatic precipitatorinterconnect ductwork, utility, instrumentation andautomated dust removal system were included inthe project scope. Based on their technical andcommercial proposal the Hamon Research-Cottrell(HRC) was selected for design and installation of

the ESP.The aim of this paper is to present the electrostaticprecipitation technology and the equipmentoverview, to summarize the basic design work.One-year operational experience is also shared inthis work.

ProcessdescriptionElectrostatic precipitation has been a reliable

technology since the early 1900's. Originallydeveloped to abate serious smoke nuisances, themanufacturers of zinc, copper, and lead quicklyfound electric gas cleaning a cost-efficient way torecover valuable product carried out of the stacksfrom furnace operations. Today electrostaticprecipitators are found mainly on large powerplants, cement plants, incinerators, various boilerapplication and FCC units [2, 3].The Electrostatic Precipitator (ESP) removessuspended particulates from the flue gas stream.The primary benefit of this function is the controlof air pollution to comply with governmental

regulations.The precipitator was installed between the flue gascooler and the stack. The combustion by-product(gas containing catalyst fines as particulate matter)of the FCC regenerator is transported to the ESP.The ESP has one chamber with three fieldspowered by one transformer-rectifier set on eachfield. The ESP is a particulate control device thatuses electrical forces to remove particulate fromthe flowing gas stream (Fig. 1.).The high voltage charge on the negative electrodes(discharge electrodes) causes discharge of

electrons into the gas stream, in form of corona,which is a luminous blue glow of ionized gases.Catalyst fines passing through the corona zone

receive a negative electrical charge, which causesthem to be attracted to the positive electrodes(collecting electrodes or collecting plates), wherethe force of the electrical field holds them.The electrical field that forces the charged particlesto the positive electrodes comes from the negative

electrodes, maintained at high voltage in the centreof the flow lane by the transformer-rectifier set. After the particulate is accumulated on thecollecting plates, it must be removed from theelectrodes while minimizing re-entrainment ontothe gas stream. The particulate is removed by“rapping”, a process whereby the depositedcatalyst fines are knocked loose from the plates,allowing the collected layer of particles to slidedown to the bottom of the precipitator. As a consequence of the ionization of the gasstream, a small percentage of particles receive a

positive, rather than negative, electrical charge.These particles are attracted to the negativeelectrode, where they accumulate. The negativeelectrodes are rapped periodically to remove theseaccumulations to reduce their possible interferencewith corona generation.The cleaned gases from the electrostaticprecipitator are transported to the stack andreleased to atmosphere. The particulate falls intothe precipitator hoppers. Dust handling system isused to transport the collected particulate matterto the dust silo.

Equipmentoverview A precipitator is relatively simple equipment. Themain components are as follows (Fig. 2.):

CASINGThe precipitator casing is divided into 5 differentmain components:• The inlet plenum, designed to obtain an uniform

flow profile across the precipitator;

• The precipitation chamber, where the electricfields are installed;• The outlet cone designed to tie the precipitator

Fig. 1. Process description of ESP (Source: HRC)

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• chamber in the flue gas outlet duct withoutdisturbing the gas flow distribution inside thechamber;

• The collecting pyramidal hoppers located undereach precipitator field;

• The penthouse mounted on the top of the

precipitator chamber and separated from thischamber by the hot roof. To maintain the high voltage charge on the discharge electrodes, itis essential that the discharge electrodes andframes be isolated at all points from ground andfrom the collecting electrodes. The penthousehouses the high voltage support insulators andrapper insulators. A seal air system is providedto prevent flue gas from contaminating this area.

The precipitator casing external walls are heatinsulated to avoid the flue gas to condensate. Notonly the flue gas acid condensation corrodes the

steel parts but also causes the collected dust toagglomerate and stick to the steel surface.

DISCHARGE ELECTRODEThe discharge electrode is the vertical pipe andspike design. The sharp edge spikes promote theCorona effect and gas ionization. The dischargeelectrodes are located in the gas stream at equaldistance of juxtaposed collecting plates. Thisdistance is one of the factors that can affectprecipitator performance. The discharge electrodesare attached to a high voltage frame. This assemblyis hung at top of the precipitator from high voltagesupport insulator.

COLLECTING ELECTRODES

The collecting plates are the grounded electrodeson which the incoming charged particulate isdeposited. The electrodes run parallel to the gas

flow and are arranged to form a series of gaspassages through the precipitation chamber. In ournew equipment the plates – called "G" OpzelTMcollecting electrode – provide quiescent zonesto aid in particulate collection and to reduce re-entrainment (see the gas velocity profile in the DRFCC ESP on Fig. 3.).

PRECIPITATOR RAPPERSTo dislodge the collected material from theprecipitator collecting and discharge electrodes,Hamon Research-Cottrell utilizes Magnetic ImpulseGravity Impact (MIGI) rappers (Fig. 4.). The MIGIrapper is a simple electromagnetic device that has

only one moving part, a 10 kg plunger. Rapperoperation is initiated by a controlled, short duration,low voltage pulse. This pulse energizes the solenoidcoil, generating a magnetic field that lifts theplunger into the phenolic guide tube. After the coilis de-energized, the plunger drops by gravity andimpacts on a stationary rapper rod that transmitsthe forces to the internal components. The rappersare installed on the precipitator cold roof.

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Fig. 2. Structure of electrostatic precipitator (Source: HRC)

Fig. 4. Structure of magnetic impulse gravity impact (MIGI) rapper

Fig. 3. Gas velocity profile in the DR FCC ESP (Source: HRC)

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TRANSFORMER-RECTIFIER (T-R)Each electric field of the precipitator is energizedby a transformer-rectifier. All transformer-rectifiersare mounted on the precipitator cold roof.The high voltage conductor connects thetransformer outlet bushing to precipitator high- voltage frames. The conductor section runningoutside the penthouse is protected by a bus duct.The transformer power is regulated by a thyristormodule controlled by a voltage/current regulator.The regulator continuously adjusts the voltage andthe current of the transformer-rectifier in order tokeep the ESP working at highest voltage within theworking limits of the equipment. Voltage or currentadjustment is carried out in function of a currenttransient detection. Current transients are due tospark or arc formation between the electrodes of

the ESP. The control strategy and the dynamicbehaviour of the regulator are able to create theoptimum working conditions in function of processtransients.

HOPPERSThe hoppers are set back from the flue gas flowand need to be heated above the flue gas aciddew point in order to avoid flue gas condensation.Catalyst fines stuck because of the condensationcan give rise to clogging of the hopper and preventthe dust handling system to work properly.

Level switch controls the dust level in each hoper.The level should be kept minimal in order to avoidclogging. At the vertical of each hopper and fixed to thelower alignment frame of the discharge electrodes,a steel rod limits the maximum capacity of thehopper and prevents the bulk material to reachthe lower part of the electrodes. If the dust levelreaches the steel rod, the high voltage frame is putto ground what would trip automatically the fieldtransformer-rectifier. Tripping the transformer willprevent the hopper to collect more fines.

DUST REMOVAL SYSTEM (DRS)Dust is continuously collected under the hoppersby a pneumatic conveyor and transported to thestorage silo. The transport system is designedfor high dust temperature. The fines vesselsand the dust pipe are heated to limit the risk ofplugging. The pneumatic action is made by drycompressed air.The dust silo receives dust and a bag filter isinstalled at top of the silo for air evacuation andpressure equalization. The dust evacuation is madeby tank trucks. Loading of the trucks is made by

loading spout, which is dedusted by the silo filter,the fan on the filter assure the depression duringtruck loading. A manual butterfly valve is installed totune the dust slow to the truck in order to maximizethe dust flow and minimize the dust fly away.

KEY INTERLOCK SYSTEMThe principal purpose of the key interlock systemis to prohibit entry into the precipitator via normalinterlocked manway access doors until the high voltage transformers are locked off and grounded.The interlock system consist of a series of locksand keys located and sequenced to control thesteps of de-energizing, grounding and opening ofequipment to prevent personnel from coming incontact with energized high-voltage components.

Design criteria ofthe ESPDesigning a precipitator for optimum performancerequires proper sizing of the precipitator in addition

to optimizing precipitator efficiency.Precipitator performance depends on its sizeand collecting efficiency. Factors that influenceprecipitator sizing are [3, 4]:• Gas volume. In DR FCC unit the design gas

flow rate is 110,000 Nm3/h.• Gas velocity. A precipitator operates best with

a gas velocity of 1,1 – 1,7 m/s (see the Fig. 3). Athigher velocity, particle re-entrainment increasesrapidly. If velocity is too low, performance maysuffer from poor gas flow distribution or fromparticle dropout in the ductwork.

• Precipitator inlet loading. In case of DRFCC unit during normal operation the design inletburden is max. 250 mg/Nm3. To maintain theperformance of flue gas cooler being in flue gassystem upstream of the ESP a cleaning processnamed soot blowing is carried out every day.During the soot blowing action the maximuminlet loading is 1000 mg/Nm3.

• Required dust emission. As it was mentionedbefore the regulation limit is 50 mg/Nm3 (on drybasis at 5 vol% oxygen). In order to answer thecurrent and expected future legislation contractorshould guarantee that the maximum emission

would be 25 mg/Nm3 (dry, 5 vol% oxygen)during normal operation measured in the stackand the average particulate matter in the outletflue gas stream 25 mg/Nm3 (dry, 5 vol% oxygen)over 4 hour period in the flue gas including onesoot blowing.

• Particulate resistivity is resistanceto electrical conduction. By definition,resistivity, which has units of ohm-cm, is theelectrical resistance of a dust sample 1 cm2 incross sectional area and 1 cm thick. Resistivitylevels are generally broken down into three

categories: low (under 1x105 ohm-cm), medium(1x105 to 1x1011 ohm-cm) and high (above1x1011 ohm-cm). Typically, particulate resistivityinvolves both surface and volume resistivity.

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• Particles in the medium resistivity range are themost acceptable for electrostatic precipitators.Particles in the low range are easily charged,however upon contact with the collectingelectrodes, they rapidly loss their negative chargeand are repelled by the collecting electrodesback into the gas stream to either escape or tobe recharged by the corona field. Particles in thehigh resistivity category may cause back coronawhich is a localized discharge at the collectingelectrode due to the surface being coated by alayer of non-conductive material. Resistivity ishighly influenced by flue gas temperature andconditioning agents, such as flue gas moistureand dust chemistry. Conductive chemicalspecies, such as sulphur and sodium will tend toreduce resistivity levels while insulating species,such as SiO

2, Al

2O

3 and Ca will tend to increase

resistivity. High resistivity can reduce precipitatorperformance. Sodium and iron oxides in the finescan reduce resistivity and improve performance,especially at higher operating temperatures. FluidCatalytic Cracking units have particle resistivitiesin the medium range.

• Particle size of the incoming particulate

has a dramatic impact on the sizing ofan electrostatic precipitator. A precipitatorcollects particles most easily when the particlesize is coarse. The generation of the chargingcorona in the inlet field may be suppressed if

the gas stream has too many small particles(less than 1 µm). Very small particles (0.2 - 0.4µm) are the most difficult to collect becausethe fundamental field-charging mechanismis overwhelmed by diffusion charging due torandom collisions with free ions. Fluid CatalyticCracking units have very fine particulate, in ourcase the particle size range is 0.36-30 µm. Sizeof the precipitator must be increased in this casebecause the fine particulate is easily re-entrainedinto the gas stream.

• Gas temperature. The effect of gastemperature on precipitator collecting efficiency,

given its influence on particle resistivity, can besignificant. The operating temperature of theinstalled ESP is 290±30°C.

• Interactions to consider. Particle sizedistribution and particle resistivity affect thecohesiveness of the layer of precipitatedmaterial on the collecting plates and the abilityof the rapping system to dislodge this layer fortransport into the precipitator hopper withoutexcessive re-entrainment.

The sizing process is complex as each precipitator

manufacturer has a unique method of sizing, ofteninvolving the use of computer models and alwaysinvolving a good dose of judgment. Based on

specific gas volume and dust load, calculations areused to predict the required size of a precipitator toachieve a desired collecting efficiency. The typicalequation used in precipitator sizing is the modifiedDeutsch equation:

where A – the collecting electrode surface areaV – the gas volumeW – the precipitation rateY – factors calculated the itemized parameters.

As a result of the sizing process HRC designed

the ESP with the main parameters listed on theTable 1.The electrostatic precipitators are very flammableequipments because the precipitator sparking ispotential source of ignition when combustibles andoxygen are present in quantities sufficient to supportcombustion. Because of this the interlock systemof ESP was paid specific attention during the designphase. To avoid getting of the combustibles intothe operating ESP the high-voltage trip is activatedwhen the regenerator temperature reaches 750°Cor the rising of regenerator temperature higher

than 20°C/10sec and/or the CO content of theflue gas reaches 180 ppm.

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Technical parameters Characteristic Number of fields 3 Number of gas passages/field 15 Gas passages spacing 400 mm Gas flow cross section 60 m2

Collecting surface/field 4005m2

Number of collecting plates/field 16 Collecting plates height 10000 mm Collecting plates length 4450 mm Number of discharge electrodes/field 120

Discharge electrodes length 10760 mm No. of collecting plate rappers/field 8 No. of discharge electrode rappers/field 4 No. of inlet distribution devices rappers 2 Seal air flow 1000 Nm3/h T-R field 1/2/3 power 110 kVA T-R field 1/2/3 secondary peak voltage 110 kV T-R field 1/2/3 secondary output current 1000 mA Number of hoppers 3

Table 1. Main parameters of the ESP [2]

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Operatingexperiences After the installation of the designed ESPcommissioning was carried out by MOL underHRC assistance in summer, 08. 08. 2008. Allprocedures set forth in the Basic EngineeringDesign Package as well as HRC’s writteninstructions were observed during commissioning. After the commissioning and acceptance period theperformance guarantee test run (PGT) was carriedout. The length of the PGT was three days andduring this procedure HRC should demonstrateguaranteed values of the ESP. The dust emissionbeside the energy consumption was the mostimportant measured parameter. The emission test,which is an isokinetic measurement, was carried

out by an accredited, independent laboratory.During the test run the FCC unit is operated innormal way at maximum throughput. As a resultof the test it was concluded that the inlet load ofthe ESP was 80 mg/Nm3 and the air pollutantconcentration was below the guaranteed values (25mg/Nm3) for every case, the maximum value of theemission was 19 mg/Nm3. Based on the results ofoutlet dust content and energy consumptions theefficiency of the ESP was acceptable (see Fig. 5.)and the project was finished in November of 2008.

A few months later the online opacity metershowed increasing emission and the smoke onthe top of the stack turned visible. Problem withthe dust handling was observed too. For findingthe reason of the failure and the solution of theseproblems a troubleshooting team was constituted,in which HRC experts were involved besides MOLmembers. Two different problems were examined:

• decreasing of the ESP effectiveness; and• clogging problem with the dust handling system.

PROBLEM WITH THE ESPEFFECTIVENESSIn the end of 2008 the catalyst fines contentof the flue gas increased to ~200 mg/Nm3 dueto attrition of the FCC equilibrium catalyst. Although the ESP load was in the design rangebut the dust emission measured in the FCCstack was higher than the guaranteed value(~ 30-35mg/Nm3). First of all the differencesbetween the design and operational parameterswere audited: since the starting of ESP theFCC unit has been operating at stable modeand all parameters were in the design rangesexcluding the steam content of the flue gas. Itwas between 14-16% while the design data was11,6%, but the added moisture is beneficial insurface conductivity of the dust particle. The

current passing through the precipitated dustlayer is conducted in a film of weak sulphuricacid (forming from SO

3 being in flue gas and

H2O) on the surface of the particles. It has a

positive effect on the ESP efficiency.The operation of the transformer-rectifierequipment was checked too. It was concludedthat the transformers operated at maximumpower level therefore, the performance of theequipments can not be increased.During the main turnaround period in April, 2009the ESP was opened. The hoppers were filled

with the precipitated fines, which may cause re-entrainment into the gas stream. To avoid thisabnormality each hoppers were drained. All ofthe electrodes and insulators were cleanedusing the HRC instructions. The whole flue gassystem was inspected by the FCC unit licensorbut no failure was detected.Due to the maintenance during the shutdowntime the performance of the flue gas coolerupstream of the ESP increased, consequentlythe inlet temperature of the ESP decreased from320°C to 270°C. After the turnaround a clarifying test was carried

out with HRC supervision. Based on the resultsof the test it was concluded, that the inlet dustload decreased significantly (to 60-80 mg/Nm3)and dust emission was lower than before themaintenance shutdown (24 mg/Nm3). In normaloperating mode the ESP efficiency fulfilled therequirements of the contract but during thesoot blowing procedure the dust emission was30 mg/Nm3, which was higher than theguaranteed value but the distance from theenvironmental limit was acceptable.The results of the troubleshooting related to

emission were the followings:

Fig. 5. The effect of ESP on the visible smoke

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• The ESP can not meet the requirements whilethe inlet dust load is close to the design limit;

• The inlet temperature affects the performancesignificantly. At lower level (270°C) the ESP isnot able to precipitate the fines with the desiredeffectiveness.

To solve these problems HRC provided additionalequipment for injection of ammonia into the fluegas steam.

The combination of flue gas analysis, flue gastemperature and dust chemistry providesthe base for dust resistivity. Typically, dustresistivity involves both surface and volumeresistivity. As gas temperature increases,surface conductivity decreases and volumeresistivity increases. In higher gas temperatureranges (>200°C) volume conductivity

predominates. Current conduction throughthe bodies (volume) of the precipitated dustparticles is governed by the total chemistry ofthe particles. Dust resistivity can be modifiedby injecting ammonia into the upstream ofthe precipitator. It forms an ammonia-basedparticulate to increase the space charge.Sulphur trioxide and ammonia may be used incombination. This solution has been successfulbecause it can lower dust resistivity and alsoform ammonia bisulphate. The latter increasesthe adhesion of particles, and thus reduces re-

entrainment losses [5]. In our case the sourceof sulphur trioxide can be the sulphur contentof the flue gas. The ammonia injection skid wasinstalled in the end of 2009 and the ESP is ableto operate with maximum effectiveness.

CLOGGING PROBLEM WITH THEDUST HANDLING SYSTEMDue to the increased level of precipitated finesclogging was observed in the dust handlingsystem. Due to the failure of level switches directsignal of the hopper level was not available in thefirst months, but during this period there weresome indirect indications for the clogging of thehoppers. The measured hopper temperaturewas decreasing along with the increasing ofblocked dust amount, which insulated the sensorof thermometers (see Fig. 6.). Besides this, thelevel of the precipitated dust silo did not increasecontinuously. As it mentioned above when the ESP was openedthe hoppers were full of fines. During the turnaround period new nozzles wereinstalled to the bottom of the hoppers to purge the

blocked dust with inert gas. With this process theclogging of the hopper can be prevented in normaloperation.When the unit was restarted after an emergencyshutdown in June the blockage problem occurredagain. To find the reasons of the clogging themoisture content of the precipitated dust wasmeasured. It was found that before the shutdownthis value was about 3% but after the startup themoisture of dust increased to 9%. It was enoughto stick on the wall of the hopper and the cloggingwas built up.

After the evaluating period the troubleshootingteam prepared an action plan to solve the cloggingproblem. The action items involved in the plan werethe followings:• Modify the start-up procedure to prevent

condensation problem;

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Fig 6. Changing of the hoppers temperature

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• Modify the vibration control code of the hopper vibrators – increasing vibration frequency;

• Increase hopper heating (to 150°C) during start-ups;

• Install trace heating on spool pieces, which is theinterface between the hopper and dust removalsystem;

• Install additional anvils on opposite hopper side;• Modify the hopper level control philosophy –

instead of keeping the level between the lowlevel switch (LLS) and high level switch (HLS) ithas to be kept below the LLS. If the level reachesthe LLS, manual intervention is needed;

• Prepare operation instruction for handling lowhopper level alarm.

By now most of the preventive action points havebeen carried out, and the dust removal system is

operating without any clogging.To summarize the operational experience: aftersolving the initial difficulties, thanks to goodcooperation between the equipment designers,operators and the project team, the ESP is able toclean the flue gas at the desired performance level.The level FCC catalyst recovery in the unit reachedthe 80% with the start of ESP. Furthermore,instead of the emission to the atmosphere, 100tons catalyst fines are collected in the dust siloevery year.

References[1] Dr. Fürcht Á.: “Mikropor emisszió a DunaiFinomító FCC üzemében”, MOL SzakmaiTudományos Közlemények, 2007/1, 76-78.

[2] Operation & Maintenance Manual ofElectrostatic Precipitator; Hamon Research-Cottrell, 2008.

[3] R. A. Mastropietro: “Impacts of ESPPerformance on PM-2.5”, European ParticulateControl Users Group Meeting, Pisa, Italy,November 7, 2000.

[4] R. A. Mastropietro: “The Use of Treatment Time

and Emissions Instead of SCA and Efficiencyfor Sizing Electrostatic Precipitators”, EPRI-DOE-EPA mega-symposium, Washington,USA, September 20-25, 1997.

[5] R. A. Mastropietro: “Practical Problems withESPs can provide significant contribution toscience”, 7th International Conference onElectrostatic Precipitation, Kyongju, Republicof Korea, August 29,1998

Keywords: emission, precipitator, operationexperience

Reviewed by István Valkai

AcknowledgementThe authors would like to thank to HRC for valuablecomments and advice.

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