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Home >> Electrostatic Precipitators >> Rebuilds and Conversions

Electrostatic Precipitator Rebuilds/Conversions      

Introduction

TAPC is the Australasian leader in rebuilding electrostatic precipitators or converting them to fabric filters.  We have many years of experience in all makes and types of ESP, so what ever style you have we can assist you in the following ways:

  • Rebuild your ESP to bring it back to its original design and performance
  • Upgrade your ESP with modern internals and electronics for improved performance and reliability
  • Convert your ESP casing into a high efficiency fabric filter


Rebuilds

Case History

Steel Manufacturer, Australia - Steelmaking furnace ventilation.
Background:
This customer had substantial problems with corrosion damage leading to poor performance of the existing ESP. As the existing performance was adequate prior to the corrosion damage, it was decided to rebuild the ESP in its original style.

Outcomes:
The ESP was returned to its original condition and once again performed as per design.

Location SA
Completion Date 2009
Project Duration   6 months
Rebuild

TAPC Scope of Work:
Design, supply, install and commission a full turnkey rebuild (in kind) of a Lurgi Electrostatic Precipitator.

Equipment Supplied:
 
  • Outlet Evase
  • Collecting Plates
  • Discharge electrodes and frames
  • Collecting system rapping
  • Dishcharge system rapping
  • Full installation
  • Major casing repairs
  • Commissioning, training & testing
Design specifications:
 
  • Gas Flow rate : 175,000Nm3/hr
  • inlet load : 20 g/Nm3 (peak)
  • outlet load : <75 mg/Nm3
  • Removal efficiency : 99.6%
  

 


Upgrades

Case History

Nickel Refinery, Australia - Dryer ventilation
Background:
Poor performance and poor reliability lead this customer to require a complete rebuild of one of their ESPs. It was decided to upgrade the collecting plates to ESP1™ plates and the old weighted wire electrodes to TAPC RDEs™.

Outcomes:
The performance increase was substantial with emissions below 50mg/Nm3 (well below EPA requirments). TAPC was awarded the upgrade of a further two units.

Location QLD
Completion Date 2011
Project Duration   5 months
Rebuild

TAPC Scope of Work:
Design, supply, install and commission a full turnkey upgrade of a Research Cottrell Electrostatic Precipitator.

Equipment Supplied:
 
  • Revised collecting plates
  • TAPC Rigid Discharge Electrodes (RDEs) and frames
  • Collecting system rapping
  • Dishcharge system rapping
  • Full installation
  • Minor casing repairs
  • Commissioning, training & testing
Design specifications:
 
  • Gas Flow rate : 200,000Am3/hr
  • inlet load : 10 g/Nm3
  • outlet load before upgrade: 250 mg/Nm3
  • outlet load after upgrade: <50 mg/Nm3
  • Removal efficiency : 99.5%
  

 


Conversions to Fabric Filters

Case History

Cement Manufacturer, Australia - Cement Finishing Mill
Background:
This customer wanted to increase their mill production capacity. In doing so they would have pushed the old electrostatic precipitator well beyond it EPA emission requirements. In this instance it was not going to be possible to just upgrade the ESP technology as the existing casing was too small. It was decided to convert the ESP casing to a fabric filter using the latest technology GE PulsePleats™ with GE Prevail™ ePTFE membrane.

Outcomes:
The new fabric filter performed so well that for the first time since the plant started, there were zero visible emissions. Due to the low pressure loss of these filter elements, the new mill performed well above its design expectations.

Location NSW
Completion Date 2000
Project Duration   4 months
Rebuild

TAPC Scope of Work:
Design, supply, install and commission a full turnkey internal conversion of a Joy Electrostatic Precipitator to a Fabric Filter.

Equipment Supplied:
 
  • Tubesheets
  • Inlet and outlet baffle plates
  • GE PulsePleat™ Filter Elements
  • Compressed air pulsing system
  • New ID fan
  • Full installation
  • Materials handling upgrades
  • Commissioning, training & testing
Design specifications:
 
  • Gas Flow rate : 35,000Am3/hr
  • Temperature : 129°C
  • inlet load : 30 g/Nm3 (peak)
  • outlet load (prior to conversion): >250 mg/Nm3
  • outlet load (after conversion): <10 mg/Nm3
  • Removal efficiency : 99.97%
  

 


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