Dry Type Converter Gas ESP Electrostatic Precipitator

🔥 Gas Processing Capacity

• 📉 Max Gas Volume: 1,400,000 m3/h
• 🌡️ Gas Temperature: 80 – 160 °C
• 🌫️ Inlet Dust Density: Up to 50 g/Nm3
• 🌪️ Max Suction Pressure: -5,000 Pa
• 🏭 Supported Units: 18 – 450 MW scale

🛡️ Structural & Safety Integrity

• 💥 Casing Shape: Cylindrical (Explosion-Proof)
• 🛑 Gas Sealing: 100% Zero Leakage Design
• 🏋️ Pressure Bearing: Up to 0.2 MPa
• 🚨 Safety Mechanism: Integrated Relief Valves
• 🔄 Operation: Handles Intermittent Flows

🎯 Purification Performance

• ✅ Outlet Emission: < 50 mg/Nm3 (Capable of < 10 mg/Nm3)
• ✅ Internal Cleaning: Specialized Scraper Device
• ✅ Dust Discharge: Special Dust Removal System
• ✅ Distribution: High-efficiency screens
• ✅ Lifespan: Designed for 20+ Years

The Imperative for Cylindrical Design

The gas generated by tilting converters during the steelmaking process is highly intermittent and extremely combustible due to surges in Carbon Monoxide (CO). Standard rectangular Electrostatic Precipitators are highly dangerous in this application because gas can stagnate in corners. The Ever-power Dry Type Converter Gas ESP utilizes a strict Cylindrical Casing. This structural geometry forces a continuous, sweeping aerodynamic flow that eliminates return flow and dead zones, preventing explosion-inducing gas mixtures.

The Core Separation Process:

1. The intermittent BOF gas enters through a precision distribution screen, ensuring laminar flow across the cylinder.
2. The Discharge System ionizes the gas stream under tens of thousands of volts, applying a strong negative charge to suspended metallurgical dust.
3. Driven by the Coulomb force, the charged particles aggressively migrate to the Collecting System plates, leaving the purified combustible CO gas to exit for downstream energy recovery.

Internal Component Configuration

The internal architecture of the Converter Gas ESP demands absolute precision to function within a pressurized, explosive environment:

• Discharge System & Support: Equipped with advanced suspension frames and robust Discharge Electrodes designed to resist the intense vibrations and thermal shocks associated with batch converter smelting.
• Rapping Gearing: The Discharge Electrode Support and Driving Device for Rapping is engineered to operate seamlessly within the sealed pressure vessel, ensuring electrodes remain clean without requiring external atmospheric exposure.
• Dust Scraper & Removal: A highly specialized Dust Cleaning Device operates at the base of the cylinder, sweeping accumulated ash into the Dust Removal Device while sustaining the 100% zero-leakage threshold.
• Safety Relief Valves: Strategically positioned on the exterior casing to mitigate any internal deflagrations instantly.

Absolute Detonation Prevention

By marrying a cylindrical structural envelope with integrated high-response explosion relief valves, the Ever-power system mathematically rejects the aerodynamic conditions required for combustible gas detonation inside the precipitator.

Zero-Leakage Guarantee

Toxic CO leakage is a severe health hazard and an economic loss. Our 100% sealing design ensures that all valuable converter gas is fully contained and routed directly to the plant’s gas holder for downstream power generation.

Ultra-High Efficiency

Despite the incredibly hostile and intermittent gas flows of a tilting converter, our specialized electrode spacing and unique scraper mechanisms guarantee outlet dust concentrations consistently drop below 10 mg/Nm3.

The Catastrophic Detonation Threat

Basic Oxygen Furnace (BOF) off-gas is highly concentrated with Carbon Monoxide. Utilizing standard rectangular precipitators in this process is a critical safety liability. Dead zones allow oxygen and CO to mix and stagnate. A single static spark from an electrode can trigger a catastrophic explosion, destroying millions of dollars in equipment, shutting down the steelworks, and threatening human life.

Lost Energy Recovery Revenue & Turbine Destruction

Modern steel plants rely on capturing converter gas to fire auxiliary power plants. Poorly sealed precipitators result in massive volumetric losses of this valuable gas to the atmosphere. Furthermore, if dust removal efficiency is poor (failing to reach sub-50mg/Nm3), the highly abrasive iron oxide dust destroys downstream gas holders and turbine blades, crippling plant profitability and causing massive maintenance overruns.

For over 20 years, Ever-power has dominated the engineering of severe-duty environmental equipment. Designing a Converter Gas ESP is the absolute pinnacle of precipitator engineering—it involves high-pressure vessel mechanics, explosive gas dynamics, and high-voltage physics. This cannot be outsourced to generalists.

• ✔️ End-to-End Metallurgical Mastery: We execute the entire project lifecycle: High-Pressure Vessel Engineering ➔ Lean CNC Manufacturing ➔ Complex Installation ➔ Intelligent Commissioning.
• ✔️ Trusted by Heavy Industry: Our bespoke BL Series protects the core converter operations of leading metallurgical conglomerates worldwide, preventing unscheduled downtime and catastrophic accidents.
• ✔️ Uncompromised Quality Credentials: Fully ISO certified for pressure vessel manufacturing, holding dedicated structural patents for explosive gas precipitators.

The Financial Risk of Subpar Filtration

• Wasted Fuel Source: Leaking or poorly performing traditional systems force plants to flare off valuable converter gas instead of recovering it, literally burning thousands of dollars a day.
• Downstream Destruction: Allowing dust loads above 50 mg/Nm3 into the gas holder severely erodes turbine blades and gas engines, causing millions in premature equipment replacement.
• Catastrophic Liability: A single dead-zone explosion can halt steel production for months, causing incalculable structural damage and revenue loss.

The Ever-power Upgrade ROI

• Maximum Energy Recovery: The 100% sealing design allows total capture of the CO gas stream. The financial value of this recovered gas powering captive turbines often covers the CapEx of the ESP within 18 to 24 months.
• Asset Protection: Reaching sub-10mg/Nm3 particulate levels ensures your gas holders and power generation turbines experience near-zero abrasion, extending their lifecycle immensely.
• Guaranteed Uptime: The explosion-proof cylindrical design allows the steelmaking process to operate continuously without safety-induced shutdowns.

🇮🇳 Tata Heavy Steelworks (India)

Application: BOF Dry Converter Gas Recovery

Challenge: Previous rectangular ESP systems experienced micro-explosions during the oxygen blow cycle, causing severe casing deformations and halting smelting operations weekly.

Solution: Installed the Ever-power Cylindrical Converter ESP rated for 0.2 MPa. The aerodynamic design eliminated CO pooling. Explosion incidents dropped to absolute zero, and gas recovery efficiency increased by 34%.

🇧🇷 Minas Gerais Metallurgy (Brazil)

Application: Converter Gas Energy Recycling

Challenge: High particulate carryover (>120 mg/Nm3) was destroying the blades of their captive power gas turbines within months.

Solution: Upgraded to the Ever-power Dry Type Cylindrical ESP. Outlet emissions stabilized firmly below 20 mg/Nm3. Turbine maintenance intervals were extended from quarterly to semi-annually, saving over $2.5M in maintenance costs per year.

🇻🇳 Hoa Phat Smelting Complex (Vietnam)

Application: 1,200,000 m3/h Converter Gas Purification

Challenge: Strict new national environmental policies required the plant to halt flaring and safely capture all converter off-gas without toxic leakage to the atmosphere.

Solution: Deployed our 100% Zero-Leakage ESP system featuring the specialized internal dust scraper. Achieved full regulatory compliance and successfully routed the clean gas to fuel their rolling mill reheat furnaces.

🇨🇳 Tangshan Iron & Steel (China)

Application: High-Volume BOF Upgrade

Challenge: Required an ESP upgrade within a highly constrained spatial footprint that could still handle 0.2 MPa pressure surges and strict sub-10mg emissions.

Solution: Engineered a highly compact vertical cylindrical precipitator using ultra-efficient internal distribution screens, meeting the tight safety directives, space limitations, and ultra-low emission targets flawlessly.