Descrição
Ionization Catcher | Advanced Tar & Particulate Elimination
Eradicate sticky tar, heavy water mist, and corrosive particulates that destroy downstream equipment. Engineered by Ever-power, the BL-Series Ionization Catcher utilizes a high-voltage electrostatic field to capture complex impurities with absolute efficiency. Protect your induced draft fans, prevent catalyst blinding, and transform hazardous tar waste into a recoverable asset with our internationally leading separation technology.
⚙️ Executive Brief Card
🌊 Processing Capacity
- 📉 Standard Gas Volume: 10,000 – 30,000 m³/h (Highly Scalable)
- 🌫️ Target Pollutants: Tar, Water Mist, Oil Fumes, Fine Dust
- ⚡ Electrode Tubes: 37 to 91+ (Galvanized φ250x4000mm)
🎯 Purification Performance
- ✅ Capture Efficiency: > 99% for Tar & Mist
- ✅ Operating Resistance: Extremely Low (300 Pa)
- ✅ Power Consumption: 15 kW to 42 kW
🛡️ Core Technology
- ⚡ Corona System: High-voltage DC ionization
- 🔌 Rectifier: High Voltage Electrostatic Silicon Rectifier
- 🛡️ Insulator Protection: Thermally insulated, electrically heated box
📊 Technical Specifications & Performance Index
The Ever-power BLBZQ Series Ionization Catcher is designed in a vertical cylindrical configuration to maximize space utilization while delivering phenomenal gas-liquid-solid separation. Below are the standard specifications for our core modules.
| Model | Gas Volume (m³/h) | Equipment Size (mm) | Electrode Tubes (pcs) | Tube Specification | Wind Resistance (Pa) | Power Consumption (KW) |
|---|---|---|---|---|---|---|
| BLBZQ-10000 | 10,000 | Φ2300 * 8000 | 37 | δ=0.8mm, Galvanized Round Tube Φ250 * 4000mm | 300 | 15 |
| BLBZQ-15000 | 15,000 | Φ2600 * 8000 | 55 | δ=0.8mm, Galvanized Round Tube Φ250 * 4000mm | 300 | 22 |
| BLBZQ-20000 | 20,000 | Φ3100 * 8500 | 73 | δ=0.8mm, Galvanized Round Tube Φ250 * 4000mm | 300 | 29 |
| BLBZQ-30000 | 30,000 | Φ3800 * 9000 | 91 | δ=0.8mm, Galvanized Round Tube Φ250 * 4000mm | 300 | 42 |
* Note: For process flows exceeding 30,000 m³/h, multiple units can be deployed in parallel, or custom mega-scale units can be fabricated to site requirements.
🔬 Ionization Catcher Introduction & Core Concepts
In industries such as coking, carbon manufacturing, and heavy chemical processing, exhaust gases are heavily laden with sticky coal tar, oil mists, and saturated droplets. Traditional dry baghouses will instantly blind and clog under these conditions, while wet scrubbers fail to capture fine aerosols effectively.
The Ionization Catcher (Electrostatic Tar Precipitator) is the definitive solution. The core concept relies on high-voltage electrostatic principles. When smoke containing tar and droplet impurities passes through a powerful electric field, a corona discharge occurs. The impurities adsorb negative ions and electrons. Driven by the Coulomb force of the electric field, these charged particles migrate rapidly to the precipitation electrode (the tube wall), where they release their charge and adsorb onto the surface.
🏗️ Product Core Components
1. The Corona System
The heart of the catcher. It consists of highly engineered corona wires, high-voltage porcelain bottles, suspension rods, upper and lower umbrella rings, and tensioning weights. Installed inside the tar removal tower, it generates a ferocious high-voltage electric field that ionizes the surrounding gas medium, imparting a negative charge to all tar, mist, and dust passing through.
2. High Voltage Electrostatic Silicon Rectifier
Transforms standard alternating current (AC) into the massive, stable high-voltage direct current (DC) required by the corona system. It ensures continuous, uninterrupted corona discharge even under heavy particulate loading.
3. Insulator Box with Thermal Protection
Because the gas stream is laden with moisture and sticky tar, high-voltage insulators are at extreme risk of tracking and short-circuiting. Our insulators are housed in a dedicated thermal insulation box equipped with an electric heating device. This prevents moisture condensation on the porcelain, ensuring absolute electrical safety and preventing system trips.
4. High Voltage Control Cabinet
The central nervous system of the Ionization Catcher. It manages power input, working voltage adjustment, and output. It features rapid operational fault alarms and automated high-voltage cut-offs to prevent internal sparking from escalating into fires.
⚙️ Working Principle
The continuous operation of the Ionization Catcher relies on the physics of electrostatic precipitation combined with the fluid dynamics of viscous liquids:
- Gas Entry & Distribution: Dirty, tar-laden gas enters the lower section of the tower and is evenly distributed upward through the honeycomb array of precipitation tubes (anodes).
- Ionization & Charging: As the gas passes the central corona wire (cathode), the intense high-voltage field ionizes the gas. Free electrons and negative ions attach themselves to the tar droplets, oil fumes, and dust particles.
- Migration & Capture: The negatively charged tar and dust are violently repelled by the cathode and attracted to the grounded inner walls of the precipitation tubes. Upon impact, they lose their charge and adhere to the tube wall.
- Gravity Discharge: Over time, the mass of the tar and liquid impurities adsorbed on the precipitation electrode increases. Once it overcomes surface adhesion, the collected liquid acts as a self-cleaning mechanism, automatically flowing down the tube walls. It collects in the bottom cone and is discharged for recovery, while 99%+ clean gas exits the top of the tower.
🏭 Perfect Manufacturing Facilities
The structural integrity and absolute vertical alignment of the electrode tubes are paramount. A misalignment of just a few millimeters can cause high-voltage arcing and catastrophic failure.
Ever-power operates a massive industrial park with an annual production capacity exceeding 50,000 tons. We utilize specialized production lines explicitly for polar plates and discharge electrodes. Our facility deploys CNC Cutting Machines, Robot Automatic Welding stations, and large-scale edge planers to guarantee absolute dimensional tolerance. Operating strictly under the ISO9001 quality management system, our fabrication ensures perfect electrode concentricity and flawless equipment longevity.
💻 Supporting Control & Instrumentation
Managing high-voltage direct current (tens of thousands of volts) in explosive, tar-rich environments requires flawless automation. Ever-power provides a complete, turnkey suite of intelligent electrical control equipment.
- Spark Management System: The control cabinet automatically detects micro-arcing inside the tower. It instantaneously drops the voltage to extinguish the spark and ramps it back up in milliseconds, ensuring safety without losing capture efficiency.
- Insulator Heater Control: Automatically monitors ambient and internal temperatures, engaging the insulator box heaters to strictly prevent condensation and electrical tracking.
- DCS Integration: All panels are built to seamlessly integrate with your plant’s central control room, providing real-time telemetry on voltage, current, and system resistance.
🤝 Integrated Supply & Expertise
Since 2000, Ever-power has evolved from an equipment manufacturer to a comprehensive EPC (Engineering, Procurement, and Construction) integrated supplier.
Leveraging our deep R&D activities and vast technical cooperation, we deliver complex, multi-stage projects. Our integrated task force comprises the VOCs Business Dept, Desulfurization & Denitration Dept, De-NOx Dept, Fluid Suspension Dept, and Carbon Neutrality Dept. This means when you purchase an Ionization Catcher, you are buying a system perfectly engineered to integrate with your upstream boilers and downstream RTOs or scrubbers, guaranteed to work flawlessly as a unified ecosystem.
🌍 Successful Case Display
Shanxi Coking Group (China)
Application: Coke Oven Gas Purification
Challenge: Heavy coal tar was blinding downstream desulfurization equipment, causing massive plant downtime.
Ever-power installed a multi-unit Ionization Catcher array. Tar capture efficiency exceeded 99.5%. The recovered coal tar was sold as a chemical byproduct, turning a severe maintenance headache into a new revenue stream.
Gujarat Carbon & Chemicals (India)
Application: Carbon Baking Furnace Exhaust
Challenge: Thick asphalt fumes and pitch mist were escaping to the atmosphere, violating local EPA opacity laws.
The BLBZQ-30000 effortlessly condensed the heavy asphalt mist. The extremely low 300 Pa resistance meant no upgrades to the existing ID fans were required, saving significant CapEx.
Vietnam Rubber Corp (Vietnam)
Application: Rubber Vulcanization Exhaust
Challenge: Complex, oily, and sticky aerosols were rapidly blinding activated carbon filtration boxes.
Installed as a pre-treatment stage before final VOC oxidation. The Ionization Catcher stripped 99% of the oil mist, extending the life of downstream VOC media by 500%.
Rio Industrial Printing (Brazil)
Application: High-Volume Printing Oil Fumes
Challenge: Ink aerosols and plasticizer fumes required capture without using water scrubbers due to zero-liquid-discharge mandates.
The dry electrostatic nature of the equipment perfectly solved the issue. The captured oils simply drained to a collection tote for safe, liquid-free disposal.
🏆 Why Partner with Ever-power?
Designing an Electrostatic Tar Precipitator requires absolute precision. A slight vibration or misalignment inside the high-voltage field causes catastrophic arcing and fire risks. It is a rigorous science we have perfected over 20 years.
- ✔️ Full Value-Chain Integration: We are true EPC contractors. We deliver comprehensive Process Engineering ➔ Precision CNC Manufacturing ➔ Turnkey Site Installation ➔ High-Voltage Commissioning.
- ✔️ Proven by Industry Giants: Our bespoke BL Series systems successfully safeguard the continuous compliance of massive conglomerates globally, including heavy chemical refineries, carbon plants, and coking facilities.
- ✔️ Uncompromised Quality Credentials: Fully ISO 9001 certified, holding multiple structural patents, ensuring flawless electrode concentricity and absolute operational safety.
📐 Selection Guide: Architecting Your Catcher
To engineer the precise Ionization Catcher for your hazardous exhaust, our technical team requires rigorous operational data to select the correct sizing and high-voltage parameters. Prepare the following data:
1. Exact Gas Properties (Crucial)
Provide the Maximum Gas Volume (m³/h), operating Temperature, and Moisture Content. We specifically need to know the concentration of Tar and Dust (mg/Nm³). High tar loads require specifically spaced electrode tubes to prevent bridging and arcing.
2. Downstream Equipment Protection
Is this device acting as a pre-filter for a downstream Catalytic Oxidizer (CO), Regenerative Thermal Oxidizer (RTO), or Desulfurization tower? Knowing your total process chain allows us to guarantee the necessary 99% capture efficiency to prevent downstream catalyst blinding or bed plugging.
3. Plant Layout & Recovery Demand
Do you intend to sell or recycle the captured coal tar or oil? We can engineer specialized heated bottom cones and discharge valves to ensure highly viscous captured materials flow smoothly into your recovery tanks.
💰 Value Quantified: Return on Investment (ROI)
Investing in an Ever-power Ionization Catcher transforms a massive maintenance liability into a highly profitable, self-cleaning asset.
The Cost of Inadequate Filtration
- Catastrophic Downstream Failure: Sending tar-laden gas directly into an RTO or catalytic bed will instantly blind the ceramics and poison the catalyst. You will face multi-week factory shutdowns to chisel out ruined ceramics, costing hundreds of thousands in downtime.
- Fan Destruction: Sticky tar accumulating on ID fan impellers causes severe dynamic imbalance. This leads to shattered bearings, destroyed motors, and constant fan replacement costs.
The Ever-power Upgrade ROI
- Unstoppable Uptime: By catching 99% of sticky tars and mists upfront, your downstream RTOs, scrubbers, and fans run flawlessly for years. Maintenance shutdowns drop to near zero.
- Energy & Material Profit: The extremely low operating resistance (300 Pa) saves massive electrical costs on your ID fans. Furthermore, the pure coal tar captured is a highly valuable chemical commodity. Selling this byproduct often pays back the equipment CapEx within the first year.
❓ Engineering & Operational FAQ
How does this differ from a standard Dry Electrostatic Precipitator (ESP)?
A standard Dry ESP captures dry dust and relies on mechanical hammers (rapping) to knock the dust off the plates. If you put tar or wet mist into a Dry ESP, the rapping hammers will fail to dislodge the sticky sludge, and the unit will short-circuit. An Ionization Catcher is specifically designed for wet, sticky, tar-heavy flows. It utilizes the liquid nature of the captured material to naturally flow down the tubes via gravity—no mechanical rapping required.
What happens if the insulators get wet?
Wet insulators cause high-voltage electrical tracking, sparking, and system failure. To prevent this, Ever-power engineers a dedicated, sealed Insulator Box equipped with internal electric heaters. This keeps the porcelain insulators completely dry and above the dew point, ensuring absolute electrical safety.
How do you prevent high-voltage fires in combustible gas streams?
Safety is governed by advanced PLC logic. The High Voltage Control Cabinet features an ultra-fast spark management system. If a micro-arc is detected, the system instantaneously drops the voltage to extinguish the spark, then ramps it back up in milliseconds. Combined with strict oxygen (O2) and LEL monitoring in the ductwork, explosion risks are entirely mitigated.
How is the captured tar or thick oil discharged?
The captured liquid flows via gravity down the anode tubes into a conical collection hopper at the base of the unit. For highly viscous tars, we can integrate steam jackets or electric heat tracing around the bottom cone to keep the material fluid, allowing it to discharge smoothly through an automated rotary or gate valve.
Protect Your Equipment & Recover Valuable Assets
Stop risking catastrophic downstream blockages and ID fan destruction. Let Ever-power’s senior engineering team design a bespoke Ionization Catcher that guarantees > 99% tar and mist removal, recovers valuable chemical byproducts, and secures your plant’s absolute operational continuity.
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