Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates

This research presents a comprehensive evaluation of Unit #4, a 210 MWe BHEL-designed boiler in a thermal power station, focusing on Flue Gas Duct Airflow Assessment (FGDAA) and Computational Fluid Dynamics (CFD) analysis of the associated flue gas duct system. The unit operates with six Electrostatic Precipitators (ESPs), three Induced Draft (ID) fans, and two Forced Draft (FD) fans, and the primary objective is to optimize flue gas distribution among ESPs to enhance plant efficiency and reliability. Cold air velocity measurements using calibrated S-type Pitot tubes provided accurate estimation of mass flow distribution in various ducts, while FGDAA under different ID fan operating conditions highlighted important operational efficiency considerations. The study identified non-uniform mass flow distribution across ESPs, which motivated detailed CFD simulations and the development of improved engineering designs for baffle and guide plates to regulate flow. In addition, material selection for these components was investigated through cost analysis and mechanical characterization. Results showed that tungsten carbide-clad plates are significantly more expensive than ceramic guide plates, while microhardness testing indicated silicon carbide as a superior material due to its higher hardness and wear resistance. Wear testing on AISI 1018 steel further demonstrated the influence of mass concentration on erosive damage, underscoring the importance of optimized flow management in flue gas environments. Overall, the study provides valuable insights into airflow control, material selection, and design optimization to improve the performance and service life of flue gas duct systems in thermal power plants.