Electrostatic separation processes

Optimization of electrostatic separation processes demands the control of a multitude of factors, including the characteristics of the granular mixtures to be sorted, the feed rate, the configuration of the electrode system, the applied high-voltage and the environmental conditions. The Taguchi's experimental designs presented in this article clearly prove that the linear-interaction models of the electrostatic separation processes can reflect the effects of the main factors in a manner that is satisfactory to most case of the practical interest. The Taguchi's experimental designs are based on special matrices called orthogonal arrays.     

Charge-Decay Characteristics of Granular Materials Forming Monolayers at the Surface of Grounded Electrodes

Laboratory studies and in-field observations have shown that the charge-decay characteristics of the granular materials at the surface of the grounded roll electrode significantly influence the outcome of the electrostatic separation process. This paper validates an indirect method of charge-decay characterization, based on the measurement of the electrical potential at the surface of a monolayer of granular insulating material. The study was performed on three materials–-polyvinyl chloride, polyethylene, and rubber–-extracted from chopped electric wire wastes. The granules (characteristic size in the range 1–4 mm) were disposed on the surface of a grounded plate electrode (layer area: 100 mm $ times$ 100 mm; electrode area: 200 mm $ times$ 200 mm). A wire-type corona electrode, energized from a dc high-voltage supply, was employed for charging the granules. The potential due to the charge at the surface of the granular layer was measured with the capacitive probe of an electrostatic voltmeter connected to a personal computer. Data acquisition and processing were done using the LabView environment. The influence of particles characteristics and of ambient factors was studied. The findings enabled a more accurate modeling of discharging phenomena that affect the performances of electrostatic separators. The method can be easily adopted in electrostatic discharge studies for material characterization.      

High-Voltage Monitoring in Electrostatic Separators

High voltage is known to be one of the main control variables in any electrostatic-separation process. From this perspective, the aim of this paper is twofold: to develop an effective high-voltage monitoring system and to demonstrate that it can be a useful tool for controlling the overall operating conditions of an electrostatic-separator system. A custom-designed virtual instrument was employed for processing the experimental data provided by a high-voltage probe, the output of which was connected to an electrometer. In several experiments, the output of the high-voltage probe was also connected to a digital oscilloscope, in order to obtain a better understanding of the variation of the electrode potential after a spark discharge. The laps of time without corona discharge and/or with low electric field intensities could thus be accurately determined, and the impact of the spark discharges on the outcome of the separation process evaluated. The dispersion of high-voltage measured values was found to increase in the presence of the material. The statistical analysis of the data revealed a significant correlation between the standard deviation of the high-voltage and the concentration of metal in the processed material. The results of this paper could be helpful for those seeking the optimization of the operating conditions for the electrostatic separation applications, in which the metal content in the feed materials exhibits substantial fluctuation with time     

高压脉冲负电晕荷电喷雾试验研究

为减少化学农药带来的污染,采用了荷电喷雾新技术。首先对负高压脉冲电晕荷电机理进行了理论分析,再用网状目标法通过调节电压、极距、电极直径、电极数目等参数进行电晕荷电试验,比较各因素对电晕放电伏-安特性影响及荷电后雾化效果;测量不同电压下雾滴的索太尔直径;并用高速摄影拍摄雾滴带电射流破碎时的状态,得到射流破碎时的雾滴形状。理论分析和试验结果表明,电压越高,雾滴谱较窄,雾滴粒径变细,均匀度越高;揭示了不同影响因素下的雾滴荷电特性,为负高压脉冲电晕荷电喷雾技术的应用和设计提供了理论基础和试验数据。     

Charging and discharging of insulating particles on the surface of a grounded electrode

The aim of the present paper is to analyze the corona charging of millimeter-size insulating disks, as well as their discharging when they are no longer exposed to the action of an external electric field. The experiments were carried out on a roll-type electrostatic laboratory separator, equipped with a wire-type corona electrode, simulating the actual charging/discharging conditions in an industrial unit. Disks of various sizes were charged on the surface of the roll electrode, then the high voltage supplied to the corona electrode was turned off and the particles were collected in a Faraday pail, connected to an electrometer. The charge measurements were performed at various time intervals from high-voltage turn-off. In this way, the charge decay could be recorded and the discharge process fully characterized. The measured data show that the discharge process depends on the nature, size, and shape of the particles, as well as on the contact conditions between the particles and the grounded roll electrode. These data could guide the design of the electrostatic separation experiments that precede any new industrial application of this technology.     

Multiple-needle corona electrodes for electrostatic processesapplication

Corona from high-voltage electrodes is employed in various electrostatic installations, such as ozonizers, air filters, powder sprayers and separators. Multiple-needle electrode designs are preferred whenever low corona onset voltage and good resistance to mechanical shocks are required. This paper aims at identifying a simple solution to overcome the main drawback of this type of electrode, the nonuniformity of the generated space charge. Experiments were carried out with various models of electrodes, having one or several rows of stainless steel needles. A current probe, consisting of an enameled copper wire (0.4 mm diameter), was embedded in the center of a plane collecting electrode. For a given interelectrode distance (5-50 mm) and a fixed position of the multiple-needle electrode, the collecting plate was translated along two orthogonal directions, so that the current probe could scan a 75 mm×75 mm square. The results depended on the interelectrode distance and on the high-voltage level. An explanation is given to some observations made on a roll-type electrostatic separator provided with two models of multiple-needle corona electrodes. An improved electrode design was proposed for the industrial installations     

Optimization of electrostatic separation Processes using response surface modeling

The efficiency of electrostatic separation processes depends on a multitude of factors, including the characteristics of the granular mixtures to be sorted, the feed rate, the configuration of the electrode system, the applied high voltage, and the environmental conditions. The possibility of optimizing the operation of industrial electrostatic separators using rather simple computed-assisted experimental design techniques has already been demonstrated. The aim of the present work is to analyze the peculiarities of application of a more sophisticated group of response surface experimental design techniques that make use of quadratic functions for modeling the electrostatic separation process. One unique contribution to this work is to consider the economic value of the process in addition to the technical result. The 11 electrostatic separation tests, corresponding to a central composite design, were carried out on samples of chopped electric wire wastes. The CARPCO laboratory roll-type electrostatic separator employed for this study enabled a rigorous control of two factors: the applied high-voltage level and the speed of the rotating roll electrode. The objective was to maximize the benefits from the recycling of both constituents of the binary copper-polyvinyl chloride granular mixture. The optimum operating conditions computed with the quadratic model derived from the experimental results were in good agreement with the data of pilot-plant tests. Thus, the highest extraction of useful materials was obtained at high voltage and low speed, while the optimum conditions for greatest economic value were found to be high voltage and high speed. The response surface methodology can be easily applied to most of the industrial applications of electrostatic separation technologies.     

Computational and Experimental Study of Ionic Space Charge Generated by Combined Corona–Electrostatic Electrode Systems

Numerical computation of the electric field intensity and space charge density in electrode systems consisting of ionizing and nonionizing elements, connected at the same direct current (dc) high-voltage supply and facing a grounded plate, is a difficult problem, which is of interest to several electrostatic processes applications. The aim of the present paper is to demonstrate the effectiveness of an original method of field computation in the analysis of the factors that influence the distribution of the ionic space charge in such combined corona–electrostatic electrode systems. The computations and the experiments were carried out for an ionizing wire of diameter 0.3 mm, located at different distances$h$(10–30 mm) from a tubular support of diameter 25 mm. Several interelectrode distances (20–45 mm) were simulated. The extension of the zone at the surface of the grounded electrode, which is affected by the space charge, diminishes when reducing the intervals between these elements of the electrode system, and, at similar applied voltage, the density of the corresponding corona current increases. The experimental data were in good agreement with the computed results, validating the accuracy of the numerical method of space-charge calculation in this special electrode configuration.     

Electrostatic separation of brass from industrial wastes

Previous studies have demonstrated that electrostatic separation can be successfully employed for the recycling of nonferrous metals from chopped electric wire and cable scrap. The aim of this paper was to investigate the possibility of using the electric field forces for the selective sorting of other granular mixtures, such as brass dross. Laboratory tests of electrostatic separation were carried out on three samples: 0.08-1 mm, 0.08-0.2 mm, and 0.2-1 mm, containing more than 66% of brass. Sample 1 was separated in a corona-electrostatic field, generated by a standard electrode arrangement: a grounded rotating roll electrode (diameter 150 mm) and two high-voltage electrodes (wire-type dual corona electrode+tubular electrode). Processing of the other two samples was carried out in a custom-designed separator comprising an extended corona field generated between a matrix-type multineedle corona electrode and a roll electrode of large diameter (250 mm). Chemical analysis of the products showed that more than 90% of the brass can be recovered with a purity higher than 95%. The extended corona field electrode arrangement proposed in this paper seems to be a promising solution for the effective recycling of other granular wastes containing copper, aluminum and their alloys     

静电放电对无绳电话充电接触失效的影响

进行高压静电条件下的加速失效模拟实验,测量无绳电话充电接触失效循环寿命,证实人体静电放电对充电电极寿命的影响。通过扫描电子显微镜观察触头显微形态和进行表面元素成分的半定量分析,从理论上研究充电接触失效的微观过程和作用机理。研究结论对合理选择电极材料、进行表面处理和防护以及改进电极组件设计具有参考意义。     

High-voltage electrode position: a key factor of electrostatic separation efficiency

Industry application of electrostatic separation technologies still faces a major difficulty: good results can be obtained only by adequate control of a multitude of operating parameters. The aim of the present paper is to analyze a key factor of electrostatic separation efficiency: the position of the high-voltage electrodes. Experiments were performed with two types of granular materials: chopped electric wire wastes and foundry sands. The electrostatic separator employed for the tests was provided with a wire-type corona electrode, associated - in some experiments - with a tubular-type electrostatic electrode, at various angular and radial positions, with respect to a rotating roll electrode connected to the ground. The experimental data are discussed in relation to the results of the numerical analysis of the electric field, carried out with a charge simulation program. They show that the outcome of the separation process (i.e., the weight percentage of the conductor and nonconductor fractions, as well as the purity of the recovered materials) depends on the configuration of the electrode system. The position of the electrodes affects both the particles charging conditions on the surface of the roll electrode, and the trajectories of the charged particles in the high-intensity electric field of the separator. Some recommendations could be formulated for the industrial application of the electrostatic separation technology.     

Analysis of the behavior of ions produced by pulsed coronadischarge

The motion of an ion cloud which is produced by a corona discharge with the high-voltage pulse of a short duration and is introduced into parallel plate electrodes was calculated numerically. The ion cloud initially placed at the tip of a needle electrode was simulated by a number of ring charges and the trajectories of individual ring charges were calculated by using electric field strength obtained with a charge simulation method. Not only movement of the ion cloud but also the waveform of the induced current flowing through a ring electrode located at the center of the parallel plate electrode were simulated and analyzed. The ion cloud with an initial diameter of 0.5 mm expands to 5 mm by electrostatic repulsion within 10 μs after the beginning of drift. During drifting toward the counter electrode, the ion cloud extends wider to a diameter of around 20-25 mm. The size and velocity of ion clouds agree with those estimated by experiments and the waveform of induced current obtained by experiments was reproduced by this simulation     

经济型高压电除尘控制器的研究

电除尘技术是利用高压产生的强电场使气体电离,进而使粉尘荷电,并在电场力的作用下,使气体中的悬浮粒子分离出来的技术。静电除尘电源作为静电除尘设备的主要设备,是影响除尘效率的重要因素。本文详细介绍了一种基于三相高压整流装置的经济型除尘电源的设计与研究,详细介绍了基于单片机芯片dsPIC30F6014A的电源控制系统的总体设计方案、硬件电路设计、软件编程设计、与人机交互界面的通讯方法等。最后通过实验证实了设计系统的可行性和正确性。     

Corona inception in typical electrode configurations forelectrostatic processes applications

The corona inception electric field at the surface of a wire electrode is usually evaluated by an empirical formula established by Peek. That formula was found to be valid in several simple electrode configurations (wire cylinder, wire plate), which are typical to electrostatic precipitators. The aim of this paper is to extend the study to other situations encountered in electrostatic applications. The experimental setup specifically modeled the several electrode arrangements which are commonly used with roll-type electrostatic separators. It consisted of wire-type corona electrodes, connected to a regulated DC high-voltage supply, and a rotating roll electrode, connected to the ground. The effect of associating the corona wire to one or several tubular electrodes of various shapes and sizes was investigated. The experimentally determined corona inception voltage was used as input data of a boundary-element-method program for the electric field computation. The computed values of the electric field were compared with those given by Peek's formula for wire electrodes of the same radius. The derived conclusions can be of help in the custom design of the corona electrode arrangements for various electrostatic applications     

Separation of Fine Granular Mixtures in S-Plate-Type Electrostatic Separators

Plate-type electrostatic separators are commonly used for the selective sorting of conductive from nonconductive constituents of a granular mixture. This paper addresses the more delicate issue of granular materials that are characterized by finite nonzero resistivities. The study was conducted with three materials having similar granule size range and specific weight but slightly different electrical properties. Two sets of experiments were performed for evaluating the effect of electrode geometry on the behavior of each of the materials. These results were then employed for predicting the outcome of the electrostatic separation of binary mixtures of good and poor conductors. A third set of experiments validated the predictions and pointed out a couple of nonelectric factors that might deteriorate the performance of a plate-type electrostatic separator in an industrial environment.     

Drop size measurements in electrostatic paint sprays

Drop-sizing experiments were performed on an electrostatic fan-spray atomizer operated in the airless mode. Tests were conducted with and without application of a high-voltage charge to the electrode tip placed downstream of the nozzle exit. A nonintrusive Malvern 2600 particle sizer, based on the forward scattering of a 5 mW He-Ne laser beam, was used to yield line-of-sight and cross-sectional drop size distributions. The atomizer was traversed across the laser beam, and drop size profiles as a function of distance from the centerline were developed. Enamel paint with a viscosity of 17 cp was sprayed over a differential pressure range of 1.38 to 6.20 MPa. Results indicate that at low injection pressures the charge application has a significant effect on the average drop size and the spatial drop distribution. However, as injection pressure is increased, the electrostatic influence on drop size and distribution decreases     

背负式静电喷雾器设计与试验

为改善传统背负式施药器械的喷雾效果,运用高压静电喷雾技术,设计了背负式静电喷雾器。该喷雾器由蓄电池、隔膜泵、高压静电发生器、喷枪、直射喷头和药箱组成,采用直接充电的方式对雾滴进行充电。为考察该喷雾器的性能,用网状目标法对荷质比进行了测量,用Oxford激光粒子图像分析测试系统测试了雾滴粒径及速度,最后用纸卡法测试了雾滴覆盖度。测试结果表明:荷质比随喷嘴压力的加大基本呈线性增长,因而在保证零部件及系统可靠的前提下,设计静电喷雾器时可适当增加喷嘴压力;静电促进雾滴吸附于作物表面、使雾滴粒径细小且分布均匀、改善了雾滴的速度分布均匀性,从而使雾滴能够均匀吸附于作物表面各部位,并显著提高了雾滴的覆盖度。     

Set Point Identification and Robustness Testing of Electrostatic Separation Processes

Identification of the optimal operating conditions and evaluation of their robustness are critical issues for the industrial application of electrostatic separation techniques. In spite of extensive investigations performed in recent years, no standard procedure is available for guiding the research of the set point and for minimizing the process sensibility to changes in certain critical factors. The aim of this paper is to formulate a set of recommendations regarding the choice of high-voltage, roll-speed, and feed-rate values for an important class of electrostatic separation applications: the selective sorting of conductive and nonconductive constituents of granular industrial wastes. The experiments were carried out on a laboratory separator, built by one of the authors, with various samples of chopped wire wastes furnished by l'Entreprise des Industries des Cacircbles, Biskra, Algeria. Several one-factor-at-a-time experiments, followed by two factorial designs (one composite, the other fractional), were performed based on the following three-step strategy: 1) identifying the domain of variation of the controlled variables; 2) finding the best choice of the set point; and 3) assessing the robustness of the process, i.e., testing whether the performance of the system remains satisfactory even when the factors vary slightly around that point. The results presented in this paper are strictly valid only for a well-defined category of processed materials, but a similar approach could be adopted for a wider range of electrostatic separation applications     

Optimal high-voltage energization of corona-electrostaticseparators

The selection of the high-voltage supply can play an important role in the optimization of electrostatic separation processes. This paper aims to evaluate the influence of the main high-voltage parameters (waveform, polarity, level) on the efficiency of electrostatic separation, in the case of insulation-metal granular mixtures. A roll-type laboratory high-tension separator was employed for the experimental study, and the tests were carried out with samples of granular materials taken from the technological flowsheet of a recycling plant for electric wire scraps. The oscillograms of the voltage and of the current across the separator proved to be of great use for studying the transition from corona to spark discharges. The experiments, performed under various operating conditions (roll speed, roll radius, high-voltage level, interelectrode distance), show the existence of a strong interdependence between these parameters, the frequency of spark discharges, and the efficiency of the separation process. The reported results suggest that monitoring the frequency of the spark discharges could be of use for controlling the optimum operating voltage for a given electrostatic separation application. Although the full-wave rectifier allows for lower operating voltages than the half-wave rectifier, its general effectiveness in electrostatic separation processes is superior. Good insulation-metal electrostatic separation can be achieved at either positive or negative polarity of the high-voltage supply, but negative electrode energization is recommended for most industrial applications     

Experimental Study of the Corona Discharge in a Modified Coaxial Wire-Cylinder Electrostatic Precipitator

Coaxial wire-cylinder electrode arrangements are widely used for the electrostatic precipitation of dust particles contained in flue gases. The aim of this paper was to evaluate a new design, which was expected to increase the particle collection efficiency. The collector electrode of the several models under study consisted of a cylinder with alternate small- and large-diameter sections. In a first set of experiments, the current–voltage characteristics of each model were compared with those obtained for a standard wire-cylinder electrode arrangement, at both polarities of the high-voltage supply, and for three values of the inlet airflow rate, namely, 0, 4.5, and 6 $hbox{dm}^{3}/hbox{min}$, with the corresponding air velocities in the large-diameter sections being 0, 6.0, and 8.0 cm/s. A second set of experiments showed that the current density distribution inside the models depends on the geometry of the electrode system but is roughly the same at 4.5 and 6 $hbox{dm}^{3}/hbox{min}$. The particle collection efficiency of the different models was evaluated in a third set of experiments, performed with 2-g samples of starch powder, under various operating conditions. Data analysis revealed that the modified precipitators have higher efficiency than the standard model. As expected, for a given geometry of the electrode arrangement, the efficiency was found be lower at higher inlet airflow rates. These findings could serve in the design of new industrial electrostatic precipitators.