For overseas steel plants, dust removal in the sintering section is a "hard nut" - the flue gas temperature exceeds 200 ℃, the dust concentration is high, and it contains corrosive gases such as SO ₂. Ordinary dust collectors either have frequently damaged filter bags or do not meet emission standards; Not to mention the requirement of "dust emissions ≤ 5mg/m ³" by the US EPA. Once exceeded, a single fine can reach 3% of the company's annual revenue. And with the characteristics of "no filter material electrostatic adsorption, corrosion resistance and durability, low energy consumption", electrostatic precipitators have become the preferred choice for ultra-low emission steel sintering, easily passing EPA certification and helping factories reduce costs and increase efficiency.
1、 Directly addressing the pain points of sintering: why electrostatic precipitators are an "exclusive solution"
The difficulty of dust removal in the steel sintering section is precisely the advantage of electrostatic precipitators:
1. Can withstand high dust and high temperature
The dust concentration in sintering flue gas often reaches 30-50g/m ³, and the temperature remains stable at 180-220 ℃. Under these conditions, the filter bags of traditional bag filters will age and wear due to high temperature and dust within 3-6 months, requiring frequent shutdowns for replacement, with a cost of over 20000 US dollars per replacement. And electrostatic precipitators do not require filter materials, relying on the electrostatic adsorption of dust by the electrode plates. The electrode plates are made of high-temperature resistant alloy material, which can operate in an environment of 200 ℃ for a long time without deformation. The continuous operation life of the equipment can reach 8-10 years, and there is almost no need to stop due to "consumable damage".
2. Corrosion conditions are "long-lasting"
The sintering flue gas contains corrosive gases such as SO ₂ and Cl ⁻, and ordinary carbon steel equipment will corrode and perforate after 1-2 years. However, the core components of the electrostatic precipitator have undergone "dual anti-corrosion": the electrode plate is made of 316L stainless steel, with an acid and alkali corrosion rate of ≤ 0.01mm/year; The inner wall of the shell is coated with polytetrafluoroethylene to isolate direct contact with smoke. The overall anti-corrosion life of the equipment is three times longer than that of ordinary dust collectors, especially suitable for markets with high environmental requirements and long equipment service life such as North America and Europe.
2、 Ultra low emission EPA: 3 major technologies enable emissions to be ≤ 5mg/m ³
The US EPA has strict requirements for dust emissions in the steel industry, especially in the sintering section, which needs to be stably controlled below 5mg/m ³. The electrostatic precipitator achieves "ultra-low emissions" through precise design:
1. Efficient polar plate design: more thorough adsorption
Adopting a "Z-shaped electrode plate+multi electric field layout", the electrode plate spacing is reduced to 150mm, and the electric field strength is increased by 30%. Even fine dust of 0.1 μ m can be effectively adsorbed, and the dust removal rate remains stable at over 99.95%.
2. Intelligent dust cleaning: no dust at all
Equipped with a "wet+mechanical vibration" dual cleaning system: wet cleaning is used for sticky dust, and the electrode plate is washed evenly with water flow to avoid dust agglomeration; Mechanical vibration is used for dry dust, and the vibration frequency is automatically adjusted according to the thickness of the dust, which not only thoroughly cleans the dust, but also does not produce secondary dust, ensuring stable export concentration.
3. Uniform airflow distribution: no dead corners for purification
Install a "porous flow equalization plate+guide vanes" at the entrance of the equipment to allow dust laden flue gas to enter the electric field evenly, avoiding the escape of dust caused by rapid local airflow.
3、 Energy saving and cost reduction: Save 30% of operating costs compared to traditional equipment
Electrostatic precipitators not only meet standards, but also help steel plants reduce long-term energy consumption and maintenance costs:
1. Low energy consumption operation: much cheaper electricity bills
Compared to bag filters that require overcoming filter bag resistance, electrostatic precipitators have an airflow resistance of only 600-800Pa and a 20% reduction in fan power.
2. No filter material cost: less wasted money
Traditional bag filters require the replacement of filter bags twice a year, with a cost of $80 per bag. One device requires 120 filter bags, and the annual cost of filter materials is nearly $20000; The electrostatic precipitator has no filter material and only needs to replace the anti-corrosion coating every 3 years, with a cost of about $5000. The annual maintenance cost is only 1/4 of that of the bag filter.
4、 Foreign trade adaptation: customized for global working conditions, worry free customs clearance
According to the different working conditions of steel plants in different regions, electrostatic precipitators can be "localized adjusted" to ensure that they are ready for use on the ground:
1. High temperature scenario in the Middle East: Install a cooling fan on the top of the equipment to avoid electrical component failures caused by high temperatures, and adapt to outdoor environments above 45 ℃ in the Middle East during summer;
2. Nordic high humidity scenario: The electrical cabinet is treated with IP65 waterproofing to prevent short circuits caused by moisture, which is in line with the rainy climate of Nordic countries;
3. Compliance certification: In addition to passing EPA certification, CE and UL certifications can also be provided, which are compatible with EU and North American power grids (110V/220V optional). No additional testing is required during customs clearance, resulting in a 50% increase in efficiency.
Summary: The Double Optimal Choice of "Compliance+Cost Reduction" for Steel Sintering
For overseas steel plants, electrostatic precipitators are not simply "dust removal equipment", but a comprehensive solution that "passes EPA, is corrosion-resistant, and saves costs" - it solves the pain points of high temperature, high dust, and high corrosion in the sintering section, achieving ultra-low emissions; At the same time, through low-energy consumption and filter free design, long-term operating costs are reduced. In the context of the continuous upgrading of global environmental standards, choosing the right electrostatic precipitator can not only maintain compliance bottom line, but also enhance factory competitiveness, becoming a "reliable partner" for the steel sintering section.