Field Evaluation of Wet Electrostatic Precipitator Efficiency During Commissioning in a Sulfuric Acid Plant

Abstract

Copper smelting and associated sulfuric acid production generate gas streams containing sulfur dioxide and fine particulate matter, requiring effective emission-control systems. This study evaluates the field performance of a wet electrostatic precipitator (WESP) during commissioning at a sulfuric acid plant. A quantitative descriptive evaluation was conducted using operational records, field measurements, and inspection observations collected between February and April 2024. The analysis considered DC voltage and current, voltage utilization relative to the 80 kV design value, estimated particle resistivity, particle migration velocity, and the condition of collecting electrodes. The recorded operating voltages were approximately 27.3–30.5 kV, corresponding to voltage utilization of 35.3–38.1% across the five reported fields. The manuscript reports an actual collection efficiency of 35%, compared with a design target of 99.52%; however, the underlying calculation and supporting inlet/outlet particulate measurements must be verified before this value can be interpreted as a measured efficiency. The reported migration velocity was 1.29 × 10⁻⁷ m/s, compared with a design-derived value of 1.49 × 10⁻⁴ m/s. The findings indicate that low operating voltage and observed electrode degradation may have contributed to the deviation from design performance. The study highlights the need to document the calculation basis and sampling record when evaluating WESP performance during commissioning.