Electrostatic Precipitators for Mining Equipment

GEECOM, through the provision of Electrostatic Precipitator solutions, enables organisations in mining and other sectors in Southern Africa ensure that air emissions from their plants are compliant with the legal threshold in respective countries (in South Africa’s context this is The National Environmental Management: Air Quality Act, 2004 (Act No. 39 of 2004).

With the world feeling the effects of climate change, there is an increased burden on industry to do its bit in environmental conservation through the adoption of technologies that contribute to cleaner and better air quality.

Through its extensive expertise in the provision of customised electrostatic precipitator solutions, GEECOM has been at the forefront of this drive by helping mining companies ensure that particulate emissions from their plants are within the permissible legal threshold. With a team of vastly experienced application engineers and equipped with innovative environmental control technologies, the company is well poised to play its part in seeing to it that operations of its clientele remain sustainable.

“We are keen to help industry comply with evolving compliance requirements through the provision of electrostatic precipitator solutions,” affirms Gustl Mischkulnig, Managing Director of GEECOM.

“We can guarantee that we are more than capable, and our track record in Southern Africa speaks volumes about our capabilities,” he adds, highlighting how the company’s customised approach and the convenience of a turnkey offering have helped companies to meet statutory challenges.

Challenge of statutory requirements

As far as reducing emissions levels goes, the experiences of every client in mining are unique. However, they all boil down to meeting statutory regulations relating to The National Environmental Management: Air Quality Act, 2004 (Act No. 39 of 2004) in South Africa’s context.

The Act stipulates allowable particulate matter emission levels for each industrial process. “Based on normal non-compliance, the Client is required to either reduce relevant production or apply for permission to implement applicable dust abatement plans. Most Industrial Processes are required to meet particulate matter values of 50 mg/Nm3,” states Gustl.

GEECOM’s solution

As every client’s need is unique, what works with one client may not always apply to another. So, GEECOM created a solution tailored at meeting every client’s unique requirement. The company’s solution involves providing technical evaluations based on previous or new performance tests to indicate either the client’s compliance or non-compliance with the statutory regulations.

Once such evaluations are completed, various techniques based on formulas specific to Electrostatic Precipitators are used to evaluate the requirements for the possible upgrade of existing plant or implementation of new plant leading to full compliance with dust abatement requirements. Each solution is evaluated individually and a relevant outcome is tailor-made to meet the client’s specific application.

Convenience of a turnkey service

Recognising the complexity of the process of reducing emissions, as far as contemporary industry needs are concerned, GEECOM offers the convenience of a turnkey solution, which is customised to the respective needs of clientele. “We are a South African company with 100% local input in terms of Design, Engineering, Manufacture, Supply, Installation and Commissioning, with proven successes in many projects. Consequently, we are to provide a one-stop, turnkey application with highly effective solutions specific to each project,” Gustl says.

Reducing downtime

Downtime to electrostatic precipitators is the least desirable experience, but it is inevitable and it is entirely upon a mining company to minimise its occurrence. Cognisant of this, GEECOM, through its offering, ensures that clientele take a proactive view regarding minimising downtime.

The company has introduced many mechanical and electrical product innovations which are seen as extremely beneficial, not only for the provision of required results but also to the general operation and maintenance of proposed Electrostatic Precipitators. It also guarantees the client of efficient and extremely rapid after sales services which results in minimum plant downtime most of the times.  Last but not least, it presents Electrostatic Precipitator training courses, which ensures that the Client is made fully aware of every particular part of the plant, its operation and maintenance processes.

Meeting client’s project expectations

As you would have thought, clients are very particular about their needs and there is little – if any – margin for error, as compliance is obligatory. Therefore, GEECOM endeavours that the electrostatic precipitators are delivered according to the client’s project expectations.

For this reason, the company’s application engineers undertake the following steps: Ensuring that the initial technical evaluation is sound; Relevant solution is implemented accurately; Installation is carried out by technical personnel who are experienced in Electrostatic Precipitator technology and commissioning. Furthermore, optimisation is addressed by specialists with many years of experience in the particular field of technology.

Also, with 37 years of operation, GEECOM has a vast knowledge of Electrostatic Precipitators based on accumulated field specific know-how. This is passed on to the client at all times, which contributes to successful relations based on mutual partnerships rather than mere ‘client-supplier ‘arrangements.

Compliance with the Air Quality Act

Gustl warrants that engaging GEECOM for their electrostatic precipitator requirements ensures that mines meet the legal particulate matter emission levels, complying with the Air Quality Act. “Mines are able to reduce the risk of environmental damage or improve the collection of product residues, and are assured of a plant which is relatively easy to operate and maintain,” he says.

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Minimising Post-commissioning Downtime

The team at GEECOM go all-out to ensure that Electrostatic Precipitators installed work with minimal downtime.  Without doubt, the most practical ways of minimising unwanted downtime they have adopted is ensuring that technicians, operators and maintenance personnel are fully trained to address any unusual events or actual failures. “The training courses provide the backbone of this first line of action by the plant’s staff during unusual events. GEECOM also provides full and rapid support either via telephone or actual visits to site to address all technical issues.”

Besides, post-commissioning interventions are carried out regularly to address optimization processes which may be required due to plant process changes or other different requirements. Both mechanical and electrical support is provided by in-house staff fully trained in Electrostatic Precipitators.

Last but not least, inhouse manufacturing in a fully equipped factory environment enables spare parts to be made available at short notice in a fully equipped factory environment. The factory is dedicated specifically to mechanical as well as electrical products, elements and systems for Electrostatic Precipitators.

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Continuous improvement – Research & Development (R&D)

Recent regulation necessitates that mining companies should meet emissions threshold at all costs. For GEECOM, this means constant improvement to its current technology to cope with demand for Electrostatic Precipitator solutions.

Its Research and Development Department is continuously looking at possible improvements to applicable equipment and elements with special emphasis on product life-time as well as system advancements. Also, a fully sized and operational Electrostatic Precipitator is installed at its premises, which allows for on-time evaluation of specific requirements or planned improvements.

So far, based on this R&D, various enhancements have been introduced which have already been proven as resulting in benefits to the continued use of Electrostatic precipitators in any industry. Some of these are as follows:

• Collector Electrodes (Plates) manufactured from Stainless steel which provide for very smooth surfaces for highly effective removal of deposited dust during rapping actions;
• Discharge electrodes of the Rigid mast type which address higher power intensities and larger electrical field coverage by means of perfect compatibility geometry;
• Swing arm technology for higher vibration distribution of rapping forces applied to Discharge Electrodes
• Direct line rapping systems for Discharge electrodes eliminating quick wearing elements such as lifting arms and cams; and
• Power and control systems of conventional type (50 Hz), medium-frequency as well as High Frequency which provide application of higher power inputs to Electrostatic Precipitators resulting in increases in efficiency and therefore lower emission levels.

Gustl. concludes, “In general, Electrostatic Precipitators supplied by GEECOM continue to offer a highly efficient and cost-effective solution to the reduction of particulate matter at many industrial sites. Moreover, unlike other dust abatement processes, the normal operating costs are relatively low and improvements can be easily introduced, as and when required or made available by the relevant technology developments.”