Catalogue Air Pollution Control SystemsElectrostatic Precipitators (ESPs)

Electrostatic Precipitators (ESPs)

We engineer and supply Electrostatic Precipitators (ESPs) as part of complete industrial heating and utility solutions. Share your capacity, fuel type, application, and site details — our team will recommend a suitable configuration and quote.

About Electrostatic Precipitators (ESPs)

Gyantosh's Electrostatic Precipitators (ESPs) are engineered to provide highly efficient removal of particulate matter from industrial exhaust gases, helping industries achieve cleaner emissions while complying with stringent environmental regulations. Designed with advanced electrostatic separation technology, our ESP systems efficiently capture fine dust particles, fly ash, smoke, and other suspended particulates without significantly restricting the flow of flue gases.

Unlike conventional filtration systems, Electrostatic Precipitators utilize high-voltage electrostatic fields to electrically charge airborne particles as they pass through the ionization section. These charged particles are then attracted to and collected on oppositely charged collection electrodes. The accumulated dust is periodically dislodged by an automated rapping mechanism and collected in hoppers positioned below the collection plates for easy disposal or material recovery.

Our ESP systems are specifically designed for applications involving high gas volumes, elevated operating temperatures, and continuous industrial operation. Their low-pressure-drop design minimizes fan power consumption while maintaining exceptionally high dust collection efficiency, making them one of the most energy-efficient air pollution control solutions for large industrial plants.

Manufactured using premium-quality steel structures, precision-fabricated collecting electrodes, discharge electrodes, and high-voltage electrical components, every Electrostatic Precipitator is built to deliver long service life, dependable operation, and consistent emission control under demanding industrial conditions. The robust construction, modular design, and intelligent control systems ensure reliable performance with minimal maintenance and reduced operating costs.

Electrostatic Precipitators are particularly suitable for applications where large quantities of flue gases containing fine particulate matter are generated. Their ability to efficiently handle high-temperature gases while maintaining low pressure losses makes them an ideal choice for steam boilers, thermic fluid heaters, hot air generators, power plants, furnaces, cement plants, steel industries, and other heavy industrial applications.

Suitable for heating systems up to 100 Lakh kcal/hr, Gyantosh's Electrostatic Precipitators provide industries with an efficient, durable, and environmentally responsible solution for controlling particulate emissions while improving overall plant sustainability.

Key Features

High particulate collection efficiency of up to 99.9%
Low pressure drop resulting in reduced energy consumption
Suitable for high-temperature flue gas applications
Efficient removal of fine dust, fly ash, and smoke particles
Advanced high-voltage electrostatic charging system
Heavy-duty steel construction for long operational life
Automatic electrode rapping mechanism
Hopper-based dust collection and discharge system
Minimal maintenance and low operating costs
Modular construction for easy capacity expansion
Suitable for continuous 24×7 industrial operation
Intelligent high-voltage control system for optimum performance
Reliable operation under varying gas flow conditions
Designed to comply with CPCB, SPCB, and international emission standards
Suitable for retrofit as well as new industrial installations

Electrostatic Precipitators (ESPs) Specification

Suitable For

Industrial heating systems up to 100 Lakh kcal/hr

Collection Efficiency

Up to 99.9% particulate removal

Operating Temperature

Up to 250°C (standard), 250°C – 400°C (high-temp applications)

Pressure Drop

Low pressure drop design

Cleaning Mechanism

Automatic Mechanical / Electromagnetic Rapping

Dust Discharge

Rotary Airlock Valve / Screw Conveyor

Construction

Modular heavy-duty steel with precision electrodes

Particulate Matter Handled

Fly AshCoal DustBiomass AshCement DustFurnace DustFine Carbon ParticlesSmoke ParticulatesMetal OxidesMineral DustProcess DustIndustrial SootCombustion Residues

Suitable For

Industrial heating systems up to 100 Lakh kcal/hr

Custom capacities available on request

Operating Temperature

Up to 250°C (Standard Design)250°C – 400°C (High-Temperature Applications)

Higher values available for specialized applications

Collection Technology

High Voltage Electrostatic Charging System

A controlled high-voltage DC electrical field ionizes the flue gas, imparting an electrical charge to suspended dust particles for efficient collection.

Collection Electrode System

Charged dust particles migrate toward specially designed collection plates where they adhere until removed through automatic cleaning.

Automatic Rapping Mechanism

Mechanical or electromagnetic rappers periodically dislodge accumulated dust from collection plates and discharge electrodes, allowing continuous operation without interrupting production.

Hopper & Dust Collection System

Collected particulate matter falls into specially designed hoppers fitted with rotary airlocks or screw conveyors for efficient dust handling and disposal.

Intelligent Transformer-Rectifier (TR) Control Panel

The high-voltage power supply continuously monitors and adjusts voltage levels to maximize collection efficiency while ensuring safe and reliable operation.

Applications

Steam BoilersThermic Fluid HeatersHot Air GeneratorsIndustrial FurnacesPower Generation PlantsCement PlantsSteel & Metal ProcessingWaste Heat Recovery SystemsBiomass Combustion SystemsIncineratorsMineral Processing PlantsIndustrial Process Exhaust Systems

Industries Served

Thermal Power PlantsBoiler & Heating PlantsCement IndustrySteel IndustryChemical IndustryPaper & Pulp IndustrySugar MillsFood Processing IndustryTextile IndustryMining & Mineral ProcessingFoundriesEngineering & ManufacturingBiomass Power PlantsWaste-to-Energy PlantsRenewable Energy Projects

Advantages

Exceptional Particulate Removal Efficiency

Advanced electrostatic charging technology effectively captures even extremely fine particulate matter, helping industries achieve exceptionally low emission levels.

Low Pressure Drop

Unlike fabric filtration systems, ESPs create minimal resistance to flue gas flow, reducing fan power consumption and improving overall energy efficiency.

Ideal for High Gas Volumes

Designed to efficiently handle large flue gas volumes, making them particularly suitable for medium and large industrial plants.

High Temperature Capability

Capable of operating efficiently with elevated flue gas temperatures without degradation of collection performance.

Continuous Automatic Operation

Automated rapping systems continuously remove accumulated dust while the system remains operational, eliminating production interruptions.

Low Maintenance Requirements

With no filter bags requiring periodic replacement, ESPs offer lower maintenance costs and extended equipment life for suitable applications.

Environmental Compliance

Designed to assist industries in complying with CPCB, SPCB, and other applicable environmental emission standards while supporting cleaner industrial operations.

Optional Accessories

Transformer-Rectifier (TR) Set

Automatic Voltage Controller (AVC)

High Voltage Control Panel

Mechanical/Electromagnetic Rapping System

Collecting Electrodes

Discharge Electrodes

Hopper Heating System

Rotary Airlock Valve

Screw Conveyor

Ash Handling System

Access Platforms & Ladders

Chimney

PLC-Based Control Panel

SCADA Integration

Differential Pressure & Temperature Monitoring

Instrumentation & Safety Controls

Frequently Asked Questions(10)

What particulate collection efficiency can I expect?

Gyantosh Electrostatic Precipitators deliver particulate collection efficiencies of up to 99.9%, among the highest achievable for industrial air pollution control systems.

How does an ESP differ from a Fabric Filter (Bag Filter)?

An ESP uses high-voltage electrostatic fields to charge and collect dust particles on electrodes, offering low pressure drop and no filter media to replace — ideal for high gas volumes and elevated temperatures. A Fabric Filter physically traps dust on filter bags, offering very high efficiency for fine particulates but with higher pressure drop and periodic bag replacement. GyanTosh can help you select the right technology for your application.

What size heating system can this be paired with?

Our ESP systems are custom-designed for industrial heating systems up to 100 Lakh kcal/hr, with sizing based on your specific flue gas volume, dust loading, and particulate characteristics.

What operating temperatures can the ESP handle?

Standard ESP designs handle temperatures up to 250°C, with high-temperature applications supported up to 400°C. Higher temperature designs are available for specialized industrial processes.

How is accumulated dust removed from the collection plates?

An automated rapping mechanism — mechanical or electromagnetic — periodically dislodges accumulated dust from the collection plates and discharge electrodes, which then falls into hoppers for disposal, all without interrupting plant operation.

Does an ESP require more maintenance than a bag filter?

No — since ESPs have no filter media requiring periodic replacement, they typically offer lower routine maintenance requirements. Maintenance instead focuses on electrode cleanliness, rapping mechanisms, and the high-voltage control system.

Does this help with CPCB/SPCB compliance?

Yes — Electrostatic Precipitators are a widely accepted technology for meeting CPCB, SPCB, and other applicable particulate emission standards for industrial heating and process plants, including power plants and cement industries.

Can the ESP be expanded if my plant capacity increases?

Yes — the modular construction allows additional collection fields or chambers to be added, making it possible to scale up capacity for future plant expansion.

Is an ESP suitable for retrofit on an existing boiler or furnace?

Yes — Gyantosh ESP systems are engineered for both new installations and retrofit on existing steam boilers, thermic fluid heaters, furnaces, and other combustion systems.

Can GyanTosh handle the complete turnkey installation?

Yes. GyanTosh provides complete turnkey solutions covering engineering, supply, civil coordination, installation, commissioning, operator training, and post-handover support — single-point accountability from start to handover.

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