Wet Electrostatic Precipitator Application for Fine Particle and Acid Mist Control in Sulfuric Acid Plants

Abstract

Fine particulate emissions and acid mist generated from sulfuric acid plants represent critical environmental and operational challenges due to their corrosive nature, contribution to atmospheric pollution, and adverse effects on human health and industrial equipment. The present study investigates the application of wet electrostatic precipitator technology for the effective control of fine particles and acid mist in sulfuric acid production systems. The research focuses on evaluating collection efficiency, gas cleaning performance, operational stability, and energy consumption under varying industrial operating conditions. Experimental observations indicate that wet electrostatic precipitators provide highly efficient removal of submicron particulate matter and sulfuric acid aerosols through electrostatic charging and wet surface collection mechanisms. The influence of gas velocity, electrode configuration, electric field strength, moisture content, and inlet pollutant concentration on removal efficiency is systematically analyzed to determine optimal process parameters. Results demonstrate that the wet electrostatic precipitation process achieves substantial reductions in particulate emissions and acid mist concentrations while minimizing pressure losses and secondary pollutant formation. In addition, continuous wet operation effectively reduces particle re-entrainment and electrode fouling, thereby improving long-term system reliability and maintenance performance. Comparative evaluation with conventional gas cleaning technologies reveals superior efficiency in controlling ultrafine particles and acidic aerosols, particularly under high-temperature and high-humidity industrial conditions. The study further highlights the potential of integrating wet electrostatic precipitators with existing sulfuric acid plant emission control systems to enhance environmental compliance and process sustainability.