Numerical simulation of the electrostatic powder coating process with a corona spray gun

In this paper results of investigations are described aiming to numerically simulate the electrostatic powder coating process using an extended commercial computational fluid dynamics (CFD) code. The fully three-dimensional turbulent flow was calculated. Based on the Lagrangian approach the trajectories of the powder particles were modelled considering electric and aerodynamic forces. In the calculations of the particle propagation both the particle size distribution and the particle charge distribution obtained through experiments have been applied. The model accounts for the space charge effect of the charged particles and the turbulence dispersion on the particle trajectories. It was found that the space charge plays an important role for the final spray pattern shape, also increasing the transfer efficiency. The numerical results, such as velocity profiles, static and dynamic film thickness on the target were in good agreement with experiment.     

Modeling of the electrostatic corona discharge reactor

A model is presented for the electrostatic corona discharge reactor (ECDR) in a pin-plate configuration. The main objective is to describe the fundamental chemistry and physics governing the discharge behavior and to predict the ECDR performance under various operating conditions. The electric field strength is estimated assuming a space-charge-free field. A two-term spherical harmonic expansion is used to solve the Boltzmann equation for the electron energy distribution function (EEDF) and calculate the electron-molecule reaction rates using collision cross-section data. Species continuity equations are solved for the dry and wet air systems to predict ozone and NO_x at various feed flow rates (1630, 4890, 14, 670 cm/s) and an applied voltage of 10 kV. Among the various results reported, it is noted that the calculations indicate the Maxwell EEDF cannot be used because it overpredicts the electron-molecule rate coefficients by several orders of magnitude     

The measurement of charging efficiencies and losses of aerosol nanoparticles in a corona charger

A methodology is proposed for the measurement of a number of parameters relevant to the performance evaluation of aerosol corona chargers. These parameters are intrinsic and extrinsic charging efficiencies, and diffusion and electrostatic particle losses. The methodology is essentially the same as that used in earlier works, except that free ions are removed just after the charger outlet in order to minimize the extent of possible after-charging effects which might lead to measurement errors. However, the experimental results show that after-charging is negligible and that, consequently, practically all the effective ion–particle collisions take place before the aerosol leaves the charger. Formation of new particles during corona discharge, which could in principle be an additional cause of measurement error, has not been observed in the working voltage range of the charger. Particle diffusion and electrostatic losses have been measured at varying values of the voltage applied to the charger: for a given particle size, diffusion loss decreases and electrostatic loss increases as the charger voltage is increased. The intrinsic charging efficiency increases with particle size and charger voltage. In contrast, the extrinsic charging efficiency, which is the parameter of importance in practice, attains a maximum value for a given charger voltage in such a manner that this optimum voltage depends on particle size.     

Effect of air flow on corona discharge in wire-to-plate electrostatic precipitator

This paper analyses corona discharge in ambient air with laboratory-scaled wire-to-plate electrostatic precipitator (WPESP). The electric field is behind the electro hydrodynamic (EHD) flow in air. Its measurements provide complementary results for the corona discharge study because the classical theory based on the current and voltage data is unsatisfactory. Taking into account the dynamic air flow velocity is perpendicular to the active wires, measurement method of the positive and negative DC corona current density and electric field, has been introduced. It has been shown also that the dynamic air flow velocity modifies the current density and the electric field distributions on the planes surfaces of the WPESP.     

Influence of the corona-wire diameter and length on corona discharge characteristics of a cylindrical tri-axial charger

In this paper, the corona discharge characterization in terms of current–voltage relationships of a unipolar cylindrical tri-axial charger on the effects of the corona wire diameter and length have been experimentally studied and discussed. A commercial computational fluid dynamics software package, COMSOL Multiphysics™, was used to predict the electric field distribution in the ion generation and charging zones of the charger and the ion penetration through the perforated screen opening on the inner electrode of the charger. It was found from experimental results that both positive and negative charging currents in the charging zone of the charger increased with increasing corona and ion-driving voltages. At the same corona and ion-driving voltages, both positive and negative coronas were decreased with increasing diameter of the corona-wire. Compared with the corona-wire of 22 mm in length, the magnitude of both positive and negative charging currents were markedly higher for corona-wire of 11 mm in length at the same corona voltage. It was found that the charging currents for negative coronas were about 1.2 times higher than those positive coronas at the same corona and ion-driving voltages. Numerical results of the electric field distribution and the ion and charged particles migrations in the discharge and charging zones of the charger is correlated to have the same direction with the experimental results of the current–voltage relationships. Also, this can be used to guidance in describing the electric field distribution and the behavior of ion and charged particle trajectories that cannot be seen from experiments in order to improve the applicably design and refinement of a unipolar cylindrical tri-axial charger.     

Measurement of the electrostatic powder coating properties for corona and triboelectric coating guns

Measurements have been made of the deposited powder layer for conventional electrostatic corona powder guns and triboelectric guns. By selectively removing the powder layer under computer control conditions, measurements of the powder thickness, and the adhesive properties of the powder layer have been obtained for variation in the coating process and detailed comparisons have been obtained for both coating systems.     

Three-dimensional EHD simulation for point corona electrostatic precipitator based on laminar and turbulent models

The three-dimensional flow interaction for tuft or point corona for industrial electrostatic precipitators was investigated using both laminar and turbulent flow models. The secondary flow distribution based on laminar flow model forms a pair of organized donut-shaped rings generated from every corona or tuft points, while a pair of rings is less organized for turbulent flow model. When the primary flow exists, the organized spiral motion for turbulent model is further diffused in the direction of gas flow and increased N_EHD, which leads to turbulent flow. Turbulent model appears to be more appropriate for predicting the wire-plate ESP based on experimental investigation.     

Polarization behaviour of paper during corona charging

The polarization phenomenon of papers containing different amounts and different types of inorganic fillers during corona charging was studied using a dose-charging method. This method enables to investigate the phenomena in the conditions close to the real ones. It revealed that the paper composition affects the polarization tendency during the corona charging of paper. The filler influences the paper's dielectric constant and hence its electrical capacitance, charging potential and polarizing electric field. It was shown that paper polarization depends mainly on the electric field and this is caused by the orientation polarization and the role of the filler origin and its concentration in the polarization was surprisingly low. Polarization temperature dependences enable to propose the paper polarization mechanism. Paper polarizability is dominated by cellulose and the moisture content in it, and the liability of cellulose and hydrogen bonds hydroxyl groups.     

Anodic oxidation during electrostatic bonding

During electrostatic bonding, anodic oxidation of the anode material, for instance silicon, is thought to be the essential step in the bonding mechanism, leading to the formation of a permanent, strong and vacuum-tight bond. Despite the perceived importance of this step in the bonding mechanism of this well-established bonding technique, there is little experimental evidence for anodic oxidation during electrostatic bonding. One reason is that a thin (approximately 10–20?nm) amorphous anodic oxide layer is difficult to detect adjacent to an amorphous cation-depleted glass. Here, silicon–Pyrex and aluminium–Pyrex electrostatic bonds are made and the anodic oxidation process is studied directly using transmission electron microscopy. The consumption of silicon is demonstrated by the movement of the crystalline–amorphous interface compared with a marker under the original silicon–Pyrex interface. The formation of an anodic silica layer can also be demonstrated using electron-energy-loss spectrometry. An amorphous reaction layer 5–20?nm thick is formed during the bonding cycle. For aluminium anode materials bonded at 450°C a nanocrystalline γ-Al₂O₃ reaction layer is formed, which can be readily detected by transmission electron microscopy. At a bonding temperature of 350°C, no such crystalline reaction layer can be detected between Pyrex and aluminium.     

An experimental study of relative humidity and air flow effects on positive and negative corona discharges in a corona-needle charger

In this paper, the effects of inlet air RH and air flow rate on positive and negative corona discharges in a corona-needle charger have been experimentally studied and discussed. Its corona discharge characterizations in terms of current-to-voltage relationships of the corona-needle charger on the effects of inlet air RH and air flow rate were evaluated at applied corona voltages between 0 and 3.1 kV, an air flow rates between 5 and 15 L/min, a relative humidity between 20 and 90%, and an operating pressure of about 101.3 kPa. Experimental results were shown that discharge current is strongly affected by the RH level of the inlet air. The positive discharge current was found to be decreased with increasing RH value at RH values below 60% and increased with increasing RH value at RH value above 60% in the same corona voltage. The negative discharge current was found to be stable with increasing RH value at RH values below 40% and increased with increasing RH value at RH value above 40% in the same corona voltage. For the air flow rate effects, the positive discharge current was found to slightly decrease when the air flow rate increased at RH value below 90% and to increase with the air flow rate at RH value of 90%. For the negative corona, the discharge current was also found to monotonically decrease when the air flow rate increased.     

The correlation between corona current distribution and collection of fine particles in a laboratory-scale electrostatic precipitator

An analysis of the electrostatic gas cleaning fundamental phenomenon shows an essential influence of discharge electrode construction on the gas cleaning process efficiency.In the physical model tests there were used rigid discharge electrodes with corona emitting elements of various geometries. Different constructions of discharge electrode were tested in the aspect of discharge current uniform distribution on collecting electrode surfaces. Measurements of discharge current distribution has been carried out for discharge electrodes with different spike shapes and in different electric field geometry. The research aim was to determine the optimal discharge electrode construction ensuring high collection efficiency of fine particles. Collection efficiency measurements of selected fly ash samples (from coal fired boilers) were carried out on a laboratory testing bench in a horizontal electrostatic precipitator model.     

Numerical analysis on the electrostatic capture of airborne nanoparticles and viruses in a homemade particle concentrator without a unipolar charger

A numerical analysis on the electrostatic capture of airborne viruses and nanoparticles in a homemade particle concentrator without a unipolar charger using commercial CFD software (CFD-ACE+) was presented. We simulated the effects of inlet/outlet configurations and particle diameters on the collection efficiency of the particle concentrator, and the simulation was in good agreement with the experimental measurements. We investigated the effects of the electrode arrangement on the collection efficiency. We also discussed the maximum collection efficiency and the relationship between the electric field intensity, the positions of the simulated particles on the inlet surface, and the collection efficiency.     

On the possibility of corona initiation near a conducting drop nonlinearly vibrating in an external electrostatic field

An analytical asymptotic expression for the field strength near an ideal incompressible electrically conducting liquid drop nonlinearly vibrating in external electrostatic field E ₀ is found in an order of 5/2 in a small parameter. The small parameter here is the amplitude of deformation of the spherical shape of the drop. It is found that the strength of the electric field resulting at the tops of the drop exceeds the corona-initiating field even if E ₀ is one order of magnitude lower than the value at which the drop becomes unstable against the induced charge (that is, at such values of E ₀ as are observed in storm clouds in full-scale experiments).     

Nanoparticle process formation in zinc implanted silicon with followed thermal annealing

Results of temperature treatment effect on near surface layer properties of Zn ion implanted Si substrate are presented. Radiation induced point defects and Zn in depth profile was studied by Rutherford back scattering (RBS) method with use of channeling technique. Topology of substrate surface was studied by atomic force microscopy (AFM) and scaning electron microscope (SEM). Phase composition of samples was test by x-ray diffraction in grazing geometry.     

Self-similar signature of the active solar corona within the inertial range of solar-wind turbulence

We quantify the scaling of magnetic energy density in the inertial range of solar-wind turbulence seen in situ at 1 AU with respect to solar activity. At solar maximum, when the coronal magnetic field is dynamic and topologically complex, we find self-similar scaling in the solar wind, whereas at solar minimum, when the coronal fields are more ordered, we find multifractality. This quantifies the solar-wind signature that is of direct coronal origin and distinguishes it from that of local MHD turbulence, with quantitative implications for coronal heating of the solar wind.     

Negative ion formation and evolution in atmospheric pressure corona discharges between point-to-plane electrodes with arbitrary needle angle

The change in the distribution pattern of negative ions HO^–, NO_x^-_{x}^{-} and CO_x^-_{x}^{-} observed on arbitrary point-to-plane electrode configuration has been investigated by varying the angle of needle to the plane electrode, under atmospheric pressure corona discharge conditions. The stationary inhomogeneous electric field distributions between the point-to-plane electrodes with arbitrary needle angle were calculated. The experimental and theoretical results obtained suggested that the negative ion evolutions progress along field lines established between the electrodes with arbitrary configurations and the resulting terminal ion formation on a given field line is attributable to the electric field strength on the needle tip surface where the field line arose. The NO_x^-_{x}^{-} and CO_x^-_{x}^{-} ions were dominantly produced on the field lines arising from the needle tip apex region with the highest electric field strength, while the field lines emanating from the tip peripheral regions with lower field strength resulted in the formation of the HO^– ion.     

静电放电电磁脉冲模拟装置

介绍了静电放电电磁脉冲（ESD EMP）的特性。研究了用ESD 模拟器产生ESD EMP的方法,并给出了ESD EMP的时域波形和频谱。在研究ESD模拟器的基础上,首次通过ESD模拟器和GTEM室的结合,在GTEM室内产生了均匀的、重复性和线性好的ESD EMP。实验表明,用这种装置能够实现对静电放电电磁脉冲的实验室模拟。实现了人们用GTEM室产生ESD EMP的梦想。     

静放电电磁脉冲模拟装置

介绍了静电放电电磁脉冲（ESD EMP）的特性，研究了用ESD模拟器产生ESD EMP的方法，并给出了ESD EMP的时域波形和频谱。在研究ESD模拟器的基础上，首次通过ESD模拟器和GTEM室的结合，在GTEM室内产生了均匀的，重复性和线性好的ESD EMP。实验表明，用这种能够实验对静电放电电磁脉冲的实验室模拟，实验了人们用GTEM室产生ESD EMP的梦想。     

静电放电电磁脉冲模拟装置

 介绍了静电放电电磁脉冲（ESD EMP）的特性。研究了用ESD 模拟器产生ESD EMP的方法，并给出了ESD EMP的时域波形和频谱。在研究ESD模拟器的基础上，首次通过ESD模拟器和GTEM室的结合，在GTEM室内产生了均匀的、重复性和线性好的ESD EMP。实验表明，用这种装置能够实现对静电放电电磁脉冲的实验室模拟。实现了人们用GTEM室产生ESD EMP的梦想。     

Sulfur dioxide (SO2) gas transfer process enhanced by corona discharge

The sulfur dioxide (SO₂) gas transfer process in a corona discharge field has been studied. The experiments were conducted to investigate the effects of voltage, length, and height of the discharge area on the electric transfer of SO₂ as well as on the desulphurization efficiency. Experimental results show that corona discharge can facilitate the SO₂ gas transfer process. The rate and efficiency of desulphurization increase with increasing voltage, length of discharge area, and input power. The addition of a uniform electric field to the corona-discharge field improves the electronic transfer of SO₂. Measured desulphurization efficiency was as high as 95%, and the augmentation of desulphurization efficiency due to corona discharge was nearly 50% under the conditions tested.