ESP upgrades
ESP and Electrocyclone systems sized from a project-specific design basis. Precipitator upgrades for fuel changes, higher gas volume and tighter emission limits.
US–Thai global manufacturer · Made in Thailand · Delivered in 19 countries
Electrostatic Precipitators, the Electrocyclone™ and Boiler Revamping — engineered for industrial reality.
Arrow Energy is a US–Thai global manufacturer of electrostatic precipitators (ESP), the proprietary Electrocyclone™ hybrid particulate collector, and boiler revamping and energy-efficiency solutions — 606 projects across 19 countries for sugar, biomass, cement, pulp and paper and power plants, engineered around each plant’s actual fuel, operating duty and compliance basis, from technical assessment through commissioning.
Boiler retrofits
Boiler retrofits, combustion improvement and biomass conversion. Grate, fuel-feeding and secondary-air upgrades, with reverse engineering where drawings are missing.
Heat recovery
Economizers, air preheaters, superheaters, deaerators and PRDS. Heat recovery sized to the plant's measured gas and steam balance, not to a catalogue duty.
Lifecycle support
Remaining-life assessment, root-cause study, detailed engineering and in-house manufacturing. Commissioning supervision, exact-replacement spares and field service.
Design basis, not a measured result. Arrow Energy sizes electrostatic precipitator collecting area for a design collection efficiency of 99.9 % and a stack outlet below 10 mg/Nm³ at 7 % O₂, dry, on the fuel, gas volume and inlet loading stated in each project’s design basis. The figure guaranteed on any given project is the one written into that contract, against the reference conditions that contract defines. Measured results are published in the project reference database on a stated basis — sampling method, reference O₂ and the standard applied — and are not interchangeable with this design figure.
02 — Selected industrial references
Trusted by industrial operators worldwide
Selected customer and project relationships across sugar, biomass, power, cement, paper and process industries.
03 — Core technology platforms
ESP, Electrocyclone™ and boiler platforms — design basis stated
Each platform explains where it fits, the operating inputs that govern selection, and the evidence required before a performance figure is published.
Particulate control
Electrostatic precipitator
Selection starts with actual gas flow, temperature, moisture, particle-size distribution, ash chemistry, resistivity behavior and gas distribution. Effective migration velocity is validated for the project basis.
- Gas volume
- Measured flow, not nameplate
- Operating temperature
- 135–230 °C · design 250 °C
- Emission basis
- mg/Nm³ @ 7 % O₂, dry
- Collecting area / fields
- Deutsch · Matts-Öhnfeldt, k 0.5
Proprietary · first stage
Electrocyclone™
A proprietary first-stage separator intended to reduce the particulate duty reaching the downstream collector. Geometry, electrical configuration and performance must follow Arrow-approved engineering data.
- Stage efficiency
- 85–95 % of inlet load
- Particle distribution
- Tested on 25 fuels
- Pressure drop
- Stated at operating duty
- Temperature limit
- 450 °C operating
Heat recovery
Economizer
Feedwater heating from backpass gas, engineered around gas-side fouling, water-side pressure, corrosion margin, approach temperature and the existing boiler heat balance.
- Tube material
- SA-210 · SA-213 to code
- Heating surface
- From boiler heat balance
- Recovered duty
- Approved H&M balance
- Fuel saving
- ≈1 % per 20 °C FW rise
Heat recovery
Air preheater
Combustion-air heating with cold-end metal temperature evaluated from the gas/air heat-transfer coefficients, fuel chemistry and acid-dewpoint margin—not from a simple arithmetic average.
- Recovered duty
- Approved H&M balance
- Air temperature rise
- Balanced to cold end
- Cold-end margin
- Above acid dewpoint
- Configuration
- Per project design
Pressure parts
Boiler pressure parts
Superheaters, water walls, headers and tube bundles engineered from verified operating conditions, approved drawings, material-temperature limits and the applicable pressure-part code.
- Applicable code
- ASME · JIS design
- Material traceability
- Mill cert to finished part
- Fabrication capability
- In-house, Samut Sakhon
- NDT
- RT · UT · PT · MT
Flue-gas handling
ID fan, ducting & dampers
Fan selection reconciles the clean and fouled system-resistance curves, operating range, gas density, control method, motor reserve, erosion allowance and the required draught margin.
- Design flow / pressure
- Clean + fouled curves
- System margin
- Test-block criterion
- Motor rating
- Above test-block duty
- Control
- VFD · inlet guide · damper
04 — The flue-gas path
The flue-gas path: boiler outlet to stack, one worked example
This interactive schematic shows the engineering relationship between the boiler, heat recovery, first-stage separation, ESP, ID fan and stack. The numerical dataset is an illustrative worked example on a stated basis — not a project reference or a guarantee. Select a stage.
ILLUSTRATIVE CALCULATION — NOT A PROJECT REFERENCE OR GUARANTEE
ρN,wet 1.24 kg/Nm³ · cp 1.20 kJ/kg·K
All concentrations @ 7 % O₂, dry
ρN,wet 1.24 kg/Nm³ · cp 1.20 kJ/kg·K
All concentrations @ 7 % O₂, dry
Stage 1 of 8
Furnace & grate
26.1 t/h bagasse fired on a spreader / travelling grate. Fly-ash carryover from the grate is 0.65–0.85 of the ash in the fuel, plus unburnt carbon — which is why raw dust leaving the furnace sits at thousands of mg/Nm³, not hundreds.
26.1 t/h fuel130.3 t/h gas105 100 Nm³/hcarryover 0.65–0.85
Full node data as a table (accessible, indexable, and quotable)
| # | Stage | Function | Key design figures | Dust out |
|---|---|---|---|---|
| 1 | Furnace & grate | Combustion; fly-ash carryover | 26.1 t/h fuel · 105 100 Nm³/h | 6 000 mg/Nm³ |
| 2 | Superheater | Steam temperature control | 60 t/h steam · cp 1.20 kJ/kg·K | 6 000 mg/Nm³ |
| 3 | Economizer | Feedwater heating | 598 m² · 4.61 MW | 6 000 mg/Nm³ |
| 4 | Air preheater | Combustion-air heating | 4.16 MW · air 75 → 215 °C | 6 000 mg/Nm³ |
| 5 | Electrocyclone | First-stage bulk separation | 3 × Ø3.2 m · 16.5 m/s · d₅₀ 21 µm · Δp 83 mmWC | 720 mg/Nm³ |
| 6 | Electrostatic precipitator | Final collection | 3 888 m² · SCA 75.7 s/m · 4 fields · w 4.5 cm/s | 24 mg/Nm³ |
| 7 | ID fan | Draught | 270 mmWC · 177 kW shaft · 250 kW motor | 24 mg/Nm³ |
| 8 | Stack | Dispersion | Ø2.1 m × 45 m | 24 mg/Nm³ |
Why the first stage changes the whole train
Without the Electrocyclone, the same duty and the same outlet figure need 6 309 m² of collecting area across six fields. With it, the ESP is 3 888 m² across four — 38 % less collecting area and about 9 m less casing length, on the same guarantee.
Why we quote n−1
A two-field ESP is not guarantee grade. On this design, four fields give 24 mg/Nm³ — but with one field out of service it is 57 mg/Nm³. That is the number that matters during a campaign, and it is the one we design to.
05 — Industries served
Industries: sugar, biomass, cement, pulp & paper, carbon black
Ash chemistry, resistivity and carryover differ by an order of magnitude between bagasse, rice husk and cement kiln dust. Every industry page starts from the fuel, not from the equipment.
Sugar & ethanol
Bagasse · low-resistivity, high-carbon ash- Projects
- 100+
- Typical ESP w
- 3–5 cm/s
Biomass power
Rice husk · EFB · palm fibre · wood · cassava- Projects
- 150+
- Ash
- High silica
Pulp & paper
Bark · recovery & power boilers- Projects
- 50+
- Duty
- Continuous
Cement
Kiln, cooler and raw-mill gas- Projects
- 50+
- Temp.
- To 450 °C
Carbon black
Fine, low-density particulate · resistivity must be tested- Projects
- 50+
- Particle
- < 1 µm
Food & beverage
Package boilers · mixed fuels- Projects
- 50+
- Scale
- 10–60 t/h
Waste-to-energy
RDF · acid gases & heavy metals- Projects
- 10+
- Train
- Multi-stage
Thermal power
Coal · co-firing · retrofits- Projects
- 50+
- Scope
- Uprate · life ext.
06 — Featured engineering results
Featured ESP and Electrocyclone™ projects
Filterable by industry, technology, region, fuel, capacity band and year. Every project carries the same nine fields, and every result says whether it was measured on a witnessed stack test or is a design basis.
170 t/h · Electrocyclone + ESP
Bagasse boiler with a Gen-1 Electrocyclone and ESP train in commercial operation on mixed agro-residue — bagasse, rice husk, palm shell and cassava.
In commercial operationDesign basis
250 t/h biomass boiler
Electrocyclone for the largest unit of its type in Thailand — under construction, not yet in commercial operation.
Under constructionDesign basis
100 % in-house · bank tubes + header
Boiler revamp — new bank tube assembly and header with welded tube stubs, fabricated in Samut Sakhon to the applicable pressure-part code with mill-certificate traceability.
Fabricated in-houseShop scope
Project results are published only after the customer identity or confidentiality treatment, plant status, scope and measurement basis have been approved. The full register is on the project references page.
07 — Proprietary technology
The Electrocyclone™ hybrid cyclonic–electrostatic collector
A mechanical and an electrostatic stage in one vessel. The cyclone body takes the bulk load by inertia; the charged core collects what inertia cannot reach. Everything downstream is then sized for what is actually left — which is where the cost comes out.
Lower load
Reduces the particulate duty presented to the downstream final collector.
Smaller duty
May reduce downstream collecting-area and casing requirements when supported by the approved design.
Δp stated
Pressure drop must be shown at the actual gas flow, temperature, density and operating condition.
Proof linked
Efficiency, cut size and operating limits must link to approved test or calculation evidence.
08 — Global footprint
Offices and delivery footprint: Thailand, USA, Latin America, India, Indonesia
Group entities and delivery presence. Project pins are drawn from the same records that render the project database — one dataset, two views.
Head office Bangkok and factory & R&D Samut Sakhon, Thailand · Arrow Energy USA LLC, Winston-Salem, NC · PT Arrow Energy Indonesia, Jakarta · Arrowrise Energy Pvt. Ltd., India · Arrow Energy Brazil LTDA. Project pins are indicative of delivery regions, not a count.
09 — Manufacturing and engineering
“Owning the factory is not a marketing point — it is what lets us commit to a shutdown date.”
One engineering organisation, one design basis, one accountable partner — with the commercial and technical interface in your region and the fabrication shop under our own roof.
In-house
Fabrication shop at Samut Sakhon, operated by Arrow
One basis
Engineering, fabrication and site execution in one organisation
Traceable
Material traceability and inspection scope agreed per project
Qualified
Welding procedures and welder qualifications maintained in house
Inside the shop — collecting electrode manufacturing, Samut Sakhon
10 — Retrofit and lifecycle services
ESP upgrade, boiler retrofit and lifecycle services
Each service states a typical outage window and a scope boundary — the two things a plant manager needs before they can raise it internally.
01ESP modificationPlates, electrodes, rapping, gas distribution, controlsOutage-specific→
02Pollution control system upgradeCapacity uprate or a new emission limit on existing casingOutage-specific→
03Boiler retrofitA 45-year-old boiler returned to modern efficiency from incomplete original documentationProject-specific→
04Commissioning & troubleshootingPerformance shortfall diagnosis on any make of ESPBy region→
05Site survey & technical assessmentFuel, gas duty, resistivity, existing condition — before anyone quotesScope-specific→
06RLA and inspectionRemaining-life assessment on pressure parts and headersOutage-specific→
07Turnkey EPCDesign, supply, erection, commissioning, performance testProject-specific→
08Spares & aftermarketCollecting and discharge electrodes, TR sets, controllers, rappers, insulatorsAvailability check→
11 — Carbon and decarbonisation
Decarbonisation: fuel switching and heat recovery, quantified
Our decarbonisation argument is fuel saved and heat recovered, measured on the plant. Where a technology is still in development we say so on the page.
Fuel
Fuel switching and biomass conversion assessed against boiler, handling and emissions constraints.
Heat
Economizer and air-preheater opportunities quantified from an approved heat and mass balance.
Combustion
Improvement opportunities tied to measured operating data and a defined verification plan.
Carbon
Project and credit advisory shown only for approved standards, jurisdictions, partners and service scope.
12 — Technical resources
Technical resources: ESP sizing guides and calculators
Written by Arrow engineers, on their own pages, so a specifying engineer — or the assistant they are researching with — can read and quote it. Not a PDF wall.
Engineering knowledge base
How an ESP is actually sized
- ESP sizing and SCA
- Effective migration velocity by fuel
- Dust resistivity: the 10⁸–10¹¹ Ω·cm window
- Rapping and re-entrainment
- Gas distribution and CFD
- Cold-end corrosion and acid dewpoint
- Biomass ash characteristics
- Emission standards by country
Engineering tools
Check it yourself
Three browser tools that return a working figure — and end with “send this configuration to our engineers”, which pre-fills the enquiry with what you entered.
- ESP sizing check — SCA and area from gas duty and target outlet
- Economizer fuel-saving estimate
- Emission unit converter — mg/Nm³ ↔ grains/scf, O₂ correction
Downloads
Datasheets and certificates
Every download states format, size and language, so you know what you are clicking.
ISO 9001:2015 certificate · PDF · TÜV Rheinland No. 01 100 2035118 · valid to 2026-10-08
All downloads
13 — Engineering questions, answered
Frequently asked questions
Direct answers, each self-contained, each carrying its numbers. The same answers are published as structured data for answer engines.
What does Arrow Energy supply?
Arrow Energy Co., Ltd. designs, manufactures and commissions electrostatic precipitators, the proprietary Electrocyclone pre-collector, bag filters, boiler pressure parts, economizers, air preheaters and flue-gas treatment systems, with fabrication at its Samut Sakhon factory in Thailand and delivery through assessment, engineering, installation, commissioning and spares.
How is an electrostatic precipitator sized?
From project gas data, not catalogue ratings: gas flow, temperature, moisture, particle-size distribution, ash chemistry and resistivity. Collection area follows from the Deutsch-Anderson relation corrected by Matts-Öhnfeldt (k ≈ 0.5). The homepage design basis — a 60 t/h bagasse boiler at 6,000 mg/Nm³ — needs SCA 75.7 s/m and 3,888 m² of collecting area for 24 mg/Nm³ at 7 % O₂ dry.
What is the Electrocyclone?
The Electrocyclone is a proprietary hybrid particulate pre-collector developed by Arrow Energy that combines cyclonic separation with electrostatic augmentation. It removes 85–95 % of particulate load ahead of an ESP or bag filter, operates up to 450 °C, absorbs 120–140 kW on a mid-size duty, and occupies 60–65 % of the footprint of an equivalent ESP stage.
Does Arrow Energy guarantee an emission value?
Guaranteed figures are stated per project, after a technical assessment, on a defined basis: mg/Nm³ at a stated reference O₂, dry or wet, over a stated load range. The figures on this page are an internally consistent design basis for a worked example — they are labelled as such and are not a guarantee.
What data should I send for a technical assessment?
Fuel type and moisture, boiler capacity in t/h, flue-gas flow in Nm³/h, gas temperature, current emission in mg/Nm³ with its reference O₂, and the limit you must meet. With a fuel analysis and a recent emission test attached, an Arrow engineer can return an assessment basis rather than a brochure.
Where is Arrow Energy based, and where is the equipment manufactured?
Arrow Energy Co., Ltd. is headquartered in Bangkok, Thailand, with its factory and R&D centre in Samut Sakhon, where ESP collecting electrodes, discharge electrodes, casings and boiler pressure parts are fabricated in-house. Arrow Energy USA LLC in Winston-Salem, North Carolina, coordinates projects in the Americas, with regional entities in Indonesia, India and Brazil. Arrow Energy is not affiliated with Arrow Energy Pty Ltd of Australia.
When is the Electrocyclone™ used instead of, or in front of, an ESP?
The Electrocyclone™ is a first-stage collector: it removes 85–95 % of the inlet dust by combined centrifugal and electrostatic action at up to 450 °C, so the downstream ESP or bag filter is sized for a fraction of the raw load. It is selected where inlet loadings are high — bagasse, rice husk and other biomass ash — and where the outlet limit still requires a final ESP stage. On its own it is not a guarantee-grade final collector for limits below about 50 mg/Nm³.
Does Arrow Energy supply and support projects in the United States and Latin America?
Yes. Arrow Energy USA LLC handles engineering coordination, contracts and site support for North America, and Arrow Energy has delivered ESP and Electrocyclone™ projects in Colombia, Brazil and Mexico with Spanish- and Portuguese-speaking engineers. Equipment is manufactured in Thailand and shipped with third-party inspection where the contract requires it.
14 — Engineering consultation
Request a technical assessment
Boiler make and capacity, fuel, existing pollution control, current outlet, target limit and your next shutdown window. Attach the drawing, the fuel analysis or the stack-test report — we will not ask you to email it separately.
Enquiry received.An Arrow engineer will reply within one business day. Your reference is . If it is urgent, call +66 2115 0653 (Thailand) or +1 336 344 7329 (Americas).
IndonesiaPT Arrow Energy Indonesia, Jakarta
IndiaArrowrise Energy Pvt. Ltd.
BrazilArrow Energy Brazil LTDA
Response commitment
An engineer — not a mailbox — replies within one business day.