Multiphysics Optimization of Polymer–Metal Hybrid Electrode Geometry in Electrostatic Precipitators for Enhanced Particle Collection Efficiency

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Year : 2026 | Volume : 14 | 01 | Page :
    By

    Shivam Kapure,

  • Poonam Rathod,

  • Abhay Patil,

  • Hariom Rai,

  • Pramod Kothmire,

  1. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, IIT Bombay, Pune, Maharashtra, India
  2. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, IIT Bombay, Pune, Maharashtra, India
  3. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, IIT Bombay, Pune, Maharashtra, India
  4. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, IIT Bombay, Pune, Maharashtra, India
  5. PhD scholar, Department of chemical engineering, IIT Bombay, Maharashtra, India

Abstract

Electrostatic precipitators (ESPs) remain one of the most effective technologies for controlling fine particulate emissions in industrial exhaust systems. However, their performance is strongly influenced by electrode geometry and material characteristics, which govern electric field distribution, corona stability, and particle migration behaviour. In this study, a comprehensive numerical investigation is carried out to optimize electrode geometry using a multiphysics modelling framework, while introducing a novel polymer–metal hybrid design to enhance performance and reduce system weight. The discharge electrodes are coated with a thermally conductive hexagonal boron nitride (h-BN) reinforced epoxy polymer composite, selected for its dielectric stability, corrosion resistance, and lightweight characteristics, while maintaining compatibility with high-voltage operation. Simulations were performed using COMSOL Multiphysics by coupling electrostatic field analysis, fluid flow dynamics, and particle tracing mechanisms. Four electrode configurations—two-spiked vertical, two-spiked horizontal, three-spiked, and four-spiked geometries—were analyzed over a particle size range of 1–15 µm under varying applied voltages. The model captures particle charging, migration, and collection processes under realistic operating conditions. Analytical predictions based on the Deutsch–Anderson equation were used to validate the numerical results. The findings reveal that the four-spiked electrode configuration produces the most uniform and intense electric field, resulting in improved particle charging and enhanced trajectory control. The inclusion of the h-BN epoxy composite coating contributes to stable corona generation, reduced electrode degradation, and improved thermal management. The study demonstrates that integrating optimized geometry with advanced polymer materials can significantly enhance ESP efficiency while enabling lightweight and durable designs.

Keywords: Electrostatic precipitator; Multiphysics modelling; Electrode optimization; Hexagonal boron nitride epoxy composite; Particle charging; Corona discharge; Lightweight polymer systems

How to cite this article:
Shivam Kapure, Poonam Rathod, Abhay Patil, Hariom Rai, Pramod Kothmire. Multiphysics Optimization of Polymer–Metal Hybrid Electrode Geometry in Electrostatic Precipitators for Enhanced Particle Collection Efficiency. Journal of Polymer & Composites. 2026; 14(01):-.
How to cite this URL:
Shivam Kapure, Poonam Rathod, Abhay Patil, Hariom Rai, Pramod Kothmire. Multiphysics Optimization of Polymer–Metal Hybrid Electrode Geometry in Electrostatic Precipitators for Enhanced Particle Collection Efficiency. Journal of Polymer & Composites. 2026; 14(01):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=242557


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Ahead of Print Subscription Original Research
Volume 14
01
Received 20/04/2026
Accepted 30/04/2026
Published 01/05/2026
Publication Time 11 Days
32

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