Thermo–Electrical Performance Enhancement of a Lightweight Polymer–Metal Hybrid Electrostatic Precipitator Using Epoxy-Based Composite Housing for Industrial Particulate Control

Year : 2026 | Volume : 14 | Special Issue 02 | Page : 652 668
    By

    Bharat Mankar,

  • Yash Gopale,

  • Sakshi Balghare,

  • Prasad Jadhav,

  • Pramod Kothmire,

  1. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  2. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  3. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  4. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India
  5. Associate Professor, Department of Mechanical Engineering, MIT Academy of Engineering, Alandi, Pune, Maharashtra, India

Abstract

Airborne particulate emissions, particularly PM₁₀ and PM₂.₅ produced by industrial activities and combustion processes, they continue to pose a significant threat to both the environment and public health. Electrostatic precipitators (ESPs) are widely recognized for their ability to achieve high collection efficiencies; however, conventional metallic constructions often lead to increased system weight, higher fabrication costs, and long-term corrosion-related challenges. In this study, a lightweight hybrid material approach is proposed by integrating an epoxy-based polymer composite (glass fiber–reinforced epoxy, GFRE) as the external housing material, combined with stainless steel discharge and collecting electrodes. The epoxy-based composite is selected due to its low density, high corrosion resistance, electrical insulation capability, and ease of fabrication, making it an attractive alternative to traditional metallic casings such as aluminium. Stainless steel electrodes are retained for their superior electrical conductivity, mechanical strength, and stability under high-voltage corona discharge conditions (18–22 kV). This hybrid material configuration enables improved structural efficiency while maintaining reliable electrostatic performance. A coupled thermo-electrical and fluid flow analysis is performed using computational fluid dynamics (CFD) and analytical modeling to evaluate the influence of material selection on ESP performance. Key parameters such as electric field distribution, particle migration velocity, pressure drop, and thermal behavior are systematically analyzed. The results indicate that the incorporation of the epoxy-based composite significantly reduces the overall system weight while maintaining uniform electric field distribution and stable corona generation. Additionally, the polymer housing minimizes thermal losses and enhances corrosion resistance, thereby improving long-term durability. The study highlights that polymer–metal hybrid ESP designs offer a promising pathway toward lightweight, energy-efficient, and cost-effective air pollution control systems, aligning with the growing demand for sustainable industrial technologies.

Keywords: Electrostatic precipitator, epoxy composite, polymer–metal hybrid system, PM₂.₅ removal, thermo-electrical performance, lightweight design, CFD analysis

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Bharat Mankar, Yash Gopale, Sakshi Balghare, Prasad Jadhav, Pramod Kothmire. Thermo–Electrical Performance Enhancement of a Lightweight Polymer–Metal Hybrid Electrostatic Precipitator Using Epoxy-Based Composite Housing for Industrial Particulate Control. Journal of Polymer & Composites. 2026; 14(02):652-668.
How to cite this URL:
Bharat Mankar, Yash Gopale, Sakshi Balghare, Prasad Jadhav, Pramod Kothmire. Thermo–Electrical Performance Enhancement of a Lightweight Polymer–Metal Hybrid Electrostatic Precipitator Using Epoxy-Based Composite Housing for Industrial Particulate Control. Journal of Polymer & Composites. 2026; 14(02):652-668. Available from: https://journals.stmjournals.com/jopc/article=2026/view=241127


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Special Issue Subscription Original Research
Volume 14
Special Issue 02
Received 15/04/2026
Accepted 22/04/2026
Published 02/05/2026
Publication Time 17 Days
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