16

CHAPTER 3

POWER SUPPLY FOR OZONE GENERATION SYSTEM

This chapter explains the significance of Ozone, application areas of

Ozone, artificial Ozone generating system, power supply requirement for Corona
discharge type Ozonator, conventional power supply system-its simulation, and
experimental results.

3.1 Artificial Ozone Generators

Ozone is one of the main oxidant elements for bleaching and

disinfecting in many applications. It does not generate any residues harmful by-
product during the process. It is used in many industries such as paper mills,
cement mills for cooling tower applications and also disinfection element for
food processing, water, and air treatment. Ozone is tri-atomic oxygen found in
nature within the stratosphere known as Ozonosphere. It is formed by lightning
from atmospheric oxygen. This ozone adsorbs the harmful ultra violet rays from
the sun and protects us from its harmful effects. Ozone is tri-atomic oxygen (O3),
with a delta negative and a delta positive electric charge. The structure of ozone
as shown in Figure 3.1
 17

Figure 3.1 Ozone gas formation

The ozone molecule is very unstable and has a short half-life. Therefore,
it will decompose to oxygen form in the small time interval.

2O3 ⇋ 3O2 (3.1)

3.1.1 Properties of Ozone

• Formula: O3

• Melting point: -193°C

• Boiling point: -112°C

• Density : 2.14g/liter

• Solubility in water @ 19°C: 0.381 liters O3/liter Water

• Solubility in water @ 60°C: 0 liter O3/liter water

• Strong UV adsorption @ 254 nm

• Ozone at atmospheric conditions is more unstable and reduces to

Oxygen. Ozone has a half life of 20 minutes in water and 60 mints

in air

• Decay products are environmentally safe

• Ozone is a colorless gas, 1.5 times heavier than oxygen

 18

• It has a very pungent smell at, as low as at the concentration of

0.03 ppm in air

• Ozone is a very powerful oxidizing agent and hence a very

powerful disinfectant

3.1.2 Advantages of Ozone

Ozone is the strongest oxidant and disinfectant for the treatment of

water and air.
No organic waste after water treatment
It is sufficiently soluble and stable such that its disinfectant or
oxidation properties can be used fully.
Applying ozone to any medium does not need any other chemicals to
additionally
Ozone can eliminate a different inorganic, organic and micro-
biological problems.
Ozone eliminates taste and odor problems in water and air
No air pollution
keeps environment very clean and neat

3.1.3 Application of Ozone for drinking water treatment

Removal of an organic and inorganic matter.

Removal of micro-pollutants, such as pesticides.
Improve the disinfection and reduction of disinfection byproducts in
the water.
Odor and taste elimination

3.1.4 Application of Ozone for Air treatment

Total elimination of indoor fungi and microbes

 19

Removal of toxic gasses, odor, and smoke

To maintain co2 level within limits

3.1.5 Other Ozone applications

Disinfect laundry in hospitals and care homes etc.

Kill bacteria on food and other eatable items
Sanitize swimming pools.
Kill insects in stored grain
Wash fresh and vegetables and fruits to kill yeast, mold, and bacteria
in the storage place
Clean and bleach fabrics
Assist in processing plastics to allow adhesion of inks without
infection

3. 2 Ozone generation

The ozone is generated naturally and artificially. Natural method is

generating low-level ozone concentration and is not usable for industries
purpose. The following methods are used for ozone generation in artificially:
Radiochemical
Electrolysis
Corona Discharge
Ultraviolet Radiation

3.2.1 Radio chemical method

In this method, the ozone is produced by radioactive rays. The high

energy irradiation splits the oxygen gas and forms the ozone gas. The ozone
production is increased by selecting proper pressure conditions. This method is
 20

complex due to the removal of harmful isotopes. The ozone production is also
low. It is not suitable for commercial use.

3.2.2 Electrolysis method

In this method, the current is passed through the liquid solution. As a

result, some chemical reaction occurs this process is called as electrolysis. The
electrolysis set up as shown in Figure 3.2.

Figure 3.2 Electrolytic ozone generation cell designs

The liquid splits into H2, O2, and O3. In this method, ozone production
is low and requires high potential. This method is not suitable for commercial
and industrial applications

3.2.3 Ultraviolet (UV) ozone generation method

In this method, UV lamp is placed center part of the system is sealed

completely to avoid leakage. This closed unit has oxygen inlet on one side and
ozone outlet in another end. The oxygen gas passes through this UV lamp. The
UV lamp emits the light wavelength around 185nm to 350 nm length. Figure 3.3
shows the different wave spectrum. The (O2) molecules are ionized with the help
 21

of UV lamp energy. This O- ion attaches to other O2 molecule thus forming O3

gas in the unit.

Low-frequency in nm

Figure 3.3 Ultraviolet (UV) ozone generator

The major drawbacks of this method are: less ozone per hour, less UV
lamp life

3.2.4 Corona Discharge method

In this method, the oxygen gas is passed between two electrodes. When
high potential above
ve 3kV is applied as shown in Figure 3.4, between these
electrodes, the oxygen molecule will be converted into ozone.
Ozone reaction is given by

3O2+Energy=2O3 (3.2)

This method is mainly used for

f commercial production.

Figure 3.4 Corona discharge cell configurations

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Advantages of Corona Discharge ozone generation

• More ozone production compare than another method for the same
volume of feed gas
• Life time of ozone generator is more
• More cost effective compare than UV method.

The amount of ozone produced together with high reliability and the
efficiency of that production are directly related to the following parameters:

Feed gas quality

Power input.
Ozone chamber construction
Temperature.

3.3 Ozone plant for drinking water treatment

Figure 3.5 shows the ozone plant for drinking water treatment. This
ozone plant has the following parts such as
• Oxygen generator
• Power supply section
• Chiller for cooling water
• Electrode chamber
• Water trap
• Venturi injector
• Static mixer
• Ozone reaction tank
• Circulation and outlet pump
 23

Figure 3.5 Overall ozone plant layouts for drinking water treatment

3.3.1 Oxygen generator

The quantity of ozone produced in a given Ozonator depends on the

oxygen gas feed to the ozone chamber. The ozone concentration is directly
proportional to the gas flow. The ozone concentration is varied depending on the
oxygen gas purity. The ozone concentrations of 1-3% fusing air, and 3-10%
using oxygen can be achieved.

3.3.2 Power supply section

The amount of ozone produced in the ozone chamber depends on the

power applied to the plates. The minimum voltage required for ozone generation
above 2kV (peak), the maximum voltage is 10kV. The operating frequency may
be low-frequency range 50 Hz to 400 Hz or high-frequency range 2 kHz to 10
kHz. The power is controlled by controlling the frequency. As a result, this
system produces ozone in linear control and has less dielectric voltage stress
 24

compared to the low-frequency system. The high-frequency unit has a small size
and high performance compared to a low-frequency unit.

3.3.3 Chiller for cooling water

The ozone generation is an inefficient process whereby about 80% of

the applied electrical energy is wasted in the form of heat energy. This
temperature rise increases the stress of the Ozonator components and reduces the
ozone output because ozone destroys at a certain temperature. The ozone
production depends on the cooling water quality and temperature. It affects the
ozone generator efficiency and operation. The cooling water is circulated
between inner and outer ss pipe. The vertical tube design has better cooling
compared to horizontal type design.

3.3.4 Electrode chamber

The design of an Ozone chamber is critical to making sure maximum

ozone output from given working conditions such as power input and feed gas
while maintaining reliable and stable operation. Two hallow pipes with a
dielectric in between are formed as a capacitor.

Figure 3.6 Ozone Generating Tube (Electrode) Configuration

 25

This set up is called as an electrode or ozone chamber. This electrode

contains outer pipe (-VE)
( glass dielectric and inner Stainless foil (+VE) as
shown in Figure 3.6
.6.. The center part has a glass tube. It acts as a dielectric
die
medium. It is made of quartz glass or ceramic. The ceramic tube has high
dielectric strength than the quartz. The ozone output is increased due to high
dielectric strength. The cooling water is circulated between the two plates to
maintain the temperature
erature below room temperature.

3.3.5 Water trap

The water trap is placed between ozone generator and venturi injector
for transferring gas between two parts. The ozone gas is passed through water
trap arrangement. It is used to transfer a large amount of
of gas from one place to
another place.

3.3.6 Venturi Injectors

A Venturi injector shown in Figure 3.7

3. is a very common device of
ozone injection for water treatment. It operates on the principles of vacuum
suction created by an advanced Venturi complex. It requires
equires a pressure
differential across the device to create a vacuum to pull ozone gas into the
device. Injection is activated when there is a pressure differential between the
water entering the injectors and the water, leaving the channel. This pressure
differential is between 5-75%
5 75% according to the required injection rate.

Figure 3.7 Venturi injector

 26

3.3.7 Static mixer

A venturi injector creates the very small bubbles in the water line.
These bubbles are mixed with water with the help of the static mixer. The energy
needed for mixing comes from a loss in pressure as water flow through the static
mixer

3.3.8 Ozone reaction tank

The reverse osmosis (RO) water is stored in one large size tank called
as ozone reaction tank. The RO water is recirculated through circulation pump.
During water circulation time, the ozone gas is mixed with water with the help
of venturi injector and static mixer.

3.3.9 Circulation and outlet pump

The separate pipe line is required for water inlet and outlet to avoid
pressure and flow drop. One pump is used for recirculation process, so this pump
is called as recirculation pump. Water outlet has one pump is called as outlet
pump.

3.4. Power supply for ozone generation system

Various power supply converters were developed for ozone generation

system. Of which main types are:
Transformer-less single switch resonant converter based power supply
Low-frequency AC power supply
High-frequency AC power supply.
 27

3.4.1 Transformer-less single switch resonant converter based power

supply
Transformer-less single switch resonant converter shown in Figure 3.8
was proposed to reduce the ozone generator power supply size.

Figure 3.8 Transformer less single switch resonant inverter

The LC resonant network is used parallel to the ozone chamber to form

resonant. This resonant is used to increase the voltage gain of the system. Thus
the sinusoidal high voltage is achieved without using step up transformer. The
major drawbacks of this configuration are:
It is suitable only lower capacity
It is required more magnetic components
It has more noise

3.4.2 Low-frequency AC based power supply

In this method, the line voltage is directly converted into the low-
frequency high voltage with the help of step up transformer as shown in Figure
3.9. In this method, the output voltage controlling is not possible without using
an auto transformer.

Figure 3.9 Low-frequency AC power supply

 28

The major drawbacks of this configuration are:

The ozone output
outp is not controllable
The transformer size is large
The system cost is more and system is bulky

3.4.3 High-frequency
frequency AC power supply

In this method, the low voltage low-frequency

low frequency is converted into high
voltage high-frequency
frequency with the help of high-frequency
hi frequency inverter. This high-
high
frequency inverter may be used Fly back, Push-pull,
Push pull, half bridge inverter, and
Full bridge inverter. The block diagram of the power supply is as shown in
Figure 3.10a.. The AC supply is converted into DC with the help of uncontrolled
unco
rectifier. The high-frequency
frequency inverter converts this DC into high-frequency
high AC
output and fed to step up transformer. The step up transformer gives 300V input
to 5kV output. This high voltage is applied to ozone chamber.

Figure 3.10a Block diagram

diagr for High-frequency
frequency high voltage power
supply for ozone generation system

3.4.3.1 Draw backs of Fly back converter:

• It is used up to 1kW
1kW power applications not suitable for higher
capacity
• It is required center
cente tap transformer
 29

• It has poor input power factor

3.4.3.2 Draw backs of push pull inverter:

• It is used up to 1kW power applications not suitable for higher

capacity
• It is required center tap transformer
• It has poor input power factor

3.4.3.3 Draw backs of half bridge inverter:

• It is used up to 1kW power applications not suitable for higher

capacity
• It is required special care for an electrolytic capacitor.
• It has poor input power factor

Fly back topology is suitable for low power application and is less efficient
due to transformer leakage inductance. Push-pull converter needs center tapped
transformer and have poor supply power factor. The half bridge inverter is also
used for low power application. Due to these reasons and requirement of higher
capacity, full bridge topology is preferred.

3.5 Full bridge inverter based high-frequency high voltage power supply

This circuit is considered as a base circuit for the current research work.
The circuit operation, draw backs, simulation results and hardware
implementation are discussed in this section.

3.5.1 Circuit description

The PWM inverter based ozone generating system is shown in Figure

3.10b. It consists of AC supply, uncontrolled rectifier a high-frequency full
bridge PWM inverter using power IGBTs, high-frequency step up transformer
 30

and an electrode tube. The output voltage of the inverter is stepped up to above
4-5kV (peak value) using High-frequency step-up transformer and then is fed to
the electrodes for ionizing the gas. The UU-80 ferrite core is used.

Figure 3.10b PWM inverter based power supply

Single pulse width modulation is applied to generate the pulses for the
inverter switches.

3.5.2 PWM Inverter operation

The switching pattern of the full bridge PWM inverter is as shown in Fig
3.10c. It contains Gate pulse, drain current and drain-source voltage of the
switch and transformer primary side voltage. The dead time is introduced
between one switch turn off and another switch turn on interval. It is used to
avoid a short circuit between two switches in the same leg of the inverter. The
circuit operation corresponding to the switching patterns can be separated into
six modes as follows. The inverter each mode operation and current flow
directions are shown in Fig 3.11 and Fig3.10c.
 31

Figure 3.10c Timing diagram of the PWM inverter system

Mode 1(t0 to t1): This mode allows the energy fed back to the DC
supply from an electrode and high-frequency transformer. During this interval,
both switches S1 and S4 turn on. The current flows back to the DC supply via
Ds4-tr-Lke-Ds1-DC supply. The output voltage Vp is equal to dc supply voltage
Vdc. The voltages across switches S1 and S4 are zero. At that same time
voltages across switches S2 and S3 are Vdc. The assumption is that the voltage
across switches during turn-on is negligible. The supply return to source so this
mode is called inverting mode.

Figure 3.11a mode-1 operation

 32

Mode 2(t1 to t2): This mode allows the energy transfer from source to
load so this mode is called rectifying mode. During this interval, both switches
S1 and S4 are still turn on. The current flows from DC supply to load via DC
supply- Ds1-Lkg-tr-Ds4-Vdc. The output voltage Vp is equal to DC supply
voltage Vdc. The voltages across switches S1 and S4 are zero. At that same time
voltages across switches, S2 and S3 are Vdc. The transformer primary side
transfers the energy to secondary and delivers to the load.

Figure 3.11b mode-2 operation

Figure 3.11c mode-3 operation

 33

Mode 3(t2 to t3): This mode is in a freewheeling time interval. During

this interval, both switches S1 and S4 turn on. The output voltage Vp is equal to
zero. The current flows through Ds2-Lke-tr-S4. As a result, the voltage across
S2 becomes zero.

Mode 4(t3 to t4): This mode is also an inverting mode similar to the
first mode. This mode allows the energy fed back to the DC supply from the
electrode and high-frequency transformer. During this interval, both switches S2
and S3 turn on. The output voltage Vp is equal to DC supply voltage -Vdc. The
voltages across switches S2 and S3 are zero. At that same time voltage across
switches, S1 and S4 are Vdc.

Figure 3.11d mode-4 operation

Mode 5(t4 to t5): This mode is similar to mode two but only difference
the current direction is opposite. During this interval, both switches S2 and S3
are still turn on. The current flows from DC supply to load via DC supply-Ds3-
tr-Lkg-Ds2-Vdc. The output voltage Vp is equal to DC supply voltage -Vdc. The
voltages across switches S2 and S3 are zero. At that same time voltage across
switches, S1 and S4 are Vdc. The transformer primary side transfers the energy
to secondary and delivers to the load.
 34

Figure 3.11e mode-5 operation

Mode 6(t5 to t6): This mode is in a freewheeling time interval. During

this interval, both switches S2 and S3 turn on. The output voltage Vp is equal to
zero. The current flows through Ds1-Lkg-tr-S3. As a result, the voltage across
S1 becomes zero. After completing mode-6 operation, the cycle of the operation
is repeated

Figure 3.11f mode-6 operation

Figure 3.11 PWM inverter modes of operation

 35

3.5.3 High-frequency Transformer design

The transformer output power is given by

=( ∗ ∗ ∗ )/528000 (3.3)

Where

- window area of the core in cm2 (8.67cm2)

-core area in cm2 (3.8cm2)

- flux density in Gauss (1000 G)

- Operating frequency.

Load = 350W, Ferrite core UU80. Input voltage Vdc-320V, Frequency 6

kHz,

500 W transformer is selected with following specifications:

= / (3.4)

Input current =1.56A

No of primary turns is determined using the equation

10#
! = ∗ (3.5)
$% ∗ ∗ ∗

Where

Kf- Form factor for square wave Kf=4

10#
! = 320 ∗ = 350 '
4 ∗ .1 ∗ 3.8 ∗ 6000

Required output RMS voltage=4000V.

Secondary turns are found using equation (3.6)

 36

! ∗ '
!' = (3.6)

350 ∗ 4000
!' = = 4375 ) '
320

Power supply efficiency is calculated using this formula:

∗ 100
*%% +(%) = (3.7)

Where

Pout-Output power in watts

Pin-Input power in watts

= '∗ ' (3.8)

= '∗ ' (3.9)

Where

Vin rms- Input voltage in RMS (Volts)

Iin rms- Input current in RMS (Amps)

Vout rms- Output voltage in RMS (Volts)

Iout rms- Output current in RMS (Amps)

3.6 Simulation results

The simulation is carried out in MATLAB/Simulink environment. The

PWM inverter circuit which was used to supply power for Ozonator is shown in
Figure 3.12. It consists of AC source, a rectifier, a smoothing capacitor, high-
frequency inverter, high-frequency step up transformer and electrodes. The input
 37

voltage and current waveform are as shown in Figure 3.13. Figure 3.14 shows
the rectifier output voltage with ripple. Figure 3.15 and 3.16 shows the gate
pulse, switch current and voltage across the switches for S1 and S2. Figure 3.17
shows the transformer primary side and secondary side current. It has more
distortion. Figure 3.18 and 3.19 shows the transformer primary and secondary
side voltages respectively. The FFT spectrum of the output current is
Shown in Figure 3.20. Input and output powers are shown in Figures
3.21 and 3.22 respectively.

Figure 3.12 PWM Inverter based ozone generator circuit diagram

 38

Figure 3.13 Input voltage and current waveform

Figure 3.14 Rectifier output voltage

 39

Figure 3.15 Gate pulse, drain-source voltage and drain current for
Switch1

Figure 3.16 Gate pulse, drain-source voltage and drain current for
Switch2
 40

Figure 3.17 Transformer primary and secondary side current

Figure 3.18 Transformer primary side voltage

Figure 3.19 Transformer secondary side Voltage

 41

Figure 3.20 FFT analyses for current

Figure 3.21 Input Power

Figure 3.22 Output power

 42

Figure 3.23 shows the Comparison graph between an input voltage and
output voltage. The output voltage varies linearly with an input voltage. Figure
3.24 shows the comparison between an input voltage and output power. Figure
3.25 shows the comparison between an input voltage and efficiency. The input
and output parameters of the PWM inverter based power supply for ozone
generator system is given in Table 3.1. This power supply has an efficiency
(81%) and input power factor (0.31).

DC voltage vs Output voltage

6000

5000
Output voltage (V)

4000

3000

2000
Vo_pwm inv
1000

0
0 100 200 300 400
Input voltage ( V)

Figure 3.23 Comparison graph between input voltage and output voltage

DC voltage vs Output Power

400
350
Output Power (W)

300
250
200
150
100
Po_pwm inv
50
0
0 100 200 300 400
Input voltage (V)

Figure 3.24 Comparison graph between input voltage and output power
 43

Input voaltge Vs Efficiency

95

90

85

% of Efficiency
80

75

70

65
Effi_pwm inv
60

55
0 100 200 300 400

Input voltage (V)

Figure 3.25 Comparison graph between input voltage and efficiency

Table 3.1 System Parameters

Parameter PWM inverter

Input DC voltage 300 V

Input PF 0.31
Output Voltage (Vpeak) 5400 V
Input power 427 W
Output power 345W
Efficiency (%) 80.7
THD (%) 15.99

3.7 Experimental results

The experimental set up is shown in Figure 3.26. Required switching

frequency for the inverter is 6 KHz. The pulses for PWM inverter generated
using PIC16F877A microcontroller. This PIC controller has in built ADC, PWM
 44

generator and fast response. The pulses from microcontroller are given to
M57962L IC which is used as a driver. The M57962L IC has in built short
circuit protection. The IGBTs CT60AM-18F is used. CT60AM-18F has 60A
current rating and 900 V voltage rating. Ferrite core U80 used for the high-
frequency transformer. Table 3.2 shows the implementation circuit components
and rating of the device are used. The input voltage and current waveform are
shown in Figure 3.27. The input current waveform is not a sinusoidal, as a result,
the power supply has poor power factor. The gating pulses for the switches 1,
four are shown in Figure 3.28 and for switches 2 and 3 in Figure 3.29
respectively. The switching pulses and drain-source voltage for the switches 1, 4
and switches 2, 3 are shown in Figure 3.30 and 3.31 respectively. Figure 3.32
shows the transformer primary side voltage of the PWM inverter which was used
for Ozonator. The voltage is trapezoidal in nature. Figure 3.33 shows the
transformer secondary side voltage of PWM inverter. The output of the inverter
is fed to electrodes for producing ozone. Figure 3.34 shows the ozone analyzer
reading for 5LPM oxygen flow for PWM inverter.

Table 3.2 Implementation circuit components and rating

Components Name Rating

Rectifier diode UF5408 8A,1000V
Capacitor electrolytic 1000 uF,400V
Driver IC M57962L 30V,250mA
IGBT CT60AM-18F 60A,900V
Transformer U80 Ferrite core 1:16
Electrode SS TUBE 1 meter
Controller Digital controller PIC16F877A
 45

1) Electrode 2) HT Transformer, 3) Power Supply 4) Digital CRO, 5) Oxygen

concentrator. 6) Ozone analyzer 7) High voltage measuring Probe.

Figure 3.26 Experimental Setup

Figure 3.27 Input voltage and current wave form

 46

Figure 3.28 Switching Pulses for Switch 1 and 2

Figure 3.29 Switching Pulses for Switch 3 and 4

Figure 3.30 Switching Pulse and drain-source voltage for Switch 1

 47

Figure 3.31 Switching Pulse and drain-source voltage for Switch 2

Figure 3.32 Transformer Primary Voltage of PWM Inverter

 48

Figure 3.33 Transformer Secondary Voltage of PWM Inverter

Figure 3.34 Conventional inverter fed Ozonator Output

3.8 Summary

In this chapter significance and application of ozone gas, ozone

generation methods were discussed. The basic PWM inverter feeding Ozonator
electrodes was simulated and experimentally validated. From the results, it is
observed that the input power factor is very poor and input current is distorted,
and efficiency is also low. Therefore a parallel resonant inverter with power
factor correction is suggested as power supply circuit which is discussed in the
next chapter.