A cathode wire is a key component in an electrostatic precipitator (ESP) system that is basically used to generate a corona discharge that ionizes dust particles in industrial exhaust gases. These ionized particles are then attracted to the collecting electrodes that effectively removing contaminants from the airflow. As a result this cathode wires play a crucial role in achieving clean air emissions and environmental compliance.
SENOTAY cathode wires—also known as corona discharge electrodes—are engineered to maximize particulate ionization inside Electrostatic Precipitators (ESPs). By applying high-voltage direct current (20 - 70 kV ), these precisely weighted or rigid discharge wires generate a concentrated, uniform corona field that charges passing sub-micron dust particles, ensuring rapid migration to the collecting plates. Available in barbed, twisted, and rigid mast designs, they resist mechanical fatigue, spark erosion, and intense chemical corrosion in power generation, cement manufacturing, and metallurgical plants.
| Electrode Feature | Standard Discharge Wires | SENOTAY Structural Advantage |
| Tensile Stability | Prone to sagging or snapping under heat | Cold-drawn high-tensile alloys maintain straightness |
| Discharge Points | Uneven corona field distribution | Precision stamp-welded barbs optimize ionization |
| Sway Resistance | High swinging rates causing short circuits | Reinforced end sleeves minimize mechanical sway fatigue |
Factory-Direct Pricing. Certified Quality. Dedicated Support.
We eliminate industrial trading markups to supply factory-direct wholesale pricing straight from our automated wire-drawing lines. This direct procurement setup optimizes replacement budgets for complete ESP internal rebuilds and routine maintenance.
Manufactured inside our ISO 9001 certified facility with full CE compliance, our discharge electrodes are fabricated from premium materials including Stainless Steel (SS304, SS316L, 904L), Titanium, and Hastelloy. Strict straightness tolerances eliminate field alignment issues and spark-over hazards.
We treat snapped electrodes or shorted ESP fields as an absolute operational emergency. To keep your industrial ventilation systems compliant, standard geometries and custom-length orders leave our regional logistics nodes within 48-72 hours.
Lifetime Technical Support: Direct engineering consultations covering voltage-current curve optimization, spacing calculations, and material selection for high-acid environments.
Full System/Parts Availability: On-demand factory access to all corresponding internals, including collecting plates, rapping rods, high-voltage insulators, and alignment weights.
Remote Troubleshooting: Immediate diagnostic support for field anomalies like recurring electrical short-circuits, severe wire ash buildup, or localized spark-over failures.
Trusted by industrial environmental equipment and material handling plants worldwide. Ready for yours.
Our cathode wires are made from top-quality materials, such as:
· High Carbon Steel Wire –this is for superior conductivity and mechanical strength.
· Stainless Steel (SS304, SS316, etc.) – It is for excellent corrosion resistance in harsh environments.
· Alloy Steel – It is for enhanced durability and temperature resistance.
All materials undergo rigorous treatment processes to achieve uniform surface finish and optimum electrical performance.
Type No. | Material | Diameter (mm) | Tensile Strength (MPa) | Surface Treatment | Application Type | Max Temp (°C) |
CW-01 | High Carbon Steel | 2.5 | 800 | Galvanized | Power Plant ESP | 450 |
CW-02 | SS304 | 3.0 | 900 | Polished | Cement Industry | 600 |
CW-03 | SS316 | 2.8 | 950 | Passivated | Steel Plant | 700 |
CW-04 | Mn-Steel Alloy | 3.2 | 870 | Coated | Chemical Processing | 550 |
CW-05 | Low Carbon Steel | 2.0 | 780 | Zinc-Plated | Paper Mill | 400 |
CW-06 | Nickel Alloy | 3.5 | 1000 | Electro-Polished | Refineries | 750 |
CW-07 | Titanium Alloy | 3.0 | 1100 | Oxide Film | Waste Incineration | 800 |
CW-08 | Copper-Clad Steel | 2.6 | 850 | Copper Coating | Textile Mill | 500 |
CW-09 | Galvanized Iron | 2.2 | 760 | Zinc Coating | Pulp Industry | 420 |
CW-10 | Stainless 310S | 3.4 | 960 | Pickled | Petrochemical | 750 |
Cathode Wire Specifications - Model CW-ESP-400
Parameter | Specification | Tolerance | Standard | Application |
Wire Diameter | 2.5 mm | ±0.05 mm | ASTM B258 | ESP Discharge Electrode |
Material Composition | 316L Stainless Steel | - | ASTM A276 | Corrosive Environments |
Tensile Strength | 850 MPa | ±25 MPa | ISO 6892-1 | High Mechanical Stress |
Surface Finish | Electro-polished | Ra ≤ 0.2 µm | ASTM B912 | Reduced Particle Adhesion |
Operating Temperature | 400°C Max | - | - | High Temp ESP Units |
Electrical Resistivity | 0.73 μΩ·m | ±0.02 | ASTM B193 | Optimal Corona Generation |
Spool Length | 500 meters | ±5 meters | - | Production Efficiency |
Weight per Spool | 19.2 kg | ±0.5 kg | - | Shipping & Handling |
Corrosion Resistance | 1000 hr Salt Spray | No Corrosion | ASTM B117 | Marine Environments |
Certification | ISO 9001:2015 | - | Quality Management | Industry Standard |
Property | Typical Value | Description |
Tensile Strength | 780–860 MPa | Ensures high mechanical stability |
Electrical Conductivity | ≥ 14 MS/m | Enables efficient corona discharge |
Melting Point | 1400–1500°C | Suitable for high-temperature environments |
Coefficient of Thermal Expansion | 16×10⁻⁶ / °C | Maintains structural integrity |
Corrosion Resistance | Excellent | Enables long service life in harsh conditions |
Elastic Modulus | 200 GPa | Provides flexibility and shock resistance |
Density | 7.8 g/cm³ | Ensures strength-to-weight balance |
Industries Where ESP Cathode Wire Is Used
Power Generation Plants (coal-fired, biomass, thermal)
Cement Production
Metallurgical Industries
Chemical & Petrochemical Plants
Pulp and Paper Mills
Waste Incineration Plants
Foundries and Steelworks
At HEBEI OUTAI, we apply advanced technologies and stringent quality control in every stage of production:
Automated forming and straightening ensures precise geometrical accuracy.
Surface treatment processes enhance conductivity and resist corrosion.
High-voltage testing guarantees each wire’s corona discharge capability.
Customized manufacturing according to specific ESP models and environmental conditions.
These advantages make our cathode wire stand out as both durable and efficient.
▪ Polyester Filter Bag | FMS Filter Bag | Basalt Filter Bag | Nomex Filter Bag |
PTFE Filter Bag | Acrylic Filter Bag | Fiberglass Filter Bag | P84 Filter Bag | PPS Filter Bag
▪ Dust Collector Bag Cage | Galvanized Bag Cage | Silicone Bag Cage | Trapezoidal Bag Cage | Envelope Bag Cage | Cage Venturi Tube
▪ Air Filter Element | Top-mounted Dust Filter Element | Oblique-insert Dust Filter Element |
Lifting Dust Filter Element | Six-Ear Quick-release Dust Filter Element | Threaded Dust Filter Element | Flange Dust Filter Element
▪ DMF-Z Right Angle Solenoid Pulse Valve | DMF-Y Submerged Electromagnetic Pulse Valve
▪ Industrial Electric Precipitation Accessories
▪ Cathode Wire | Dust Collecting Plate | Vibrating Hammer | Bearing In Dust | Electrostatic Precipitator Porcelain Sleeve
Q1: How long does an ESP cathode wire typically last?
A: With proper maintenance, our cathode wires can last 5–10 years, depending on the environment and operating conditions.
Q2: Can cathode wires be customized?
A: Yes, Hebei Outai offers custom designs, materials and dimensions to meet the specific requirements of your ESP system.
Q3: How does cathode wire quality affect ESP performance?
A: High-quality wires ensure consistent corona discharge and reduce voltage fluctuation and greatly improving dust collection efficiency.
Q4: How often should cathode wires be inspected or replaced?
A:kindly Inspection every 6–12 months is recommended with replacement depending on wear, corrosion and discharge performance.
Q5: What makes Hebei Outai different from other manufacturers?
A: We combined advanced automatic production lines then strict quality testing, and tailored solutions to deliver superior which is very much reliable cathode wire products globally.