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AIR PREHEATER
Air Preheater
HEAT EXCHANGER
IN RECUPERATIVE TYPE HEATING MEDIUM FLUE GAS IS ON ONE SIDE AND AIR IS ON
THE OTHER SIDE OF TUBE OR PLATE AND THE HEAT TRANSFER IS BY CONDUCTION
THROUGH THE MATERIAL WHICH SEPARATES THE MEDIA. THESE ARE OF STATIC
CONSTRUCTION AND HENCE THERE IS ONLY NOMINAL LEAKAGE THROUGH
EXPANSION.
RECUPERATIVE RE-GENERATIVE
PLATE TYPE
LJUNGSTROM TYPE
• AS THE ROTOR REVOLVES, WASTE HEAT IS ABSORBED FROM THE HOT EXHAUST GAS
PASSING THROUGH ONE HALF OF THE SURFACE.
• FUEL SAVINGS WITH THE LJUNGSTRÖM AIR PREHEATER ARE ABOUT 1-1½% FOR
EVERY 4.4°C TO 10°C INCREASE IN COMBUSTION AIR TEMPERATURE, DEPENDING ON
THE APPLICATION.
•THEIR SIMPLIFIED DESIGN AND OPERATING INTEGRITY ASSURE CONTINUOUS
RELIABLE SERVICE THROUGHOUT THE LIFE OF THE PLANT.
BI-SECTOR
They are packed in containers called baskets, are placed in rotor in three tiers: -
Hot, Intermediate and Cold.
The notches are used for maintaining the spaces between the elements and
minimizing the pressure drop across the air pre-heater.
• HOT END BASKETS & HOT INTERMEDIATE : -
Hot End is the first layer & Hot Intermediate is second layer of heating element packing
from hot end side. The elements are usually made from 24 gauge / 22 gauge(0.5 –
0.8MM) open hearth steel (IS 513 Gr. DD). They are having a profile called “Double
Undulation. The notches run parallel with the rotor axis and provide the correct spacing
of sheets and the undulations run at 60° to the notches to impart turbulence. Open-
channel element, where the notches, which provide the required plate spacing, rest on
a series of point contacts on the adjacent sheet. Flow can move across the element pair
because there are openings between the two sheets along the flow length between
point contacts.
COLD END BASKETS
The elements are made of 18 gauge / 22 gauge carton steel. Enameled elements are also
used in severe corrosive conditions like for more percentage of sulphur in fuel or for low
gas duct temperature. All the heating surface elements are packed into reversible
containers called baskets to facilitate easy removal and handling. Cold end baskets are
arranged for removal through the basket removal door in the housing.
A closed element profile is the notched flat 6-mm element (NF6), the element pair is
formed by a series of notches that rest on an adjacent flat sheet with contact along the
total flow length. They provide the necessary spacing and form discrete individual flow
channels of fixed cross-sectional area along the flow length or element depth. There is no
flow communication from one channel to the adjacent one.
Sealing System Usually air leaks in to the gas in the air preheater due to pressure
differences.
This leakage air decreases the flue gas temperature without extracting the heat.
It is an implied requirement that the rotating parts should have some working clearance
between the static parts to avoid any interference between them.
Here, in air preheaters, rotors are constructed to have high clearance to take care of
thermal expansion and these gaps are closed with the flexible seal leaves
. Major types of seals used in power plant.
.
• Radial seals
• Axial seals
• Bypass seals
• Circumferential seals
• Air‐in‐Leakage (~13%)
• Gas Side Efficiency (~ 68 %)
• • X – ratio (~ 0.76)
• Flue gas temperature drop (~220 C)
• Air side temperature rise (~260C)
REGERATIVE AIR PREHEATER
Leakage Paths
Leakage whether direct or entrained has no effect on the heat transfer efficiency
of air heater; the gas temperature leaving air heater decreases by mixing of the
cooler air with the flue gas.
Air heater Air-in-leakage
Typically air heater starts with a baseline leakage of 6 to 10% after
an overhaul.
Leakage is expressed as a % of inlet gas flow and not a % of fan input flow
AH Performance Indices
Leakage Weight of Air passing from Air Side to Gas Side
(Gas Out Flow ‐ Gas In Flow)
% Leakage (Air Leakage / Gas In Flow) x 100
(%O2Gas Out ‐ %O2Gas In) / (21 ‐ %O2Gas out) x
90
Air Temp Rise Increase in Temp of Air in passing through the AH = Tao ‐ Tai
Gas Temp Drop Decrease in Temp of Gas in passing through the AH = Tgi ‐ Tgo
Temperature Temp of gas entering minus Temp of Air entering AH = Tgi ‐ Tai
Head
Tgas out (no leakage) (AL * Cpa * (Tgas out ‐ Tair in) / Cpg*100) + Tgas out
X ‐ Ratio Ratio of the Heat Capacity of air passing through the AH to Heat
Capacity of the Gas passing through the AH
(Wao x CpA) / (Wgi x CpG) ; (Tgi ‐ Tgo) / (Tao ‐ Tai)
11
X – Ratio
Ratio of heat capacity of air passing through the air heater to the heat
capacity of flue gas passing through the air heater.
X‐Ratio depends on
• moisture in coal, air infiltration, air & gas mass flow rates
• leakage from the setting
• specific heats of air & flue gas
X‐rato does not provide a measure of thermal performance of the air heater, but is a
measure of the operatng conditons. A low X‐rato indicates either excessive gas
weight through the air heater or that air flow is bypassing the air heater.
.
Pressure drops across air
heater
• Air & gas side pressure drops change approximately in proportion to the
square of the gas & air weights through the air heaters.
• If excess air is greater than expected, the pressure drops will be greater than
expected.
• Deposits / choking of the basket elements would lead to an increase in
pressure drops
• Pressure drops also vary directly with the mean absolute temperatures of the
fluids passing through the air heaters due to changes in density.
Air Heaters
Factors affecting performance include
• Operating excess air levels & PA/SA ratio
• Gas analysis & Temp at APH inlet, outlet & at ID Fan Outlet
• Temperature of Primary & Secondary Air at AH in/outlet
• Power Measurement – Mills & Fans
• Control Room Data
Measurement Locations
The number and type of instruments required for conducting this test depend
on the unit being tested. The following table lists the measurement
locations.
Measurement Temperature Gas Analysers Pressure
AH Gas Inlet Yes Yes Yes
AH Gas Outlet Yes Yes Yes
AH Air Inlet Yes Yes
AH Air Outlet Yes Yes
Test set up - Operating Conditions of Test Runs
ducts
Oxygen %
3 Temperature C 0
A B C D E F A B C D E F
Air heater leakage is expressed as a percentage of gas flow entering the air heater. It’s
determined by following equation.
AL = (CO2 ge – CO2gl) x 0.9 x 100
CO2 gl
AL = air heater leakage
CO2ge = percent CO2 in gas entering air heater
CO2gl = percent CO2 in gas leaving air heater
Alternatively, the air heater leakage may also be determined from the following
equation:
AL = (O2 gl – O2 ge) x 0.9 x 100
(21 - O 2 gl)
AL = ? From following measured data
O2ge = percent O 2 in gas entering air heater (2.8 %)
O2gl = percent O 2 in gas leaving air heater (5.7 %)
Leakage Calculation
= (5.7 – 2.8) * 90
(21-5.7)
= 17.1 %
CO2 measurement is preferred due to high absolute values; In case of any
measurement errors, the resultant influence on leakage calculation is small.
EXIT TEMPERATUR CORRECTION
Air heater leakage dilutes the flue gas and lowers the as measured exit gas
temperatures. Gas outlet temperature corrected to no leakage condition is
calculated using the following formula.
Tgnl = AL x Cpa x (Tgl – Tae) + Tgl
100 x Cpg
AL= Measured Air heater leakage (17.1%)
Tgnl = gas outlet temperature corrected for no leakage
Cpa = the mean specific heat between Tae and Tgl
Tae = temperature of air entering air heater (36.1 C)
Tgl = temp of gas leaving air heater (133.8 C)
Cpg = mean specific heat between Tgl and Tgnl
What is gas outlet temperature corrected to no leakage condition ?
Tgnl = 17.1 * (133.8 – 36.1) + 133.8 = 150.5 C
100
X – Ratio
Ratio of heat capacity of air passing through the air
heater to the heat capacity of flue gas passing through the air heater.
HOT HOT
END END