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INTRODUCTION:
HEAT
EXCHANGER
HEAT
HEAT
INCREASE
HOT
10%
FOR
TYPES
RECUPERATIVE
RE-GENERATIVE
STATIC CONSTRUCTION
ROTARY BY CONSTRUCTION
TRI-SECTOR
BI-SECTOR
Quad-Sector
ROTHEMUHLE
TUBULAR TYPE
PLATE TYPE
SCAPH
Range of RAPH
Size
Type
Heat Duty(M.K.Cals/Hr)
7 - 16.5
1.2 - 3.0
2.5 - 60
17 - 18.5
3.2 - 3.8
50 - 70
19 - 24
4.2 - 6.6
70 - 200
LARGE
6.9 - 20.0
> 200
24.5 - 36
Designation of RAPH
27
VI
2000
Element depth in
mm
Trisector
Modular Rotor
Vertical Shaft; Inverted gas Flow
Size number
BI-SECTOR
TRI-SECTOR
BI-SECTOR
TRI-SECTOR
TRI-SECTOR AIR PREHEATER PERMITS A SINGLE HEAT EXCHANGER
TO PERFORM TWO FUNCTIONS: COAL DRYING AND COMBUSTION AIR
HEATING.
THE DESIGN HAS THREE SECTORS - ONE
FOR THE FLUE GAS, ONE FOR THE PRIMARY
AIR THAT DRIES THE COAL IN THE
PULVERIZER, AND ONE FOR SECONDARY
AIR THAT GOES TO THE BOILER FOR
COMBUSTION
QUADSECTOR
THE QUAD-SECTOR IS WITH FOUR
FLOW
STREAMS
THROUGH
THE
ROTOR.
RADIAL SEAL
HOT END
AXIAL
SEAL
COLD END
HOT INTERMEDIATE
SUPPORT BEARING
ROTOR:
The rotor is the heart of the equipment radially divided open ended cylinder which
contains the heating surface elements. The center shaft of the rotor is called the
post. Diaphragm plates extend out ward from the post dividing the rotor into 12 or 24
sectors which are further divided to form compartments into which the element
baskets are packed-A pin rack is located around the outside of the rotor to allow it to
be rotated by the drive mechanism.
HEATING ELEMENTS:
They are packed in a reversible 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 preheater.
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.
AIR LEAKAGE
Leakage of the higher pressure air to the lower pressure flue gas
through the clearances between the rotor seals and the sector plates.
Air to gas leakage can be increase with time, to more than twice the
immediate post overhaul level.
Leakage paths for a tri-sector APH are more complex, compared
to a bi-sector .
In a tri-sector , primary air leaks into the flue gas and secondary
air streams, while SA leaks into the flue gas stream.
Leakage occurs both on the cold end (CE) and hot end (HE).
Due to large difference in pressure between the PA and SA
streams, as well as the PA and flue gas streams, leakage in a
tri-sector
APH
isincrease
higher in
than
in a bi-sector
APH.
Can
be increase
with
differential
pressure of
two fluids
Two penalties to boiler performance occur with excessive radial seal leakage.
1.Thermal losses associated with the leakage air cooling the APH.
2. Additional auxiliary horsepower consumed by the fans for pushing more flow.
We = . v . rpm. 60
= Sp. Wt of air in Kg/m3
v = Volume of Rotor air space
* Hence amount of entrained Leakage is independent of operating and maintenance condition
B. DIRECT LEAKAGE :
Wd = A *(2g * * P)
= Coeff. Of flow rate (0.6 0.7)
g= Acceleration due to gravity
A= Gap area at hot condition (m2)
P= Diff. pr. Of two fluids
= Sp. Wt of air in Kg/m3
Variable factors areP
Hot radial
seal leakage
Circumferential
bypass seal leakage
into the warm airflow
Circumferential
bypass seal
leakage into the
cold gas flow.
Peripheral bypass
seal leakage into the
gas path
Cold radial
seal leakage
LEAKAGE PATH
THERMAL TURNDOWN
SEALING SYSTEM
SEALING SYSTEM: Usually air leaks into the gas stream due to static pressure differential. This leakage
air decrease the air leaving temperature. Various arrangements to reduce the
leakage are as follows.
The sealing arrangement consists of Radial, Axial, Bypass, Axial Seal Plate to
Sector Plate, Static, Rotor Post Seals and Mechanical Sealing Plates designed to
minimize leakage between the gas and air streams of the pre-heater.
THE RADIAL SEALS are located along the edges of the diaphragm plates and bear
against the sector plates, housed under centre sections.
THE AXIAL SEALS are located axially in line with the outer edge of diaphragm
plates and bear against the axial seal plates, mounted in the housing pedestals.
THE BYPASS SEALS are located on the housing around the periphery of the rotor
and bear against the T-bar attached to the periphery of the rotor.
THE AXIAL PLATE TO SECTOR PLATE SEALS are attached to the axial seal plats
and bear against the sector plates.
THE STATIC SEALS are fixed under the centre sections and housing pedestals and
bear against sector plates and axial seal plates respectively.
THE ROTOR POST SEALS are attached to the ends of the rotor posts and bears
against the sector plates.
RADIAL SEALS
Ideas for deflector Plates and Clay Cloth seals which cater
for thermal load dependant rotor position fluctuations have
been devised previously.
EROSION
Erosion caused by fly ash has resulted in the rapid loss of a heat exchange
element as well as damage to perimeter seals, radial seals, and rotor
diaphragms. Two other factors with regard to erosion are actually more
important than ash content: abrasiveness and ash velocity.
The abrasiveness of fly ash increases as the amount of silica and alumina
increases.
Ash velocity is as much as three times more important than ash content or
abrasiveness when it comes to determining the rate of erosion. One way to defeat
high ash velocity is to increase the fineness of the coal particles leaving the
pulverizers and balancing the coal and air flows to each of the burners.
metal surface operating at temperature below dew point i.e. mainly at the cold
end, where, as a result, most fouling and corrosion occur.
? Degree of fouling depends on heating element metal surface.
? As coal contains less sulphur, corrosion is not normally as much a problem as
fouling and hence lower exit gas temperature to a level of 120 C is permissible.
? But in the case of oil firing, the corrosion and plugging due to corrosive
products of combustion are very common.
? The gas outlet temperature and/or air inlet temperature has to be raised to
restrict the corrosion to the permissible level.
? Operating the oil fired boiler at very low excess air reduces the acid formation
and hence corrosion.
? During starting and at low loads the flue gas exit temperature falls to a low
value that will lead to corrosion.
IF: Tgi
= APH Gas inlet temperature.
Tgo
= APH Gas outlet temperature.
Tai= APH air inlet temperature.
Tao
= APH air outlet temperature
Tgo (nl) = APH Gas outlet temperature at no seal leakage.
Tao - Tai
ai =
X 100%
Tgi - Tai
Tgi Tgo (nl)
X-Ratio =
gas
=
Tgi Tai
air
20C rise in flue gas exist temperature there is decrease in boiler 1% i.e. =
loss of 26 Kcal approx.
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