Performance of Airpreheater PDF

Performance of Airpreheater
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INTRODUCTION:
Air Preheater is a heat exchanger in which air temperature is raised by transferring heat from other fluid such as flue gas. Since air preheater can be successfully employed to reclaim heat from flue gas at lower temperature levels than is possible with economizer, the heat rejected to chimney can be reduced to a great extent thus increasing the efficiency of the boiler. For every 20 ?C drop in flue gas exit temperature, the boiler efficiency increases by about 1%.Further the air preheater may also be used for heating the air to dry the coal in the pulverizing plant.
Advantages of Air Preheaters:
In addition to increase in boiler efficiency the other advantages that may result in are listed below: ? Stability of combustion is improved by use of hot air. ? Intensified and improved combustion. ? Burning poor quality fuel efficiently. ? High heat transfer rate in the furnace and hence lesser heat transfer area requirement. ? Less unburnt fuel particle in flue gas thus complete combustion is achieved. ? Intensified combustion permits faster load variation. ? In the case of pulverized coal combustion, hot air can be used for drying the coal as well as for transporting the pulverized coal to burners. ? This being a non-pressure part will not warrant shut-down of units due to corrosion of heat transfer surface which is inherent with lowering of flue gas temperature. ? Lower grades of coals can be burnt efficiently with hot air. ? Faster load variations are possible.
TYPES OF AIR PREHEATERS:
Air preheaters can be classified as Recuperative and Regenerative types based on their operating principle.
? In Recuperative type heating medium i.e. 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.
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? In Regenerative type the heating medium flows through a closely packed matrix to raise its temperature and then air is passed
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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. ? In Regenerative type the heating medium flows through a closely packed matrix to raise its temperature and then air is passed through the matrix to pick-up the heat. Either the matrix or the hoods are rotated to achieve this and hence there is slight leakage through sealing arrangements at the moving surfaces.
Tubular Air preheater (Recuperative): This usually consists of large number of steel tubes of 40 to 65 mm dia. either welded or expanded into the tube plates at the end. Either gas or air may be allowed to flow through the tube. Gas through the tube normally requires higher size tube and vertical flow to reduce fouling. Single or more passes on the gas side and multipass cross flow on the air side usually fits in with the overall plant design. The portion of airheater at low temperature zone is designed normally with a shorter tube length so as to facilitate maintenance of surfaces due to corrosion and fouling. In some cases instead of using boiler flue gases, separate external firing is used particularly during starting. Plate Type Air preheater (Recuperative): These comprise of parallel plates which provide alternate passage for gas and air. This type is simple and compact compared to that of tubular type. The narrow passes between plates make the cleaning tedious but with shot cleaning method it is improved. But replacement is a major task.
Ljungstrom Type (Regenerative): The heat transfer elements are rotated at a constant speed and they pass alternately through gas and air passes. The axis of rotation may be horizontal or vertical. The drive is normally electrical operated through reduction gear with compressed air motor as stand-by the plates forming the elements (matrix) may be varied in spacing and thickness and cold ends are made of special corrosion resistance alloy such as corten or enameled to achieve corrosion resistance. This type is very compact and lends easily for ducting arrangement Effective cleaning of heat-transfer surface by soot blowing is possible. Rothemuhle Type (Regenerative): This type is the same as the Ljungstrom type -except that the matrix element is stationary and the air gas hoods rotate. Again axis of rotation may be horizontal or vertical
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The Ljungstrom Air Preheater:
The Ljungstrom Air Preheater is more widely used than any other type of heat exchanger for comparable service. Proven performance and reliability, effective leakage control, and its adaptability to most any fuel-burning process, are the bases for the It is both designed and built to operate over extended periods with durable, uninterrupted service. Simplicity of design also makes it easy and economical to maintain while in operation and at scheduled Application Versatility Available in a broad range of sizes arrangements, and materials Ljungstrm Air Preheaters are custom-engineered to meet specific requirements and operating conditions of a variety of applications. Electric power generating plants Fluidized bed and marine boilers Pack age & large industrial boilers Hydrocarbon & chemical processes Waste incinerators & drying systems Flue gas & other reheating systems
Heat Recovery Cycle The basic component of the continuously rotating cylinder, called the rotor, that is packed with thousands of square feet of specially formed sheets of heat transfer surfaces. As the rotor revolves, waste heat is absorbed from the hot exhaust gas passing through one half of the surface. This accumulated heat is released to the incoming air as the same surfaces pass through the other half of the structure. The heat transfer cycle is continuous as the surfaces are alternately expos ed to the outgoing gas and incoming air streams The Energy Conserver For fossil fuel-fired power generators and industrial processes, the recovery of waste heat energy has proven to be one of the most effective ways to conserve fuel and lower operating costs. Fuel savings with the Ljungstrm Air Preheater are about 1-1% for every40F to 50F increase in combustion air temperature, depending on the application They not only provide the highest fuel saving efficiency that is available, but their simplified design and operating integrity assure continuous reliable service throughout the life of the plant.
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Heat energy is captured and transferred to incoming air for combustion before it is lost to the stack The result is a substantial
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They not only provide the highest fuel saving efficiency that is available, but their simplified design and operating integrity assure continuous reliable service throughout the life of the plant. Heat energy is captured and transferred to incoming air for combustion before it is lost to the stack The result is a substantial saving in fuel that would otherwise be required to bring the air up to combustion temperature
Ljungstrom Air Preheater Arrangements:
Vertical Heaters
These are the most common air preheaters, with the rotor mounted on a vertical shaft. There is a further naming convention depending on the direction of the gas flow. A Ljungstrm Air Preheater where the gas flows from the bottom to the top is referred to as vertical (V). One where the gas flows from the top to the bottom is called vertical inverted (VI). Vertical Inverted arrangements are the most common type of Ljungstrm Air Preheater because gravity aids in clearing any as h or particulate from the rotor.
Horizontal Heaters
These air preheaters are less common and have a horizontal shaft.
Bisector The majority of Ljungstrm Air Preheaters supplied are in the Bi- Sector design. These heaters have two basic streams, one of gas and one of air.
Trisector
Designed for coal-fired applications the Tri-sector air preheater permits a single heat exchanger to perform two functions: coal drying and combustion air heating.
Because only one gas duct is required, the need for ductwork expansion Joints, and insulation is greatly reduced when compared with a separate air heating system. Equipment layout is simplified, less Structural steel is needed to install the System and less cleaning equipment is required. The duct arrangement of a Tri-Sector shows the air and gas flows through the unit. The size and location of the primary air duct can vary, depending on the flow and temperature requirements 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
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Quadsector
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combustion
Quadsector
The Quad-Sector takes the family one step further, with four flow streams through the rotor The four sectors compromise one gas and one primary air as in the Tri- Sector, but there are two separate secondary air sectors
The design has the primary air sector flanked' on either side by secondary air, and this has a benefit on the total air-to-gas leakage of the unit. This method of leakage reduction is ideal for applications where the pressure differential between the air and gas sides are high, such as CFB applications.
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CONSTRUCTION DETAILS: The Air Preheater as shown in above fig. consists of the following major components: ? Rotor ? Bearing ? Housing ? Connecting Plates ? Sealing Arrangements ? Drive Units ? Cleaning Devices ? Safety Devices Rotor: ? This is the heart of the equipment resembling a solid cylinder with the extended shafts containing the heating elements. ? The diaphragm plates divide the rotor into number of sectors and these sectors are divided into compartments by division plates. Rotor Posts: ? This is a cylindrical shell with two end plates welded to it. ? At both ends trunnions are will be connected to serve the purpose of the shaft and to accommodate the bearings on them.
? The end plates are called HEADERS and support the modules that are to be assembled. ? The bottom header will support the modules through the horizontal locating pins.
Modules: ? Modules are nothing but cylindrical segments made out of two diaphragm plates and one shell plates. ? The diaphragm plates will be stayed with the cross plates to maintain their shapes. ? Inside this modules heat transfer profiles of sufficient areas are packed. ? Modular design s a new concept and has its own advantage: ? Less erection time avoiding the transit damages. ? Further it reduces storage spaces.
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.
Bearings: ? The extended ends of the rotor posts are mounted with bearing assembly. ? The bearings are of spherical rollers types to take care of even slightest axial shifts if takes place. ? Bearing at cold end are called Support bearings and bearing at hot end are called Guide bearing.
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? The bearings are of spherical rollers types to take care of even slightest axial shifts if takes place. ? Bearing at cold end are called Support bearings and bearing at hot end are called Guide bearing. Housing: ? It is made of number of panels and is assembled at site to form the housing to accommodate the rotor inside. ? The panels are of two types: 1. Main Pedestal 2. Side Pedestal. ? These Pedestals are erected on expansion plates that are mounted on support steels.
Regenerative airheaters have the following advantages over recuperative ones:
? Compact and hence save space and structure cost. Since this type of air preheater can be effectively cleaned when in service the elements can be closely packed, hence they are compact. ? This is the type that can be economically used for high capacity boiler. As the boiler size increases heat transfer area required in air preheater also increases and if the pressure drop on air and gas side is to be kept constant to limit the fan capacities and operation cost the recuperative air preheater size assumes even greater pro- portions than boiler. ? From the above two reasons, it is clear that initial cost as well as the operating cost can be kept minimum with regenerative air preheaters for higher size boilers.
? Less weight of metal permit economic usage of alloy steel like corten steel elements in the low temperature section thus corrosion problem is combated to a great extent. ? Normally the cold end element packs are separate and handy and because of the nature of this arrangement (possible only with regenerative type) the replacement cost and downtime is very low.
? Minimum metal temperature at the cold end of a regenerative heater is slightly higher than in a recuperative design operating under the same condition. This is because regenerative type works very close to the counter flow, while that of recuperative is on cross flow where metal reaches the air inlet temperature. ? Holes in the elements due to corrosion etc. will not materially affect the performance of the heater. ? Deposit on the heat transfer surface does not reduce the heat transfer. Deposit will reduce heat transfer in the case of recuperative exchangers due to their poor heat conduction.
? Ducting arrangements are neat, streamlined, simple and less costly. ? Pressure drop across the elements can be kept nearly constant throughout the operating period with on load cleaning arrangement. Off-load cleaning also helps. ? Hot primary air for coal drying in mill is possible with single air preheater of tri-sector design. This also helps to make use of a cold primary air fan.
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HEATING ELEMENTS ? Materials used for making casing, bar, baskets are very important from technical point of view. ? These parameters are essential to have better strength against corrosion. ? Maximum life of baskets used in 210 Mw is apprx. 5 years.
? The Heating Element in the form of undulated are packed into irreversible containers called BASKETS. ? The baskets of heating elements are packed in each segment of the rotor in THREE Tiers viz. HOT END BASKET INTERMEDIATE END BASKET COLD END BASKET
HOT & INTEMEDIATE LAYERS ? The heating element placed in hot & intermediate layers are having a profile called Double Undulation. ? They are generally made of carbon steel. ? The undulation in the heating elements causes turbulence to the gas & air for efficient Heat Transfer. ? The notches are for maintaining the spacing between the elements & minimizing the pressure drop across the Air-Preheater.
? The material used for Hot & intermediate Baskets are as :? Type of sheet:- 0.63 mm sheet.
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? Chemical composition:- (%)
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? The material used for Hot & intermediate Baskets are as :? Type of sheet:- 0.63 mm sheet. ? Chemical composition:- (%)
Carbon Manganese Sulphur Phosphorous 0.046 0.42 0.016 0.020
? Tensile Stress:- 292.00 N/mm ? Material Confirms to :- IS 513 Gr. DD COLD END BASKET ? The Cold End heating elements have a Notched Flat Profile (NF). ? They are made of Corten steel which is corrosion resistant, as cold end elements are prone for acid attack.
? The material used for Cold End Baskets are as :? Type of sheet:- 1.214 mm thick sheet. ? Chemical composition (%):C Si Mn P S Nickel Al 0.068 0.3 0.45 0.085 0.006 0.30 0.0067 Chromium Molybdenum Cobalt Cu Titanium Vanadium Tungsten 0.68 0.002 0.002 0.32 0.00 0.002 0.001
? Tensile Testing Observation:Yield Stress (N/mm) Tensile Stress (N/mm) Elongation (%) 383.00 569.00 26.00 ? Material Confirms to :- Corten A
BASKET CASING ? Type of sheet:- 5 mm thick plate ? Chemical composition (%):C Si Mn P S 0.16 0.23 0.93 0.024 0.018 ? Tensile Testing Observation:Yield Stress
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(N/mm) Tensile Stress (N/mm) Elongation
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Yield Stress (N/mm) Tensile Stress (N/mm) Elongation (%) 299.40 462.00 30.50 ? Material Confirms to :- IS-2062 Gr. A
STIFFNER BAR
? Type of sheet:- 16 mm thick plate ? Chemical composition (%):C Si Mn P S 0.17 0.22 1.10 0.025 0.018 ? Tensile Testing Observation:Yield Stress (N/mm) Tensile Stress (N/mm) Elongation (%) 318.50 472.40 32.00 ? Material Confirms to :- IS-2062 Gr. B
Importance of Seals: An often neglected part of air heater performance is gas leakage that occurs through the sealing system dividing the hot and cold sides as the airheater rotates at 1 to 3 rpm. The rotating wheels on air heaters are subject to huge differential temperatures from hot side to cold side, in the range of 400 F with each rotation. This end-to-end differential temperature causes the wheel to actually bend during rotation. Considering that air heaters in modern boilers exceed 50 feet in diameter, these large differential temperatures can cause the wheel to deflect as much as an inch, up or down, with each rotation. Optimal air preheater performance requires that the hot and cold sides of the air heater be properly sealed to prevent cross-air leakage that negatively affects performance. The existence of the cyclical thermal deflection that occurs in rotary air heaters, however, makes sealing especially difficult. For the most part, plant operators tend to focus on the deterioration and plugging of the heat exchange element in air preheaters, which leads to increased pressure drop and increased demand on forced draft and ID fans. In many cases, the pressure drop can become so great that the fans cannot move enough air through the preheater to sustain full load. This is especially common during summer months when warm ambient temperatures thin the incoming air, placing a greater demand on boiler fans. Improved seals are the best way to control and minimize leakage.
High Efficiency Flexible Air Preheater Seals Flexible Radial Seals
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Flexible Axial Seals Flexible Bypass Seals
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High Efficiency Flexible Air Preheater Seals Flexible Radial Seals Flexible Axial Seals Flexible Bypass Seals Flexible Circumferential Seals The flexible seal was developed to reduce normal leakage caused by the thermal expansion of the rotor while the unit is operating. Although expansion characteristics vary per individual heater, typical differential expansion in rotary type air heaters causes the rotor to pull away from the hot side and move towards the cold sector plates. This rotor expansion opens up areas of direct air to gas leakage that can be greatly reduced by installing our flexible seals. In today's power market, with new emission control systems requiring air heaters to run more efficiently than ever before, our flexible seals can help your units reduce stack emissions, increase fan reserve, heat rate and overall efficiency. The method of installation of the Flexible seal is no different than that of the original seal other than the degree of clearance set at cold conditions and the preparation of the sector plate edge.
Since this is an interference or contact seal, the wear life is not expected to exceed 18 months of continuous operation in severe cases. During this time the Flexible seal will allow all of the benefits of lower air heater leakage to its user. In some cases flexible seals have lasted 5-6 years. These benefits may range as follows: Fan requirements will be reduced while maintaining maximum air heater efficiency resulting in better overall boiler heat rate. Lower fan horsepower and/or higher fan reserve when air heater plugging is experienced. Reduced corrosion and fouling potential at the air heater cold end element layer and downstream ductwork due to undiluted exit gas flow. Less exit gas volume (velocity), which would result in maintaining a lower pressure drop through the air heater. Flexible seals come in a variety of designs and material compositions depending on the harshness of the operating environment. Some Designs feature a replaceable flexible pack which can be quickly replaced without resetting the seal body, resulting in a minimal amount of required outage time and maintenance. With the installation of Flexible seals, a 38% to 50% reduction in present leakage may be obtained, with the total leakage being reduced to a minimum of 6% to 7% in most cases. Some air preheater designs may benefit even further.
Additional Sealing Components: Rotor Post Seals Radial Static seals Axial Static Seals Bypass Static Seals Seal Tabs Rotor Post Seals Rotor post seals seal around the inner post on both the hot and cold ends of the rotors. It is recommended to replace them with the radial seals due to the ease of accessibility. Thermal growth and sector plate locations must be taken into consideration before and during installation. Basic Materials unless otherwise specified: 12 Ga. Corten Seal Body A325 Fasteners if necessary (Rotor post seals are retained by fasteners or weld depending on age and type)
Radial Static Seals Radial static seals are mounted on the radial sector plates and prevent air/gas from leaking behind the plates. On axial type air heaters, these seals are usually a slip type. This allows the plates to be adjusted or moved as necessary depending on the type and location. Basic materials include: Slip type static seal o 3/16" Corten shim plate o 3/8" Corten cover plate o 3/16" Corten seal plate o 1/2" Studs & Fasteners Non-axial types are typically 12 Ga Corten & welded. Material & fastener thickness varies depending on type. Axial Static Seals
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o 3/16" Corten seal plate o 1/2" Studs & Fasteners Non-axial types are typically 12 Ga Corten & welded. Material & fastener thickness varies depending on type. Axial Static Seals
Axial static seals are found on axial-type units only. They are mounted on the axial plates and prevent air/gas from leaking behind the plates. Axial static seals are typically a slip type that allows the Axial seal plate to be adjusted as necessary.
Basic materials include: Slip type static seal o 3/16" Corten shim plate o 3/8" Corten cover plate o 3/16" Corten seal plate o 1/2" Studs & Fasteners Material & fastener thickness varies depending on type Bypass Static Seal Bypass static seals are the most inaccessible seals in an air heater and are often overlooked. They are installed in axial type units only and are mounted directly behind the axial seal plates. They prevent air/gas from flowing between the seal plates and the ductwork. Basic Materials unless otherwise specified: 18 Ga. Corten seal body 1/4" Holding strip. 1/2" cap screw or cup pt. is typical but hardware varies.
Seal Tabs Seal tabs are found in many different locations in the various types of air heaters. They are used anywhere air/gas is bypassing seals, elements, rotor, structures, etc. Made in a variety of different shapes, sizes and materials depending on application and locations. Typical usage areas are; Outer radial seal tabs Inner radial seal tabs Axial seal tabs Circumferential mounting angle seal tabs
Advantages Of Seals: Reducing and maintaining low air preheater leakage is vital to minimize the fan horsepower required to move the air and gas flows through the air preheater. It also serves to reduce the dilution effect and corrosion potential of the leaving gas stream due to mixing with colder air at the air inlet temperature. Seals can wear due to sootblowing, corrosion, erosion, and contact with the static sealing surfaces on start up and/or shutdown. Seal wear and seal settings should be checked at least once per year so that seals can be reset to proper clearances or replaced should they exhibit excessive wear. Sealing plate surfaces may also wear due to contact with the seals and erosion, and they may also become out of level and out of plane. Seal plate wear should also be repaired as soon as detected, and plate alignments should be verified every 3-5 years and reset as soon as the need is detected. Types of Latest Sealing Offered: Duplex Sealing Duplex sealing is a system which provides reduced leakage through modifications to the rotor. Instead of a single leaf seal sweeping each sealing plate at any given instant, there are two, which together create a moving plenum across the sealing surface. This is analogous to a double orifice - there is a double restriction to flow crossing from one side of the Ljungstrm air preheater to the other.
The formation of this intermediate pressure plenum between the air and gas streams serves to reduce the air-to-gas pressure differential by a factor of nearly two. This decrease in pressure differential can reduce direct leakage by as much as 30%. Duplex sealing is normally applied to the radial and axial seals together but can be applied to either one separately, and in almost all cases this system can be retrofitted to existing air preheaters.
Modulating Active Leakage Control System (LCS) The function of the active LCS is to minimize the direct air to gas leakage that occurs when the hot end radial seal clearance
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increases as the rotor approaches its operating temperature and the hot end radial seals move away from the hot end sector
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Modulating Active Leakage Control System (LCS) The function of the active LCS is to minimize the direct air to gas leakage that occurs when the hot end radial seal clearance increases as the rotor approaches its operating temperature and the hot end radial seals move away from the hot end sector plates. The system includes a drive system to move each sector plate up and down, a rotor position sensor to determine the position of the rotor and a control system to automatically operate the drives. Ee-Zee By-Pass Seals and Rotor T-bar The bypass seals and rotor T-bar, which are used in conjunction with axial seals and axial seal plates, differ from circumferential seals in that they only reduce the quantity of air flowing over the outer rim of the rotor as the task of reducing axial leakage is handled by the axial sealing system. The bypass seals are mounted on the housing and seal against the rotor mounted T-bar. Ee-Zee bypass seals are pre-assembled seals that reduce installation cost without sacrificing reliability or life. Circumferential Seals and Circumferential Sealing Ring Circumferential seals are mounted on the rotor and the sealing ring connected to the housing. The circumferential seals and sealing ring prevent air and gas from bypassing the heating surface through the space between the rotor and the housing shell. They also prevent air and gas from flowing axially around the rotor. F-Flex Seals Hot end radial seal clearance increases as the rotor approaches its operating temperature and the hot end radial seals move away from the hot end sector plates. When this occurs, leakage in this area also increases, which can account for half or more of the total air preheater leakage. APC F-Flex seals are specifically designed for base load operated preheaters, and incorporate a tapered flexible leaf which can be set to a negative clearance in the cold condition, and which will extend in the hot condition to operate as a standard proximity seal. The taper reduces the drag on the rotor drive during startup and minimizes seal and sector plate wear. Rotor Post and Static Seals Rotor post seals prevent leakage between the ends of the rotor post and the air preheater housing. The static seals prevent leakage between the hot and cold end sector plates and the hot and cold end center sections. A Leakage Control System That Uses Thermal Growth to Maintain Sealing Efficiency The design takes advantage of normal thermal growths to achieve effective sealing with a minimum of maintenance requirements. Automatic Radial Sealing Control The actuated sealing system minimizes the direct air-to-gas leakage that is caused by changes in hot end radial seal clearance when the rotor approaches its operating temperature. It automatically adjusts the radial sealing plates as it responds to changes in seal clearance detected by a rotor position sensor.
AIR HEATER PERFORMANCE
UNIT : 3 LOAD : 206 MW SR NO. DESCRIPTION PREDICTED PARAMETERS AT 210 MW AIR HEATER A AIR HEATER B
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1 Flue Gas Temp. at APH Inlet (T@fgi) 357 333 344
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A AIR HEATER B 1 Flue Gas Temp. at APH Inlet (T@fgi) 357 333 344 2 Flue Gas Temp. at APH Outlet (T@fgo) 141 148 138 3 Flue Gas Diff. pressure across APH (mmwc) Design FG pres. At AH i/l (-)68 mmwc ESP i/l (-)201 mmwc 94 85 4 Flue Gas Pressure at APH Outlet (mmwc) -170 -165 5 Secondary Air Temp. at APH Inlet (T@ai) 38 25 25 6 Secondary Air Temp. at APH Outlet (T@ao) 331 291 265 7 Secondary Air Diff. pressure across APH (mmwc) 52 38 39 8 Secondary Air pressure at APH Inlet (mmwc) 197 182 183 9 O2 % in Flue Gas at APH Inlet (O2@fgi) 3.5 3.7 3.9 10 O2 % in Flue Gas at APH Outlet (O2@fgo) 4.75 4.3 4.5 11 CO2 % in Flue Gas at APH Inlet 15.9 13.9 13.4 12 CO2 % in Flue Gas at APH Outlet 13.8 13.5
CALCULATION
T@fgi : Flue Gas Temp. at APH Inlet T@fgo : Flue Gas Temp. at APH Outlet T@ai : Secondary Air Temp. at APH Inlet T@ao : Secondary Air Temp. at APH Outlet O2@fgi : O2 % in Flue Gas at APH Inlet O2@fgo : O2 % in Flue Gas at APH Outlet Cpa : 0.24 Cpg : 0.242
1) % Air Leakage :% Air Leakage = [(O2@fgo - O2@fgi )] * 100 [21.00- O2@fgo ] = {(4.3-3.7)*100} {21-4.3} = 3.59. 2) Corrected Temp. at APH outlet for air leakage (T@fgonl) :( T@fgonl ) = % Air Leakage * Cpa * (T@fgo -- T@ai ) + T@fgo (100 * Cpg) )
= 3.59*0.24*(148-25) + 148 (100*0.242) = 152.38 3) Flue Gas Side APH Efficiency :FG Side = {( T@fgi - T@fgonl)* 100} { T@fgi - T@ai } = {(333-152.38)*100} (333-25)
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FG Side = {( T@fgi - T@fgonl)* 100} { T@fgi - T@ai } = {(333-152.38)*100} (333-25) = 58.64 4) X-Ratio :X-R = { T@fgi - T@fgonl } {T@ao - T@ai } = {333 - 152.38} {291 - 25} = 0.68 5) % Excess Air :% Air = O2@fgi________________ {(21.00 - O2@fgi)* 100} = 3.7________ {(21.00-3.7)* 100} = 21.4
The Above Calculations are summarized as : SR NO. DESCRIPTION PREDICTED PARAMETERS AT 210 MW AIR HEATER A AIR HEATER B 1 % Air Leakage 7.69 3.59 3.64 2 Corrected Temp. at APH outlet for air leakage (T@fgonl) 148.86 152.38 142.08 3 Flue Gas Side APH Efficiency 65.25 58.64 63.30 4 X-Ratio 0.71 0.68 0.84 5 % Excess Air 20.00 21.4 22.8
AIR HEATER PERFORMANCE
UNIT : 4 LOAD : 204 MW SR NO. DESCRIPTION PREDICTED PARAMETERS AT 210 MW AIR HEATER A AIR HEATER B 1 Flue Gas Temp. at APH Inlet (T@fgi) 357 330 341 2 Flue Gas Temp. at APH Outlet (T@fgo) 141 157 146 3 Flue Gas Diff. pressure across APH (mmwc) Design FG pres. At AH i/l (-)68 mmwc ESP i/l (-)201 mmwc 76 71 4 Flue Gas Pressure at APH Outlet (mmwc) -117 -109 5 Secondary Air Temp. at APH Inlet (T@ai) 38 37.60 37.60
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6 Secondary Air Temp. at APH Outlet
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(mmwc) -117 -109 5 Secondary Air Temp. at APH Inlet (T@ai) 38 37.60 37.60 6 Secondary Air Temp. at APH Outlet (T@ao) 331 294.63 265 7 Secondary Air Diff. pressure across APH (mmwc) 52 29.43 30.00 8 Secondary Air pressure at APH Inlet (mmwc) 197 125.54 129 9 O2 % in Flue Gas at APH Inlet (O2@fgi) 3.5 4.2 4.6 10 O2 % in Flue Gas at APH Outlet (O2@fgo) 4.75 4.6 4.8 11 CO2 % in Flue Gas at APH Inlet 15.9 14.0 15.8 12 CO2 % in Flue Gas at APH Outlet - 15.8 13.6 CALCULATION
T@fgi : Flue Gas Temp. at APH Inlet T@fgo : Flue Gas Temp. at APH Outlet T@ai : Secondary Air Temp. at APH Inlet T@ao : Secondary Air Temp. at APH Outlet O2@fgi : O2 % in Flue Gas at APH Inlet O2@fgo : O2 % in Flue Gas at APH Outlet Cpa : 0.24 Cpg : 0.242 1) % Air Leakage :% Air Leakage = [(O2@fgo - O2@fgi )] * 100 [21.00- O2@fgo ] = {(4.6-4.2)*100} {21-4.6} = 2.43 2) Corrected Temp. at APH outlet for air leakage (T@fgonl) :( T@fgonl ) = % Air Leakage * Cpa * (T@fgo -- T@ai ) + T@fgo (100 * Cpg) )
= 2.43*0.24*(157-37.60) + 157 (100*0.242)
= 159.87
3) Flue Gas Side APH Efficiency :FG Side = {( T@fgi - T@fgonl)* 100} { T@fgi - T@ai } = {(330-159.87)*100} (330-37.60) = 59.18 4) X-Ratio :X-R = { T@fgi - T@fgonl } {T@ao - T@ai }
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= {330 159.87} {294.63 37.60}
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X-R = { T@fgi - T@fgonl } {T@ao - T@ai } = {330 159.87} {294.63 37.60} = 0.68 5) % Excess Air :% Air = O2@fgi________________ {(21.00 - O2@fgi)* 100}
= 4.2________ {(21.00-4.2)* 100} = 25.00
The Above Calculations are summarized as : SR NO. DESCRIPTION PREDICTED PARAMETERS AT 210 MW AIR HEATER A AIR HEATER B 1 % Air Leakage 7.69 2.43 3.64 2 Corrected Temp. at APH outlet for air leakage (T@fgonl) 148.86 159.87 146.08 3 Flue Gas Side APH Efficiency 65.25 59.18 64.30 4 X-Ratio 0.71 0.68 0.64 5 % Excess Air 20.00 25.00 22.8
Conclusion: ? As we compared the calculations of the two air preheaters of unit 3 and unit 4 we observed that the air leakage of unit 3 air pre heater is more than that of air pre heater 4.
? This indicated the effect on the flue gas temperature at the outlet of the air pre heater and hence affects the amount of heat transferred to the air passing by.
? The above factor also had an effect on the flue gas side air preheater efficiency.
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TROUBLE SHOOTING WITH AIR PREHEATERS:
Fouling, Plugging and Corrosion: ? Deposits in airheaters are initiated by condensation of acid or moisture from flue gas on metal surface operating at temperature below dew point. ? Other things remaining same, degree of fouling depends on airheater heating element metal surface. ? Minimum metal temperature occurs at the cold end, where, as a result, most fouling and corrosion occur. ? 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. ? One or some of the following method is used to combat the problem:
1. Use of low sulphur oil during the above condition. 2. By-pass cold air so that gas temperature can be kept at a higher level.
3. By-pass of gas so that acid condensation on airheater does not occur at all. 4. Increase the air inlet temperature by having steam coil air preheater.
5. Recirculate the hot air. The recirculation of part of hot air can be utilised in normal operation also if the F.D, fan is designed for the same.
During the normal operation to minimise the corrosion one or some of the following method:
1. Air inlet temperature is increased mostly by steam air heating to maintain the recommended cold end average temperature for the installation. 2. Corrosion resistant alloys like corten steel can be used for cold end.
3. Easily and economically replaceable cold end portion of airheater without much outage period. 4. Design the boiler for high flue gas exit temperature which means lesser efficiency of boiler.
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3. Easily and economically replaceable cold end portion of airheater without much outage period. 4. Design the boiler for high flue gas exit temperature which means lesser efficiency of boiler.
5. Effective on-load blowing of airheaters with superheated steam as moisture in steam accelerates fouling and corrosion.
Cleaning of Airheaters:
On-load Cleaning: (a) Recuperative Type ? Proven practical method is by shot cleaning.
(b)Regenerative Type ? Fixed or moving type soot blowers with multinozzle thoroughly clean the airheater.
Off-load Cleaning:
Recuperative Type: ? If not provided with on-load cleaning, this has to be cleaned at intervals during shutdown by hand or mechanical method. ? Large quantity of cold or warm water can also be used for this purpose. ? Small quantity of water will actually do harm by making deposit compact and hard.
Regenerative Type: ? Normally on-load cleaning devices keep them clean and if it is needed to clean during shut-down large quantities of water may be used. ? It deposit is severe; sometimes soda-ash solution may assist in dissolving it. ? Water requirement for cleaning is less when compared to static type.
Erosion
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? This problem is normally encountered in tubular type airheaters.
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Erosion ? This problem is normally encountered in tubular type airheaters. ? If the airheater is not cleaned at frequent intervals the fouling increases to a stage of plugging oftubes and velocity increases I
? In case of coal fired boiler due to erosive nature of ash, erosion of tube particularly in the lower temperature airheaters at the entry side may occur. ? This problem can be obviated by frequent cleaning of airheater and/or by using replaceable inserts at the erosion prone areas. Fire ? All types of airheaters are a potential fire hazard particularly at start-up of the boiler and shut-down especially if the heater is having a thick deposit of soot. ? Finely divided particles of combustible matter are deposited on the low temperature airheater surface when the combustion is not satisfactory in the furnace due to various reasons.
? If the ignition temperature at combustible matter is reached and sufficient oxygen is available, fire occurs and may sometime destroy the whole airheater, duct etc., if not noticed earlier and put off. ? A clean airheater will never be the cause of such a major fire.
? In addition to keep watch on the combustion in the furnace, early warning of fire and fire fighting equipments are essential. ? The outlet gas and air temperatures from the airheater will rise above normal in case of fire and is the best indication to detect fire and to take necessary step, for fire fighting. ? Fuel firing and fans are stopped and airheater is flooded with water for which fire hose and fire main will be located nearby or permanent installation by the side of airheater. ? Water from ducts and flues to be drained to avoid collapsing due to water load.
? Most of the fire in airheater occurs during starting, at low load or during shutting down. ? This is due to the fact that combustion regime is poor during the above period and could not be completely monitored due to varying conditions.
? Use of on-load cleaning at frequent intervals during the above period will reduce the hazard to a great extent. ? Cutting out of fuel automatically on fire out, and automatic combustion monitoring at all loads operation are automatically on fire out, and automatic combustion monitoring at all loads of operation are essential features of modern boiler which may eliminate this hazard.
? Passing of oil isolating valves, poor atomising oil tips are to be attended to immediately to avoid this hazard.
IMPORTANT :? Airheater by itself is not the cause of any fire and airheater fire can be extinguished only by large quantity of water. Foam, CO, etc. will not be effective .
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OPERATION AND MAINTENANCE
? During operation the degree of fouling is reflected on the pressure drop across the airheater for a particular loading condition. ? On-load cleaning if provided can be done at suitable intervals to keep the fouling to the admissible level.
? Otherwise it is essential to plan a shut-down of the unit for off-load cleaning. ? The cleaning of airheater to keep down the fouling is essential as this is the primary cause for all the airheater problems i.e. plugging corrosion, erosion and fire.
? Use of low sulphur oil, air by-pass, gas by-pass, steam coil airheaters, hot air recirculation if any provided should be resorted to at low loads and starting to reduce the fouling and corrosion. ? Low excess air will also reduce the corrosion.
? During shut-down at regular intervals the airheater has to be inspected for the rate of fouling and corrosion. ? From the rate of corrosion the length of life may be predicted and replacement can be planned accordingly, on an outage.
? During annual overhauls airheaters should be thoroughly cleaned and water-washed. During other shut-down it can be cleaned depending upon the fouling. ? Where erosion is experienced(mostly) in P.F. fired boilers) cleaning of airheater at all possible shut-downs will yield good results.
? Leakage in airheaters can be checked during operation by analysing flue gas for CO, drop across the airheater. ? This leak age is through the tube joints, corrosion, erosion holes etc. in case of tubular airheater while through seals and entrainment in the case of regenerative airheaters. Seal design and adjustments provided now offer drop of CO, to around 0.5%.
? This may rise upto 1.0% for 12 months operation. ? The CO, drop is checked before shutting down for overhaul and during the overhaul the seals are to be adjusted or replaced in the case of regenerative airheater and tube replacement, leakage arresting etc. are done in the case of tubular type.
? Since regenerative airheaters are of rotary type, it is necessary to have a preventive tubular type. ? Since regenerative airheaters are of rotary type, it is necessary to have a preventive maintenance programme, to check the drives, bearings, cleaning devices, oil circulation system etc.
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Various enhancements is Air Preheaters :-
? . To assure optimum performance and life under a variety of plant environments, steel manufactured under the latest ASME standards A1008 carbon steel and A606-04 for low alloy steel with enhanced corrosion resistance. ? Advanced Clear Element (ACE):The ACE (Advanced Clear Element) design is the optimum solution for most air heater element problems in todays power plant environment. ACE element not only provides a lower pressure drop than other available element, but its unobstructed flow pattern greatly reduces plugging from ash and ABS, and enables the element to be easily cleaned throughout its entire depth with normal soot blowing. The non-fouling and clean-ability attributes of ACE element are far superior to the DU7, DN7, and DL7 element. ? In recent years, some materials used for air preheater element have been described as LACR or Low Alloy Corrosion Resistant. ? .
? Many designs of air preheater are prone to leakage drift This can affect boiler operation in a number of ways, such as increasing fan power, increasing velocities in the precipitators, reducing the flow of hot air to the mills, or shrinking the draught fan margins. These problems can be reduced or eliminated by fitting Advanced Howden VN sealing system,
? Heating Element Development of Air Preheater :_--------
? Local heat transfer phenomena are studied using a water table with dye injection and through the use of thermo chromatic liquid crystal coatings on the element plates of airpreheater ? Using computational fluid dynamics (CFD) modeling techniques, we can quickly simulate theoretical element shapes and
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dimensional variations to optimize the heat transfer, pressure drop and cleanability attributes of the new element profiles.
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liquid crystal coatings on the element plates of airpreheater
? Using computational fluid dynamics (CFD) modeling techniques, we can quickly simulate theoretical element shapes and dimensional variations to optimize the heat transfer, pressure drop and cleanability attributes of the new element profiles. ? Promising element geometry's derived from those techniques are developed into prototypes and their heat transfer and pressure drop characteristics are accurately measured in one of the wind tunnels. ? Cleanability attributes are evaluated along with the wind tunnel results to form the basis for a cost/benefit analysis from the customers perspective.
? Advanced wind tunnel, designed for extreme accuracy, sensitivity and repeatability of Air Preheater at ALSTOM Power Inc., Air Preheater Company, 3020 Truax Road, PO BOX 372, Wellsville, NY 14895, USA _____________..................................................................................
About ABS: ? The formation of ammonium bisulfate (ABS) in the air preheater is a consequence of the operation of an ammonia based NOx reduction system in a flue gas environment containing sulfur tri-oxide (SO3) and water vapor (H2O). ABS forms in accordance with the following chemical reaction: NH3+ SO3 + H2O - NH4HSO4 ? The reaction takes place in a temperature range generally between 400 and 550F and is dependent upon a number of parameters, including the concentrations of the constituents and temperature. ? The deposit is in the form of a molten salt. ? The consequences of ABS deposits on air preheater operation include the increase of pressure differential across the air preheater, an increase in air to gas leakage within the air preheater, a reduction in the thermal performance of the air preheater and an increase in the corrosion rates of heating elements, cold end structures and down stream equipment. Prevention of ABS: ? The Ljungstrm air preheater design can be reconfigured with an ABS Tolerant upgrade to incorporate several unique design features which increases the ABS tolerance of the unit. These features include: ? A deep high efficiency cold end layer of heating element to capture the ABS deposits within a single layer of heating element, move the deposits closer to the cold end cleaning device and improve the effectiveness of the cleaning device in removing the deposits. ? Porcelain enamel coating on the cold end heating element to minimize the quantity of ABS which collects, reduce the adhesion of the deposit and inhibit corrosion which may result because of the deposit. ? Hot and cold end Multi-Media cleaning devices incorporates two sets of nozzles, a low pressure set and a high pressure set. Porcelain enamel coatings :? In applications where heat transfer surfaces are exposed to highly corrosive atmospheres and low exit gas temperatures are desired for maximum efficiency, alloy steels or porcelain enamel coatings can be utilized. ? porcelain enamel coatings as the most cost-effective means of providing an extremely high level of acid resistance for this application. ? Additionally, this enamel coating has been found to provide a highly smooth glass-like surface, more readily facilitating the cleaning of ash deposits. Clearflow Configuration :? The ClearFlow rotor configuration is fast becoming the US industry standard for controlling fouling on air preheaters submitted to cyclic and low-load operation. In our Clear flow rotor configuration (shown here to the right), element layers are arranged to maximize the soot-blowing energy to all layers, preventing diffusion of the cleaning media, which significantly improves the cleaning effectiveness. ? Further improvements in clean ability are achieved through utilization of a basket support system that minimizes obstructions to the cleaning media; such as elimination of items such as element support grids. ? The Clearflow design arrangement addresses many of the root causes of air preheater fouling, thereby minimizing the duty on air preheater cleaning equipment, and by eliminating aggressive cleaning practices, meaningful extensions in heat transfer surface life are achievable. ? This extension in life further demonstrates the benefit of controlling fouling in the Ljungstrm Air Preheater ? Many designs of air preheater are prone to leakage drift This can affect boiler operation in a number of ways, such as increasing fan power, increasing velocities in the precipitators, reducing the flow of hot air to the mills, or shrinking the draught fan margins. ? These problems can be reduced or eliminated by fitting Advanced Howden VN sealing system,
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? Airheater is used for low as well as high capacity boiler not only because it raises the efficiency of boiler but also due to many other advantages. ? Even though the recuperative or regenerative airheaters can be used for any boiler, economy and ease of maintenance dictate the use of regenerative airheater for low as well as high capacity pulverised fuel and oil/gas fired boilers.
? The common problems faced with airheaters were taken into account during the design stage itself but planned maintenance and careful operation is essential to counteract the problems successfully so that total economy in steam generation can be achieved. ? We compared the two air preheaters performance of 210MW working units of MAHA GENCO Khaperkheda power station and analyzed various factors affecting their efficiencies and provided necessary modifications which may be adopted to improve efficiency and life of the air preheaters present installed in the thermal power station. ? We also had an analysis of materials used for making casing, bar, baskets which is very important from technical point of view. ? We also studied the various chemical composition of the basket material which is necessary to achieve maximum heat absorption and to improve the life of the same.
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References :
1. Thermal Power Plant Familiarization Vol. 2 (Boiler Auxiliaries). 2. BHEL Manuals on Air Heaters. 3. Power Plant Engineering - S.Domkundwar. 4. www.alstompower.com 5. www.bhel.com 6. www.howden.com 7. www.paragon.com 8. Operation and services data sheet from MAHA GENCO Khaperkheda. 9. Boiler and maintenance section of MAHA GENCO Khaperkheda.
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Performance of Airpreheater PDF

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Performance of Airpreheater PDF

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Performance of Airpreheater

Advantages of Air Preheaters:

TYPES OF AIR PREHEATERS:

The Ljungstrom Air Preheater:

Ljungstrom Air Preheater Arrangements:

Regenerative airheaters have the following advantages over recuperative ones:

? Chemical composition:- (%)

Carbon Manganese Sulphur Phosphorous 0.046 0.42 0.016 0.020

(N/mm) Tensile Stress (N/mm) Elongation

High Efficiency Flexible Air Preheater Seals Flexible Radial Seals

Flexible Axial Seals Flexible Bypass Seals

AIR HEATER PERFORMANCE

1 Flue Gas Temp. at APH Inlet (T@fgi) 357 333 344

AIR HEATER PERFORMANCE

6 Secondary Air Temp. at APH Outlet

= 2.43*0.24*(157-37.60) + 157 (100*0.242)

= {330 159.87} {294.63 37.60}

= 4.2________ {(21.00-4.2)* 100} = 25.00

TROUBLE SHOOTING WITH AIR PREHEATERS:

? This problem is normally encountered in tubular type airheaters.

OPERATION AND MAINTENANCE

Various enhancements is Air Preheaters :-

? Heating Element Development of Air Preheater :_--------

Anda mungkin juga menyukai

= 2.430.24(157-37.60) + 157 (100*0.242)