Air Heater & Air Heater Performance Indices

AIR PREHEATER
 Air Preheater

HEAT EXCHANGER

HEAT TRANSFER FROM FLUE GAS TO AIR

HEAT REJECTED TO ATMOSPHERE REDUCED

INCREASE BOILEREFFICIENCY BY STABILIZING COMBUSTION

WITH HELP OF HOT AIR.
HOT AIR USED FOR DRYING THE COAL AS WELL AS FOR
TRANSPORTING.
10%IMPROVEMENT IN BOILER EFFICIENCY WHEN
COMPARED TO AN IDENTICAL UNIT WITHOUT AN APH.
FOR EVERY 20°C DROP IN FLUE GAS EXIT TEMPERATURE THE
BOILER EFFICIENCY INCREASE BY ABOUT 1%.
TYPES OF AIR PREHEATERS:

AIR PREHEATERS CAN BE CLASSIFIED AS RECUPERATIVE AND REGENERATIVE TYPES

BASED ON THEIR OPERATING PRINCIPLE.

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.

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.
 TYPES

RECUPERATIVE RE-GENERATIVE

STATIC CONSTRUCTION ROTARY BY CONSTRUCTION

TRI-SECTOR
BI-SECTOR
TUBULAR TYPE

PLATE TYPE

LJUNGSTROM TYPE

MATRIX ELEMENT ROTATING

HEAT PIPE or THERMOSYPHONE
TUBULAR AIR PREHEATER (RECUPERATIVE):

•LARGE NUMBER OF STEEL TUBES OF 40 TO 65 MM DIA.

•EITHER WELDED OR EXPANDED INTO THE TUBE PLATES.
•EITHER GAS OR AIR 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.

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.
•REPLACEMENT IS A MAJOR TASK.
 LJUNGSTROM REGENERATIVE AIR - HEATER

•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.

•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.
• 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 EXPOSED TO THE
OUTGOING GAS AND INCOMING AIR STREAMS.

• 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

THE MAJORITY OF LJUNGSTRÖM AIR

PREHEATERS SUPPLIED ARE IN THE BI-
SECTOR DESIGN. THESE HEATERS HAVE
TWO BASIC STREAMS, ONE OF GAS AND
ONE OF AIR.
 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
BI-SECTOR TRI-SECTOR
HEATING ELEMENTS:

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

The main purpose of these seals is to

reduce leakage between the gas and
air
 Air Heater - Performance
Indicators (Indices)

• 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

Increased AH leakage leads to

• Reduced AH efficiency

• Increased fan power consumption

• Higher gas velocities that affect ESP performance

• Loss of fan margins leading to in efficient operation and at

times restricting unit loading
 What is leakage ?

The leakage of the high pressure air to

the lowpressure flue gas due to the
Differential Pressure, increased seal
clearances in hot condition, seal erosion
/ improper seal settings.

➢ Direct – flow of air through gaps between

rotating and fixed structure; Rotor Turndown – HE grows radially
more than the CE, rotor goes outward
Leakage ≈ gap area x (density x ∆P)1/2; and downward

➢ Entrained – volume of air in porous elements

carried via rotation from air side to gas side

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.

What we measure is mainly

leakage through radial seals at
hot & cold end.

Leakage through circumferential

seals is substantial and has a
major effect on heat transfer but
nominal effect on APC.

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

Gas Side Efficiency Ratio of Gas Temp Drop to Temperature Head.

(Tgi ‐ Tgo) / (Tgi ‐ Tai)

Air side efficiency Ratio of Air Temp Rise to Temperature Head.

(Tao ‐ Tai) / (Tgi ‐ Tai)

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.

Wair out * Cpa * DTa = Wgas in * Cpg * DTg

X ratio = Wair out * Cpa = Tgas in ‐ Tgas out (no lkge)

Wgas in * Cpg Tair out ‐ Tair in

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

• Inlet air / gas temperature

Coal moisture
•
Air ingress
•
levels Soot
•
blowing
•
No. of mills in service & PA Header Pressure
•
Upstream ash evacuation
•
Maintenance practices - Condition of heating elements, seals / seal
setting, sector plates / axial seal plates, diaphragm plates, casing /
enclosure, insulation
 Air Heater Exit Gas
Temperatures
An increase in AH leakage causes dilution of flue gas & a drop in ‘As read’
exit gas temperatures; Gas temperatures need to be corrected to a
reference ambient and to no leakage conditions for comparison

Other factors affecting exit gas temperatures are

• Entering air temperature - Any changes would change gas temp in same
direction. (~10C rise in air temp ~ 10*0.7(Efficiency) = 7C rise in EGT)
• Entering Gas Temperature - Exit gas temp changes in the same
direction (~10C rise in gas temp ~ 10*0.3 (1 - Efficiency) = 3C rise in
EGT)
• X-ratio - An increase in X-ratio would decrease gas temps & vice
versa
• Gas Weight - Increase in gas weight would result in higher exit gas
temperatures
Air Heater Performance
Assessment
 Objectives
1.To determine Air heater performance indices –
Leakage, Gas-side Efficiency & X-ratio
2. To provide information for performance analysis &
identify the causes of performance degradation, if
any
3. To cross-check the readings of online instruments
around air heaters
 Air Heater Leakage Assessment

• Leakage assessment must be done by a grid survey using a portable gas

analyser. Online Leakage values should be used for relative comparison
only; absolute values may not be correct.
• The O2 readings need to be weighted with velocity pressures taken from
a pitot traverse.
• Method of determination of O2 or CO2 should be the same at inlet and
outlet ‐ wet or dry (Orsat)
(O2 dry = O2 wet / (1‐ FG Moisture))
 AH Tests –Measurements

• 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

Test runs are conducted at an easily repeatable level at defined baseline

conditions at full load with same number of mills in service and same total air
levels as previous tests. The operating conditions for each test run are as
follows.
1. No furnace or air heater soot blowing is done during the test.
2. Unit operation is kept steady for at least 60 minutes prior to the test.

3. No mill change over is done during the test.

4. All air and gas side damper positions should be checked and recorded
5.The test is abandoned in case of any oil support during the test period.
6. Eco hopper de-ashing or Bottom hopper de-ashing is not done during the test.
7. Regenerative heaters should be in service.
.
 Sampling grid in Gas Ducts at AH inlet /
outlet
Variation of Oxygen & Temperature across AH Exit FG Ducts
200 MW (Nov '07)

Single point sampling for gas 8

9

composition / temp may or

160
200
7
120

may not be representative of 6

80

the conditions in flue gas

5
40
4

ducts
Oxygen %
3 Temperature C 0
A B C D E F A B C D E F

100mm Gas Duct is divided into equal cross-

sectional areas and gas samples
are drawn to analyzers from each
center using multi point probes or
point by point traverse
Sampling Points
 FLUE GAS COMPOSITION &TEMPERATURE
A representative value of flue gas composition (O2 / CO2 /CO) is obtained by grid sampling
of the flue gas at multiple points in a plane perpendicular to the flow at air heater inlet
and outlet using a portable gas analyser. Two complete sets of data are collected for
each traverse plane during each test run to ensure data repeatability
• Flue gas samples are drawn by a vacuum pump from the test grid probes and sent to a
portable gas analyzer through a gas conditioning system.
• Typically gas-conditioning system consists of a wash bottle, partially filled with water for
cleaning the gas sample, a condenser to condense the water vapor out of the gas
sample and a desiccant column to remove any water vapor that got through the
condenser.
• Similarly a representative value of temperature is obtained by grid measurement of flue
gas temperatures at multiple points in a plane perpendicular to the flow at air heater
inlet and outlet using multi point probes.
• A single tube probe with a portable analyzer can also be used for traversing duct cross-
section. Marking / etching is done on the sampling tube at d/6, d/2 & 5d/6, if d is the
duct depth. The probe is inserted in each port & samples are drawn at different depths
as per markings
 Leakage Calculation

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

Gas Side Efficiency

Ratio of Gas Temperature drop across the air heater,
corrected for no leakage, to the temperature head.

= (Temp drop / Temperature head) * 100

where Temp drop = Tgas in(333.5C) -Tgas out (no

leakage)
Temp head = Tgasin - T air in(36.1)
What is the gas side efficiency ?
Gas Side Efficiency = (333.5-150.5) / (333.5-36.1) = 61.5 %

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.

Wair out * Cpa * DTa = Wgas in * Cpg * DTg

X ratio = Wair out * Cpa =Tgas in - Tgas out (no lkge)

Wgas in * Cpg Tair out - Tair in

Say AH leakage – 17.1%, Gas In Temp – 333.5 C, Gas Out Temp –

133.8 C , Air In Temp – 36.1 C, Air Out Temp – 288 C. What will be X-
ratio ?
 X ratio = (333.5 – 150.5) / (288 –36.1) = 0.73

AIR HEATER PERFORMANCE TEST REPORT-200 MW

Station: Report date:25.10.10

Unit: 2 Test Date:21.10.10

S.N RESULTS UNITS Design Last Test Current Test

APH A/B APH-A APH-B
1 Air Preheater Leakage % 8.8 0.0 17.8 16.7
2 APH Gas Side Efficiency % 64.3 0.0 59.5 57.5
3 Air Preheater X-Ratio --- 0.77 0.00 0.71 0.67
4 EGT-Corr to ref air temp and lkge C 141.0 0.0 172.5 176.6
5 AH to ID fan Approx. Duct Leakage % 0.0 0.0 13.1 12.1
PARAMETERS
Temperatures
1 Ambient Air C 50 0 33 33
2 Primary Air Inlet C 56 0 46.9 46
3 Secondary Air Inlet C 53 0 34.2 35.0
4 Primary Air Outlet C 318 0 298.8 303.5
5 Secondary Air Outlet C 313 0 297.3 296.3
6 Flue Gas Inlet C 343 0 347 342.3
7 Flue Gas Outlet C 134 0 144.8 149.8
8 EGT - Corr. for AH lkge C 140.7 162.9 167.5
9 EGT - Corr. for ref air inlet temp C 134.0 155.4 159.8
Avg. Oxygen in Flue Gas
10 AH Inlet % 3.87 0 2.84 3.5
11 AH Outlet % 5.26 0 5.84 6.2
12 ID fan Outlet % --- 0 7.8 8.0
DPs across AH
13 Pri Air Side mmwcl 43 0 45.5 44.8
14 Sec Air Side mmwcl 93 0 58.3 55
15 Gas Side mmwcl 108 0 89 87.5
Test Condition
1 Load MW 200 0 201
2 Coal Flow T/Hr 131.6 0 132
3 Total Air Flow T/Hr 793 0 714
4 Secondary Air Flow T/Hr 533 0 510
5 Mills In Service No. 4 nos. 0 ABCE
6 FD Fan Current A 0 0 25 20
7 PA fan Current A 0 0 96 96
8 ID Fan Current A 0 0 85 84
 Air Heaters – Some Issues

• Replacement of baskets – No change in exit

temperatures?
• Basket Replacement Criterion?
• In situ cleaning of baskets?
• Fly-ash erosion of peripheral HE Baskets?
• Choking of CE Baskets?
• Corrections to gas side efficiency?
• SCAPH?
• Restoration of inlet / outlet gas dampers?
Air Heater Performance Improvement Initiative
• Improved thermal performance of air heaters by
Reduction in Air ingress from upstream ducts &
expansion joints.
• Use of new design profile basket elements Use of
new basket profiles can be explored for better heat
recovery in air heaters
• Utlizaton of additonal heat transfer area: Also,
both Primary & Secondary air heaters may have a
space above hot end baskets, which can be utilized
for increasing the height of the basket elements.
• Good practices
 Air Heaters – Good Practices
• AH sootblowing immediately after boiler light up
• Monitoring of Lub oil of Guide & Support bearings
through Quarterly wear-debris analysis
• Hot water washing of air heaters after boiler shutdown -
flue gas temperature ~ 150 to 180 C with draft fans in
stopped condition. (Ideally pH value can verify effective
cleaning)
• Basket drying to be ensured by running draft fans for
atleast six hours after basket washing
 Air Heaters – Good Practices …contd
• Baskets cleaning with HP water jet during Overhauls after
removal from position
• Timely basket replacements; Reversal of baskets not
recommended
• Replace circumferential seals in every overhaul
• Hastealloy flexible seals sustain low leakages for 4-5
months; Use opportunity shutdowns for replacement
• Ensuring healthiness of flushing apparatus of Eco & AH ash
hoppers
 Flue Gas Bypass - Gaps between diaphragms & baskets to
be closed for better heat recovery & lower erosion rate at edges
Correct Small
Design Baskets

HOT HOT

END END

COLD COLD Excessive gaps

END END
between AH baskets &
Intermediate Baskets diaphragms, leading to
Cold End Baskets
gas bypass and erosion
 New Type of seals

➢ Gas side circumferential seals

erode with time from OH to OH
➢ Better to replace all the
segments every overhaul
➢ New seals of fish scale design
is recommended
 Heating Surface Element retrofits

• All our air heaters have DU & NF profile at Hot

end & Cold end

• Potential for improvement by changing basket

profiles

• Reduction in Air heater exit gas temperatures

to 125C
Thank You