Ash Deposition in heat transfer surface

OUTLINE
Introduction/Motivation
Problem definition
Background
Solution
Implementation
Validation
Related work
Future work and conclusions
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Introduction
Studying working mechanism of GGH, comparison of
different GGH, Water vapor condensation, Sulfuric acid
condensation, Fly ash deposition, finding governing
equation to predict modeling and develop MATLAB Program
for analysis, modeling and prediction
Ash deposition is not avoidable, may result in deteriorating
overall performance and cost of power plant
Working principle of GGH, schematic design for GGH
alignment, Water vapor and acid condensation process,
derivation of governing equation for water vapor and
sulfuric acid condensation, governing equation for ash
deposition rate
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PROBLEM DEFINITION
Due to higher organic association of inorganics or higher level of oxygen
in coals, ash formation from inorganics (Na, Mg, Al, Si, K, Ca, and Fe) is
not avoidable when power plant runs with low-rank or blending coals
Quick growth of slagging/sintering/fouling deposits
increased thermal resistance deteriorates heat transfer rate in GGH
abnormal operation occurs/deviates from design conditions
Impact on performance of the subsequent equipment in power plant
Inefficient operation and low productivity
Difficulties/troubles in operation and maintenance
Corrosion layers shorten lifetime of plant equipment
May result in deteriorating overall performance and cost of power plant
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BACKGROUND
What is GGH?
Heat exchanger where heat transfer takes place from the hot
untreated flue gas to treated flue gas
Why used in Coal power plant?
Reducing the visible plume
enhancing the process of SO2 removal

GGH System description

Gas to Gas Heater in an FGD system

Types: Flue gas heat recovery

system(FGHRS)
It can be one with two separate stages of cooling and heating system.
It can be non-leakage and corrosion resistant tubular cross flow type
It can be shell and tube heat exchanger type
It can be regenerative gas to gas heat exchanger

Flue gas heat recovery system

Employed to make use of the flue gas heat energy which otherwise would have been wasted.
GGH on the FGD side can decrease the visible plume.
Increase overall performance and cost of power plant
GGH basically positioned in three different ways.
1. Pre-heating of combustion air before entering the heater,
2. cooling the flue gas before entering and
3. after leaving FGD and finally heating flue gas between FGD and DeNox.
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It includes two separate stage of cooling and heating called clean gas re-heater and
flue gas cooler.

Tubular cross-flow type: heating of treated gas and the cooling of untreated flue gas
take place on the same unit.
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Regenerative gas to gas heat exchanger

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LOW-PRESSURE FEED WATER PREHEATING:

The heating potential of the flue gases is recovered by means of special corrosionprotected heat exchangers and transferred to the low-pressure feed water via a heat 11

AIR HEATER BYPASS ECONOMISER (LUBECO): In FGD plants without reheating facility the heat
potential of the flue gas is recovered by means of special corrosion resistant heat exchangers and is transferred 12
to the regenerative air heater via a heat transfer agent circuit and via an additional air heater.

MEASURE FOR PROTECTION OF

GGH
The risk of corrosion in GGH is higher due to its low operating
temperature
To reduce corrosion and protect GGH, use of low alloy corrosion
resistant metal
increasing corrosion margin, coating with porcelain enamel
and other measures can be taken
For the cleaning purpose, soot blowers can be used
For choosing heat exchanger element design, pressure drop
and heat transfer characteristics should be taken in
consideration
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 Water vapor condensation rate

=

Sulfuric acid condensation rate

=
Fly ash deposition rate

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Ash Deposition
Ash deposition can be divided into 3 stages
1. Mere ash deposition condition
2. Acid ash coupling deposition condition
3. Acid-water-ash coupling deposition

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Heat Transfer Rate

=ufg Cufg,p ( Tufg,in - Tufg,out)

= K * Aeff * (Tufg-Ttfg)

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Control Volume and thermal Resistance

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