AIR HEATER PERFORMANCE

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Role of Regenerative Air Heaters

To recycle the heat of exit flue gas back in the combustion process Enabling efficient coal combustion by raising secondary air temperature. Enabling efficient pulverization process by optimizing pulverized output temperature.

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What can go wrong ?

Partly ingress of air in flue gas at air heater entry due to leakage causing lowering flue gas temperature and thereby inefficient heat transfer. It increases the required fan power and can eat away the fan margin. hoking of air heater basket resulting high dp across air heater! low heat transfer and high exit temperature.

"ow gas side efficiency. "ow #$ratio indicating bad operating condition
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Therefore..

The Performance Indicators are

Air Leakage Gas Side Efficiency X - ratio Gas & Air side pressure drops

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Data re uired
!" & #!" in $G at AP% In&et !" & #!" in $G at AP% !ut&et Temperature of air entering air heater Temperature of air &ea'ing air heater Diff( Prsr( Across AP% on air & gas side

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Samp&ing Ports in $&ue Gas Ducts )Typica& *

+,,mm

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Gas Side Pro0es

&-. &-" /-. &

Air Side Pro0es

Thermocoup&es

Tra'erse Ports

Ports

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$&ue Gas Samp&ing Train

$G Samp&e from pro0es Desiccant 4ar 1u00&e 4ar #ondenser

Datascan 1o2es

Gas Ana&ysers 3acuum Pump

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Temperature %tratification in &P' (utlet )* +uct

1 1 1 1 1 1 Temp 1 1 1 1 1 1 1 1 1 A B C Probes D E
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S1 S1 S1

1 1 111 . $ 1 11 . 1 1 111 . $ 1 11 . 1 1 111 . $ 1 11 . 1 1 111 . $ 1 11 . 9

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(1 %tratification at &P' (utlet )* +uct

1 1

11 $
1

,
1 1
1 1 1
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11 $ 11 $ 11 $ 11 $
10

1 A B C D
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Probe

( xygen in )lue * as at &' inlet 2T est x3xx4

+ 11 . 11 . & 11 . 11 . 11 . / 11 . 0 11 . " 11 . 1 11 . E 11 . ) 11 . 11 . * 11 . 11 . '

&verage (xygen values in Test x from the fourteen 11 . I probe grid in )lue *as + uct at &ir ' eater Inlet
11 . .

5(n line 5 6irconia probe

+ 11 . 11 . &
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11 .

E 11 .

) 11 .

11 .

* 11 . 11 . '

11 . 11 .

&verage (xygen values in Test xx from the fourteen 11 . I probe grid in )lue *as + uct at &ir ' eater Inlet
11 . 11 . 11 . . PMI Revision 00 11 11 . .
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Air Leakage

5eight of air passing from air side to gas side( This &eakage is assumed to occur entire&y 0et6een air in&et and gas out&et( A&most ./7 &eakage is from radia& sea&s8 9, 7 from circumference 0ypass sea&s and rest from a2ia&8 rotor post sea&s %ot End - #o&d End - Entrained Leakage Empirica& re&ationship using the change in concentration of !" or #!" in the f&ue gas : #!"in - #!"out ; ,(< ; +,, #!"out !"out - !"in ; ,(< ; +,, )"+- !"out*

#a&cu&ation

7 AL

#a&cu&ation using #!" 'a&ues is preferred 0ecause of higher a0so&ute 'a&ues and &o6er errors( The method of determination of !" or #!" shou&d 0e the same at in&et and out&et - 6et or dry )!rsat*(
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Gas Side Efficiency

=atio of Gas Temperature drop across the air heater8 corrected for no &eakage8 to the temperature head( : )Temp drop - Temperature head* ; +,, 6here Temp drop : Tgas in -Tgas out )no &eakage* Temp head : Tgasin - T air in Tgas out )no &eakage* : The temperature at 6hich the gas 6ou&d ha'e &eft the air heater if there 6ere no air heater &eakage >o6 Tgas out )no &eakage* : AL ; #pa ; )Tgas out - Tair in* ? Tgas out #pg ; +,, 5here #pa @ Specific heat of air & #pg- Specific heat of gas(
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$&ue Gas E2it Temperature

$&ue Gas E2it Temperature is corrected for de'iations of in&et air and in&et gas temperatures from design 'a&ues( Temp corrected for &eakage and temperature of entering air is Tgasout&a : Tairind )Tgasin @Tgasoutn&* ? Tgasin)Tgasoutn& @ Tairin* Tgasin @ Tairin Temp corrected for &eakage and temperature of entering f&ue gas is Tgasout&g : Tgasind )Tgasoutn& @Tairin* ? Tairin)Tgasin @ Tgasoutn&* Tgasin @ Tairin $&ue gas e2it temp corrected for de'iations from design : Tgasout&a ? Tgasout&g - Tgasoutn&

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X @ =atio
=atio of heat capacity of air passing through the air heater to the heat capacity of f&ue gas passing through the air heater( : : 5air out ; #pa 5gas in ; #pg Tgas in - Tgas out )no &eakage* Tair out - Tair in

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A* Air In - Air !ut Temperatures $or air in&et and out&et temperatures8 6eighted a'erages of primary and secondary air temperatures are used as 0e&o6( $raction of PA f&o6 : $+ : PA f&o6 - Tota& Air $&o6 $raction of SA f&o6 : $" : SA f&o6 - Tota& Air $&o6 5eighted Air Temp In : $+ ; PA Temp In ? $" ; SA Temp In 5ghted Air Temp !ut : $+ ; PA Temp !ut ? $" ; SA Temp out

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/* The specific heat of the air is ca&cu&ated at the a'erage air temperature in the A% )In&et Temperature ? !ut&et Temperature* - "( This is done 0y using ASBECs PT# A(+ Steam Generating Dnits8 $igure 9( : #pAI= )kca&-kg-E* $ormu&aF #pGair : <(H<I</IE-+< ; X/ @ "(H.HI.E@+/ ; XA @ H(A"IA"E-+" ; X9 ?,(,,,,,,,"./A"+" ; X" ?(,,,,,.AH<9". ; X ?,("9I<+.+ 5here X : A'erage air temperature in A%( .* If a #!" ana&yser is not a'ai&a0&e8 the amount of #!" in the f&ue gas can 0e ca&cu&ated 0y su0tracting the !" percentage from the constant for )!" ? #!"*( #!" )7* : )!" ? #!"* - !" : 1!"#!" - !"
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H* The specific heat of the f&ue gas is ca&cu&ated using a'erage gas temperature )Gas in&et and no-&eakage gas out&et*8 car0on content of fue&8 hydrogen content of fue&8 and amount of #!" in the f&ue gas( See ASBECs PT# A(+ Steam Generating Dnits8 $igure H( : #pGAS )kca&-kg-E* I* Air %eater Leakage )7* is defined as +,,;the mass of 6et air &eaking to the gas side di'ided 0y the mass of 6et gas entering the air heater( %o6e'er8 it is usua&&y appro2imated 0y one of the t6o e uations using measurements of gas ana&ysis8 0y 'o&ume8 on the gas sideF 7 Leakage : <,; )7#!" entering - 7#!" &ea'ing* 7#!" &ea'ing 7 Leakage : <,; )7!" &ea'ing - 7!" entering* - )"+7!" &ea'ing*PMI Revision 00 May 24, 2012

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<*

A% Gas Side Efficiency is ca&cu&ated as 0e&o6( A%E : +,, ; )Gas Temp In @ >L Gas Temp !ut* )Gas Temp In @ Air Temp In* !r A%E : +,, ; )A%GIT - EGT#orT>L* - )A%GIT @ AirT*

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THANK

O!

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