DESIGN OF AIR PRE HEATER

AND ECONOMIZER
Under the guidance of(Internal)
N.B.PRAKASH TIRUVEEDULA
ASSISTANT PROFESSOR
VIGNAN UNIVERSITY
Under the guidance of(External)
Mr. SREEKANTH JABADE
GM AND PROJECT ENGG
HARTEX RUBBER PVT LTD

Submitted by
J.SHANMUKA VENKATA GOPICHAND (101FA08133)
L.SURYA TEJA (101FA08141)
CONTENTS
1. Process of Air pre-heater
2. Economizer
3. Boiler basics
4. Heat Exchangers
5. Cross Flow & Compact Heat Exchangers
6. Design Calculation of Economizer
7. Design Calculation of Air pre-heater
8. Boiler Efficiency
9. Heat Balance sheet
10. Conclusion
Process of Air pre-heater
An air pre-heater (APH) is a general term to describe any device designed to heat air
before another process (for example, combustion in a boiler) with the primary objective of
increasing the thermal efficiency of the process.

There are two types of air pre-heaters for use in steam generators in thermal power
stations: One is a tubular type built into the boiler flue gas ducting, and the other is a
regenerative air pre-heater.

Ambient air is forced by a fan through ducting at one end of the pre-heater tubes and at
other end the heated air from inside of the tubes emerges into another set of ducting,
which carries it to the boiler furnace for combustion
 There are two types of regenerative air pre-heaters: the rotating-plate regenerative air pre-
heaters (RAPH) and the stationary-plate regenerative air pre-heaters.
Rotating-plate regenerative air pre-heater
 The rotating-plate design (RAPH) consists of a central rotating-plate element installed
within a casing that is divided into two (bi-sector type), three (tri-sector type) or four
(quad-sector type) sectors containing seals around the element.
In stationary-plate regenerative air pre-heaters the heating plate elements are also installed
in a casing, but the heating plate elements are stationary rather than rotating.
Economizer
Economizers are mechanical devices intended to reduce energy
consumption, or to perform another useful function such as preheating a
fluid.
Economizer performs a key function in providing high overall boiler
thermal efficiency by recovering low level energy from the flue gas before
it is exhausted to the atmosphere.
Economizer recovers the energy by heating the boiler feed water.
 It scavenge the waste heat from thermal exhaust flue gases by passing the
exhaust effluent through heat transfer surfaces to transfer some of the
waste heat to a process media.
It Efficiency is in direct relationship to equipment design and stack gas
velocities.
Velocity increases through the stack as firing rate increases, which results
in a decrease in contact time with the economizer heating surfaces
BOILER BASICS
The hot water or steam under pressure is then usable for transferring the heat for the steam
requirements of process industries or for power generation.
During the combustion process, oxygen reacts with carbon, hydrogen and other elements
in the fuel to produce a flame and hot combustion gases.
As these gases are drawn through the boiler, they cool as heat is transferred to water
The main components in a boiler system are boiler feed water heaters, deaerator, feed
pump, economizer, super heater, Attemperators, condenser and condensate pump.
Heat Exchangers
Heat Exchangers are classified according to their function and geometry:
Function:
Recuperative: two fluids separated by a solid wall
Evaporative: enthalpy of evaporation of one fluid is used to heat or cool the other fluid.
Regenerative: use a third material which stores/releases heat

Geometry: 1. Double Tube 2. Shell and Tube

3. Cross-flow Heat Exchangers 4. Compact Heat Exchangers
Heat Exchangers
The heat transfer rate for most heat exchangers can be calculated using the LMTD-method
(Log Mean Temperature Difference), if the inlet (T1) and outlet (T2) temperatures are
known:

T2 T1
Q U A T T
ln T2 / T1
F

U = Overall heat transfer coefficient [ W/m2-oC ]

A = Effective heat transfer surface area [ m2 ]
F = Geometry correction factor

T = Log mean temperature difference

Cross flow and compact heat exchangers

Cross-flow and compact heat exchangers are used where space is limited. These aim to
maximize the heat transfer surface area.
Commonly used in gas (air) heating applications.
The heat transfer is influenced by whether the fluids are unmixed (i.e. confined in a
channel) or mixed (i.e. not confined, hence free to contact several different heat transfer
surfaces).
In a cross-flow heat exchanger the direction of fluids are perpendicular to each other.
Compact heat exchangers
In Compact heat exchangers, the heat transfer rate is directly related to pressure loss

Advantages:
very small
Ideal for transferring heat to / from fluids with very low conductivity or where the heat
transfer must be done in very small spaces
Disadvantages:
high manufacturing costs
very heavy
Extremely high pressure losses.
DESIGN OF ECONOMIZER
ASSUMPTION:
The properties are remains constant under steady state conditions and neglect
surrounding losses. Kinetic and potential energies are neglected.
DESIGN ANALYSIS:
Heat Transfer,
Q = m x c x t
Where m = mass of fluid in kg
C = specific heat of water in kj/kg oc
t = temperature difference
 Here m = 1800 kg/h
= 5 kg/sec
Specific heat of water is 4.18 kj/kg oc
Temperature difference, t = (70oc - 40oc) = 30oc
Q = 5 x 4.18 x 30oc
Q = 627 kW
Heat loosing fluid
Qc = m x c x t
= 16 x 1.005 x (200 160)
= 643.2 kw.
 In Counter flow
LMTD = ((Th1 Tc2) - (Th2 Tc1)) / ln ((Th1 Tc2 ) - ( Th2 Tc1 ))
= ((200-70) (160-40)) / ln ((200-70)/ (160-40))
= (130-120) / ln (130/120)
= 10 / ln (1.083)
= 10 / 0.0797
LMTD = 125.47oc
 Actually this economizer is a cross flow economizer so, the LMTD equation becomes,
(LMTD)cross = F X (LMTD)counter
Here F = correction factor
It is calculated by using graphical method by using dimension parameters P, Z from graph,
P= (Tc2-Tc1)/(Th1-Tc2)
P= (70-40)/ (200-70)
P= 0.2307
 Z= (Th1-Th2)/(Tc2-Tc1)
Z= (200-160)/ (70-40)
Z= 1.33
From this values we get F = 0.98 (from graphically, pgno:31)
So we have multiplied the counter flow LMTD with correction factor F, then we
get LMTD of cross flow
(LMTD) cross = F X (LMTD) counter
= 0.98 x 125.47
= 122.96oc
 From heat transfer equation we calculate the area of economizer as follows
Q = UA Tm x F
Here F = Correction factor F = 0.98
A = Area of Economizer
A = (627 x 1000) / (850 x 125.4 x 0.98)
A = 6.01 m2
U = 850 w / m2 oc (from tables)
 From Average velocity in the tube and discharge we Calculate total flow area
m= Au
Here m = mass of water
A = Tube flow area
U = velocity of flow = 0.2 m/sec
A = 5 / (1000 x 0.2)
A = 0.025 m2
 The above area is equal to actual cross sectional area of tube
0.025 =n x /4 x d2
0.025 = n x 3.14 x (0.025)2 / 4
n= 50
From Equation 1 the area is 17.47 m2
Then the total surface area in 2 tube pass is given below
2ndL = 6.01
L = 6.01/(2 x 0.025 x 3.14 x 50)
L = 76 mtrs
 Each tube = 2.2 mtrs
No. of passes = 2
No. of tubes = 50
DESIGN OF AIR PRE HEATER
ASSUMPTIONS: The properties are remains constant under steady state conditions and
neglect surrounding losses. Kinetic and potential energies are neglected.
DESIGN ANALYSIS:
Heat Transfer,
Q = m x c x t
Where m = mass flow rate
C = specific heat of air in kJ/kg oc
C = 1.005
t = temperature difference in oc
 Here m = 5 kg/sec
Specific heat of water is 4.18 kJ/kg oc
Temperature difference, t = (110 oc - 50 oc) = 60 oc
Q = 5 x 1.005 x 60 oc
Q = 301.5 kw
Heat loosing of fluid Q = m x c x t
= 5 x 1.005 x (270-200)
= 351.75 kw
 LMTD = ((Th1 Tc2 ) - ( Th2 Tc1 )) / ln((Th1 Tc2 )- ( Th2 Tc1 ))
= ((270-110) (200-50))/ln ((270-110)/(200-50))
= (160-150)/ln (160/150)
LMTD = 156.46 oc
Actually this Air pre-heater is a cross flow Air pre-heater so the LMTD equation
Becomes,
(LMTD)cross = F X (LMTD)counter
Here F = correction factor
 It is calculated by using graphical method by using dimension parameters P, Z from graph,
P= (Tc2-Tc1)/(Th1-Tc2)
P= (110-50)/(270-110)
P= 60/160
P=0.375
Z = (Th1-Th2)/(Tc2-Tc1)
Z = (270-200)/(110-50)
Z = 70/60
Z = 1.16
From this values we get F = 0.94 (from graphically)
 So we have multiplied the counter flow LMTD with correction factor F, then we get

LMTD of cross flow

(LMTD)cross = F X (LMTD)counter

= 0.94 x 156.46

= 147.07 oc

Q = UA Tm x F

Where U = overall heat transfer coefficient

A = Area of Air Pre heater

F = correction factor

U = 50 w / m2 oc (As per standard tables)

 From Average velocity in the tube and discharge we Calculate total flow area
Here correction factor F = 0.94
A = q / U Tm x F
= (301.5X 1000) / (50 x 0.94 x 156.4)
= 43.015m2
m = A u
Here m = mass flow rate kg/sec
A = Tube flow area m2
U = velocity of flow = 0.2 m/sec
= 1.5 kg / m3
 From continuity equation
Q = A1 X V1
5 / 1000 = 3.14 X (0.04)2 X V1
V1 = 3.98 m/sec
m = A u
A= m/( x V1)
A=5/(1.5 x 3.98 ) = 0.83 m2
A = 0.83 m2
 The above area is equal to actual cross sectional area of tube
0.83 m2 = n X /4 X d2
n = 658 tubes
Length of tube for two passes
ndL = 43.015m2
L = 43.015 / (658 x 3.14 x 0.04)
L = 0.52m
No. of tubes = 658
No. of passes = 2, Length = 0.52m
BOILER EFFICIENCY
Now we calculate the boiler efficiency of thermax boiler.
Capacity of boiler = 6 tons/hour
Exisisting values
Water temperature (tw) = 35 oc
Mass of steam (ms) = 6000kg/hr
Mass of fuel (mf ) = 1250 kg/hr
Calorific value of husk = 3500 k.cal/kg = 14644.35kj/kg ( 1 joule = 0.239 k.cal )
Temperature of steam (ts ) = 190 oc
Boiler efficiency = ms (hs-hw)/mf x c.v
 Enthalpy of water at 35 oc hw =hf +x hfg
(x = 0, i.e., dryness factor, by using steam tables)
hw = 151.5 + 0 x hfg
hw = 151.5 kj/kg
Enthalpy of steam at 190 oc
hs =hf +x hfg
hs = 8067 + (0.8 X 1977.5)
hs = 2388.7 kj/kg
Therefore, boiler efficiency = ms (hs-hw) /(mf x c.v) x 100
= 6000(2388.7-151.5)/1250 x 14644.35) x 100
= 0.733 x 100 = 73.3%
8.1 BOILER EFFICIENCY WITH ECONOMIZER
Now introducing economizer the temperature of water increases from 35 oc TO 50 oc
now water temperature (tw) = 50 oc
And quality of steam increases up to 90 percent
Economizer with boiler efficiency = ms(hs-hw)/mf x c.vx100
enthalpy of water at 50 oc (hw) = hf + x hfg
= 213.7 + 0 x hfg
hw = 213.7 kj/kg
 enthalpy of steam at 190 oc (hs) = hf+ x hfg
= 806.7 + (0.9 x 1977.5) (here quality of the steam 90%)
= 806.7 + 1779.5
= 2586.45 kj/kg
Economizer with boiler effieciency = ms(hs-hw)/mf x c.v x 100
= 6000 (2586.45 - 213.7)/(1250 x 14644.35) x 100
=0.77 x 100
=77%
8.2 BOILER EFFICIENCY WITH AIR PRE-HEATER
Now we are introducing air preheater the husk consumption reduced to 1250 kg to
1083 kg/hr
Boiler efficiency with air preheater = MS (HS HW)/MF X CV X 100
= 6000 (2586.45-213.7)/1083 X 14644.35) X 100
= 14236500/15859831.05 X 100
= 0.89 X 100
Boiler efficiency with air preheater = 89%
 Water consumption per hour = 4250
Specific heat of water = 1
T = T2-T1
= 95 OC -85 OC
= 10OC
MCPT = 4250 X 1 X 10 X 24 = 1020000 K.CAL
= 291.42857 KJ/KG
Therefore 291.42857 KJ/KG Rice husk is saving
Heat Balance Sheet
Pressure of Steam = 14.2 bar
Steam produced = 6000 kg/hour
Coal used = 1250 kg/hour
Moisture in Fuel = 2% of mass
Mass of Dry Fuel gas = 9 kg of fuel
Calorific Value of Fuel = 3500 k.cal
Temperature of gas = 2000c
Temperature of Boiler room = 280c
Feed water Temperature = 500c
Specific heat of gas = 1.005 kj/kg
Quality of steam = 0.9%
 Heat supplied for the fuel = mf x c.v
H.S = 1 x 3500
= 3500 k.cal
Heat supplied = 3500 k.cal
If moisture is present then heat supplied by 1 kg of fuel = (1- mm) c.v
Where mm is percentage of moisture
= (1-0.02) x 3500
= 3430 k.cal
= 4913.043 kj
Heat utilized in producing Steam = ms/mf (hs-hw) 1
Where hs = hf + x hfg
= 806.7 + (0.9 x 977.5)
= 2586.45 kg
 hw = hf
hw = 806.7
= 6000/1250 (2586.45 206.7)
= 4.8 x 2379.75
= 11422.8 kj
 Heat carried away by the exert gases = mg cp g (Tg-Ts)
= 9 x 1.005 (2000c 500c)
= 1356.75 kj
Heat carried away by the moisture in the fuel = mm (2676 + 2.1 (Tg 100) hf )
= 0.02 (2676 + 2.1 (200 100) - hf )
= 0.02 (2676 + 2.1 (200 100) 121.4)
= 55.292 kj
Name fuel consumption Boiler efficiency
( kg/hr ) (%)
without airpreheater and 1250 73.3
economizer
with economizer 1250 77
with airpreheater 1083 89

100 1300

90 1250 1250
1250
80

70 1200

60
1150 fuel consumption ( kg/hr
50 )
1083 1100 boiler efficiency (%)
40

30 1050
20
1000
10

0 950
1 2 3
CONCLUSION
In this course of project it came to learn about the Design of Air pre-heater and
Economizer in boiler.
By using the Air pre-heater and Economizer boiler Efficiency can be increased.
Gas flow distribution or heat transfer into the economizer section is improved through use
of guide vanes at inlet of economizer duct.
Analysis of economizer module was carried out to predict the economizer feed water
outlet temperature.
The economizer size optimized by reducing the number of tubes of module by enhancing
the heat transfer across the module.
By installing the Air pre-heater and Economizer the total husk consumption rate is
reduced and the efficiency of the boiler is also increased to 73% to 89%