Air Pre-Heater

- An essential component
in
Fossil Fuel Fired Plant

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 Heat gained by boiling water 38%
•Loss due to moisture in air.
•Loss due to moisture in fuel.
Fuel Energy •Loss due to comb. gen. moisture.
100%
•Dry Exhaust Gas Losses~ 4.6%
Hot gas

Flue gas

•Heat loss from furnace surface. Heat gained

•Unburned carbon losses. by SH & RH
•Incomplete combustion losses. 38%

•Loss due to hot ash. Heat gained by economizer & air

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 AIR PRE HEATER
APH is the last
heat exchanger in
the boiler flue gas
circuit.
To achieve
maximum boiler
efficiency BYPASS SEAL RADIAL SEAL
maximum possible
useful heat must HOT END AXIAL
be removed from SEAL
the gas before it
leaves the APH.
However certain
minimum
temperature has to
be maintained in
the flue gas to
prevent cold end COLD END HOT INTERMEDIATE
corrosion

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 Air Pre-Heater-functions
• An air pre-heater heats the combustion air where it is
economically feasible
• The pre-heating helps the following
– Igniting the fuel
– Improving combustion
– Drying the pulverized coal in pulverizer
– Reducing the stack gas temperature and increasing the
boiler efficiency
• There are three types of air heaters
– Recuperative
– Rotary regenerative
– Heat pipe

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 Advantages by use of APH
• Stability of Combustion is improved by use of hot air
• Intensified and improved combustion
• Permitting to burn poor quality coal
• High heat transfer rate in the furnace and hence lesser heat
transfer area requirement
• Less un-burnt fuel particle in flue gas thus combustion and
both r efficiency is improved
• Intensified combustion permits faster load variation and
fluctuation
• In the case of pulverised coal combustion, hot air can be
used for heating the coal as well as for transporting the
pulverised coal to burners
• This being a non-pressure part will not warrant shut-down of
unit due to corrosion of heat transfer surface which is
inherent with lowering of flue gas temperature

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 Air-heater Selection

• Gas temperature entering APH

• Gas quantity entering APH

• Air quantity leaving APH

• Desired pressure drop on air/gas side

• Gas temperature leaving APH

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Air Heater in Fossil Fired Plant
 The rotating cylinder packed
with thousands of sq m of
specially formed sheets of heat
transfer surfaces
 As it revolves, heat of FG is
absorbed through one half

 The accumulated heat is released to the

incoming air as the same surfaces pass
through other half

 The heat transfer cycle is continuous as

the surfaces are alternately exposed to
the outgoing gas and incoming air
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 Types Of Air Preheater
• Recuperative
• Regenerative
• Plate type Airheater
• Steam Air Preheater
• Langsdorm type
• Rothemuhle type
• Tri sector Air Heater

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Tubular Air Heaters
(Recuperative)

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Tubular Air Pre-Heater

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 Design Parameters
• Tubes are generally arranged in staggered pattern
• Steel tubes of Dia: 37 – 63 mm
• Transverse pitch: S1/d = 1.5 – 1.9
• Longitudinal pitch: S2/d = 1.0 – 1.2
• The height of air chamber:1.4 – 4.5 m
• Gas and Air flow velocity : 10 – 16 m/s
• Plate Recuperators:
• Instead of tube, parallel plates are used
• The gas passage is 12 – 16 mm wide
• The air passage is 12 mm wide

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Regenerative air pre heater

BYPASS SEAL RADIAL SEAL

HOT END AXIAL

SEAL

COLD END HOT INTERMEDIATE

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 Rotary Plate (Regenerative)
type Pre-Heater
• Rotates with a low speed : 0.75 rpm
• Weight : 500 tons
• This consists of : rotor, sealing apparatus, shell
etc.
• Rotor is divided into 12 or 24 sections and 12 or 24
radial divisions
• Each sector is divided into several trapezoidal
sections with transverse division plates
• Heat storage pales are placed in these sections

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Electric Motor Cam Clutch Box Overrunning Clutch

Fluid Coupling Gear Box Air Motor

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 The Material used in APH for
heat storage
• Material used Cold end in the basket is a special type of
steel (corten steel (trade name)) which has high resistance
to the low temperature sulphur corrosion, thus prolonging
operational life.
• In the hot end mild steels are used

• The optimal geometric shape is usually corrugated and

sizes are determined based on design modelling and
experimental data. The turbulence of air and gas flow
through the package increases the heat transfer rate.

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Stationary-Plate Type Air Pre-Heater

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 Stationary-Plate Type Air Pre-Heater

• The heat storage elements are static but the air/gas flow
section rotates.
• The storage plates are placed in the stator.

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Trisector air Heater

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 Heating Elements
• Hot End Baskets

• Hot Intermediate Baskets

• Cold End Baskets

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 NF Profile DU Profile
1.2 mm thick 0.8 mm thick

Change in Cold End Profiles

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New Profile
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 TYPES OF SEALS
• RADIAL SEAL (HE & CE)
• AXIAL SEAL
• CIRCUMFERENTIAL SEAL
• ROTOR POST SEAL
• SECTOR PLATE STATIC SEAL

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 PERCENTAGE AIR LEAKAGE
OF TOATAL LEAKAGES

1. HE Radial seal leakage - 62.21%

2. CE Radial seal leakage - 11.98%
3. Axial seal leakage - 08.78%
4. By pass or circumferential seal leakage - 0.87%
5. Center post seal leakage - 3.17%
_______________________________________________
Total percentage = 87.01%

Entrapped leakage = 12.99%

TOTAL = 100%

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 RADAIAL SEALS &
SECTOR PLATE
• RADIAL SEALS AND SECTOR PLATES ARE
LOCATED AT THE HOT AND COLD ENDS OF THE AIR
PREHEATER. THE RADIAL SEALS ARE ATTACHED
TO THE DIAPHRAGMS, WHICH SEPARATE THE
INDIVIDUAL ROTOR COMPARTMENT.
• PURPOSE: - THE PURPOSE OF RADIAL SEALS IS
TO REDUCE THE AREA AVAILABLE FOR LEAKAGE
FROM THE AIR TO THE GAS SIDE BETWEEN THE
DIAPHRAGM AND THE SECTOR PLATE

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 AXIAL SEALS AND
SEALING PLATES

• AXIAL SEALS MINIMIZE LEAKAGE PASSING

RADIALLY AROUND THE ROTOR SHELL. THE AXIAL
SEALS ARE MOUNTED ON THE OUT SIDE OF THE
ROTOR SHELL AND SEAL AGAINST THE AXIAL SEAL
PLATES MOUNTED ON THE AIR PREHEATER
HOUSING.

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AXIAL SEAL DIAPHRAGM

COG RIM PIN

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 AXIAL
SEAL
PLATE AXIAL SEAL INSPECTION DOOR
TURN-BUCKLE

ADJUSTABLE
BOLT

JACK BOLT
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 Axial Seal Arrangement
• Curved axial sector plate adjustable from
outside
• Seal strips are attached to the rotor.
• The thickness of seal strips :
6 MM straight strips in Russian.
2.5 mm thick and bend backward in
BHEL.

BHEL APH has better accessibility of axial

seal adjustment as compared to Russian
design
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 CIRCUMFERENTIAL
SEALS
• THE CIRCUMFERENTIAL SEALS 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.

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 CIRCUMFERENTIAL SEAL-
RUSSIAN
CIRCUMFERENTIAL SEAL

H.E. DIAPHRAGM
2.5MM RADIAL SEAL H.E. ROTOR FLANGE
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 ROTOR FLANGE AXIAL SEAL

CIRCUMFERENTIAL SEAL ADJUSTABLE BOLT

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CIRCUMFERENTIAL SEALS
ACTUATING MECHANISM-
RUSSIAN
Actuating Bolt

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 ROTOR POST 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 & COLD END SECTOR PLATES AND THE
HOT AND COLD END CENTER SECTIONS.

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 SECTOR PLATE STATIC SEAL

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HE ROTOR POST SEAL01 42
 DIAPHRAGM

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CE ROTOR POST SEAL
AIR SEAL HOUSING
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ROTOR POST SEAL
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 THICKNESS OF RADIAL SEAL
STRIPS

• RUSSIAN MODEL : 6 MM

• BHEL DESIGN : 2.5 MM

• SOFT SEAL : 0.1 MM

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 FLEXIBLE / SOFT
SEALS
• THE FLEXIBLE SEALS WAS DEVELOPED TO REDUCE
NORMAL LEAKAGE CAUSED BY THE THERMAL
EXPANSION OF THE ROTOR WHILE THE UNIT IS
OPERTAING. THE ROTOR EXPANSION OPENS UP
AREAS OF DIRECT AIR TO GAS LEAKAGE THAT CAN
BE GREATLY REDUCED BY INSTALLING FLEXIBLE
SEALS.
• MERIT : - SOFT SEAL IS SET TO A NEGATIVE
CLEARANCE IN COLD CONDITION, AND WHICH WILL
EXTEND IN THE HOT CONDITION TO OPERATE AS A
STANDARD PROXIMITY SEAL.
• DEMERIT : - SINCE THIS IS AN INTERFERENCE OR
CONTACT SEAL, THE WEAR LIFE IS VERY LOW.
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 COST OF SOFT
SEALS

• RADIAL SOFT SEAL HE/ SET :- 1 LAC

• RADIAL SOFT SEAL CE/ SET :- 0.95 LAC
• AXIAL SOFT SEAL/ SET :- 0.4 LAC

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MODULAR APH - BHEL

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RADIAL SEAL

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BY PASS SEAL
RUSSIAN

BY PASS SEAL RUSSIAN

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 APH PERFORMANCE
• Boiler efficiency decreases generally on account of APH
performance degradation. This also affects ESP, ID & FD fan
loadings & at times unit capability
• Factors affecting APH performance
• Excess air level / No of Mills in service
• Primary Air to Secondary Air ratio
• Moisture in coal/ Air ingress level
• Performance of upstream ash evacuation system
• Procedure for cleaning, soot blowing & regular maintenance
etc.

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 APH PERFORMANCE
• Higher than expected leakage would decrease the flue
gas exit temperature, resulting in false sense of
improved working.
• Higher inlet flue gas temperature is rather rare, but this
could be one reason for high exit temperature.
• Optimum flue gas temperature is required for effective
ESP performance
• Unequal temperature at air heater exit should be
investigated.

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 PERFORMANCE
DEGRADATION OF APH
• Seal Leakage
• Erosion
• Corrosion
• High Press Drop Across APH
• APH Fire

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 FLUE GAS EXIT TEMP AT
APH OUTLET
• FLUE GAS TEMP AT AH OUTLET IS INDICATIVE OF HEAT
LEAVING THE UNIT .THIS IS LOWERED ON ACCOUNT OF
AH LEAKAGES.

• FGET TO BE MEASURED AT A LOCATION SLIGHTLY

AWAY FROM AIR HEATERS.

• NO OF TEMPERATURE SENSOR PROVIDED SHOULD

COVER THE DUCT ADEQUATELY.

• CORRECTED TEMP SHOULD BE USED FOR

COMPARISION.

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 AH 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
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 Air Heater Leakage - Calculation
• This leakage is assumed to occur entirely between air inlet and gas outlet
• Empirical relationship using the change in concentration of O2 or CO2 in
the flue gas
CO2 _ in  CO2 _ o u t
AL  * 0.9 *100
CO2 _ o u t
O2 _ o u t  O2 _ in
 * 0.9 *100
21  O2 _ o u t
5.7  2.8
 * 0.9 *100
21  5.7
 17.1%
• 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)

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Tgas out (no leakage) = The temperature at which the gas would have left
the air heater if there were no AH leakage

AL * C pa * (T fgt  Tair )
T fg   T fgt
C pg *100

Say AH leakage – 17.1%, Gas In Temp – 333.5 C, Gas Out Temp – 133.8 C,
Air In Temp – 36.1 C

Tgasnl = 17.1 * (133.8 – 36.1) + 133.8 = 150.5 C

100

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Air Ingress Points – Furnace Roof , Expansion joints, Air heaters, Ducts,
ESP Hoppers, Peep Holes, Manholes, Furnace Bottom
Air-in-
leakage

Furnace
Outlet
Zirconia
O2 Probe
Expansion Joints

AH ESP
Sea
l
Lkg

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 Boiler Air Ingress
• Air ingress can be quantified by the increase in oxygen %
in flue gas; The temperature drop of the flue gas from air
heater outlet to ID fan discharge also provides an
indication of the same.

Oxygen % at various locations in boiler

10

6
O2 %

0
Furn Outlet AH Inlet AH Outlet ID outlet
210 MW 210 MW 500 MW 210 MW

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 Typical Oxygen Levels at
APH Inlet / Outlet
Oxygen in Flue Gas at AH A Inlet / Outlet Oxygen in Flue Gas at AH B Inlet / Outlet

10 12 10 10

8 10 8 8

Outlet O2 %
Inlet O2 %

Outlet O2
8

Inlet O2
6 6 6
6
4 4 4
4
2 2 2 2
0 0
0 0
A B C D E F
A B C D E F
Probe
Inlet O2 Outlet O2 Inlet O2 Probe Outlet O2

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Low / High
Pressure
Water or Air

Steam

High Pressure Cleaning

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Cleaning device
Head design

• 14 kg / cm2 soot blowing

• 100 - 140 kg / cm2 HP wash
• Off-line washing
• On-line washing

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• Fully retractable 64
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THANK YOU

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