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Work optimization for rotary regenerative air preheater based on an increase

of heat capacity of the matrix and reduction of leakage in seal clearances

Conference Paper · July 2013

DOI: 10.13140/2.1.3786.2722

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 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

Work optimization for rotary regenerative air

preheater based on an increase of heat capacity of
the matrix and reduction of leakage in seal
clearances
Goran Stupara, Titoslav Zivanovica, Dragan Tucakovica, Milos Banjaca
a
Faculty of Mechanical Engineering, Kraljice Marije 16, 11120 Belgrade 35, Serbia, gstupar@mas.bg.ac.rs

Abstract:
The paper shows a reconstruction of rotary regenerative air preheater in purpose of increase of
it’s energy efficiency. The increase of matrix heat capacity was examined with minimal
modifications to geometry of heat exchanger surfaces. At the same time, the influence of lower
air leakage through the seals on the efficiency of the plant was also tested. All research were
performed for two fuel qualities. From a series of thermal and aerodynamic calculations, the
optimal work conditions of rotary regenerator were chosen in terms of energy efficiency of the
boiler plant. The shown results were verified by measurings executed at the plant after
reconstruction.

Keywords:
Rotary regenerative air preheater, steam boiler,matrix heat capacity, energy efficiency.

1. Introduction
Increase of the economic efficiency of modern steam boilers is one of main concerns of
modern energetics. Due to increase of fuel consumption there is a need for constant
improvement of combustion process, and processes of utilization of energy from flue gases.
Improtant factor that contributes to fuel savings in thermal power plants is process of air
heating with energy of flue gases at the outlet of steam boiler. Lowering of exit flue gas
temperature lowers the quantity of energy that is irretrievably lost into the atmosphere. The
heated air increases furnace temperature, which contributes to better fuel combustion and
more intensive evaporation process. Thus the air heater considerably affects the steam boiler
efficiency, and is today an indispensable component of power plants.
Due to its compactness, ease of cleaning and corrosion protection, and high performance of
energy transfer, the rotary regenerative air preheaters are mostly applied in coal fired power
plants. Rotary preheaters function by a specific principle where the heat transfer from flue gas
current to air current is done via rotary matrix. Matrix is composed of densely packed profiled
tin sheets, where the tin sheets form current space. A significant problem with rotary
generators presents the inevitable leakage of air into flue gas current due to existence of
clearance between seals and rotor, and pressure difference between the two currents.
This paper concerns the possibilities of increasing thermal efficiency of rotary regenerative air
preheaters on a steam boiler in a 350 MW power plant. Examination was conducted regarding
how much influence will increase of the matrix heat capacity with alterations to geometry of
matrix sheets have on the amount of utilized energy. As a method of improving the work
efficiency of the heating surface, contribution of introduction of more efficient rotary sealing
was also taken into consideration. For research purposes, an own code of thermal calculation
for the considered steam boiler was developed. Thermal calculation is based on Normative
method [1]. This allowed for execution of qualitative selection of tested methods for rotary
 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

regenerator work efficiency increase, and selection of optimal reconstruction of heating

surface during the regular annual overhaul of the steam boiler.

2. Working conditions
Subject steam boiler was designed for combustion of lignite with lower heating value of
7326 kJ/kg. Operational characteristics of the boiler are:
▪ Main steam mass flow rate, D = 277.8 kg/s;
▪ Main steam pressure, ps = 18.6 MPa;
▪ Main steam temperature, ts = 540 oC;
▪ Reheated steam mass flow rate, Dr = 261.1kg/s;
▪ Reheated steam pressure, prs = 4.375 MPa;
▪ Reheated steam temperature, trs = 540 oC;
▪ Steam temperature at the reheated inlet, tr = 334 oC;
▪ Feed water temperature, tfw = 205 oC.
Two rotary regenerative air preheaters are mounted at the boiler outlet. Operational conditions
dictate that the flow space for both flue gases and air to be identical. This was enabled by
placing two sector plate in the middle of rotor (Fig. 1). Rotor diameter is 12.13m. In order to
enable easy replacement of matrix damaged by low temperature corrosion, rotor was divided
into hot group (1.4 m) and cold group (0.3 m). Sheet geometry of both hot and cold group are
shown on Fig 1. Pitch of sheet of the existing hot group matrix (A) is t = 38 mm, sheet
thickness δ = 0,63 mm, overall height of matrix couple x = 11 mm, height of distance
sheet y = 3 mm, and height of undulated sheet is x–y= 8 mm. Height of undulated sheet in part

Figure 1. Geometry of matrix sheets: upper right - double undulated; lower right - notched
plain;
between two undulations is z = 3 mm. Angle of sheet bending is 30о, and pitch of sheet matrix
of rotary cold group (A) is t = 38 mm, and sheet thickness δ = 1.2 mm. Overall height of
 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

matrix couple is x = 14.2 mm, while the height of the sheet is x–δ = 13 mm. Cold group sheets
are smooth, and equivalent diameter is de = 9.8 mm.

3. Possibilities for increase of preheater efficiency

The impact which methods for increase of efficiency of rotary regenerative air preheater have
on the steam boiler efficiency has been analytically examined, using the own code for thermal
calculation. Series of calculations [2] were used for examination of influence which rotary
matrix heat capacity and contribution of more efficient air preheater sealing have on the
operation of steam boiler. Calculations were performed for guaranteed coal, and coal of better
quality (8249 kJ/kg).
3.1. Examination of influence of heat capacity increase
Heating surfaces of rotary regenerative air preheater is composed of rugged ducts, where the
height of undulated matrix sheets represent the element of ruggedness. Thickness of viscous
sublayer, that is around a millimeter for the considered operational conditions, serves as a
linear proportion for process of heat exchange in these ducts [3]. Small changes in height of
undulation lead to a significant change in heat exchange characteristics. Therefore, the height
of undulation during these analysis was changed within narrow limits permitted by Normative
method [4]. Distance between undulations determines the conditions of development and
propagation of vortices and also affects the characteristics of heat exchange, and therefore it
has not been altered in this paper. Increase of heat capacity was performed with minimal
alterations to geometry of matrix sheets. Overall height of matrix couple x and height of
distance sheet y, are varied parameters. Test case A refers to designed boiler parameters. Test
case B refers to boiler parameters with existing air preheater, where the designed geometry of
matrix was kept, and only the sheet thickness was altered. All examined cases (B – D) were
performed with altered sheet thickness and fuel of better quality. Sheets used for hot group
were δ = 0.6 mm thick, and for cold group, δ = 1.0 mm thick. Altering the heights of matrix
couple and thickness of sheets allowed placement of an increased number of sheet couples,
both in hot and cold group of rotary matrix. Alterations to geometry of matrix sheets enabled
for increase of heating surface of matrix, and it's overall mass. That influenced the increase of
heat capacity of matrix. Table 1 shows the designed and varied geometrical characteristics of
sheets for hot and cold group of matrix.
Hot group - double undulated
Varied parameters Unit
A B C D
δ mm 0.63 0.6 0.6 0.6
x mm 11 11 10.6 10.25
y mm 3 3 2.85 2.7
x-y mm 8 8 7.75 7.55
Cold group - notched plain
Varied parameters Unit
A B C D
δ mm 1.2 1.0 1.0 1.0
x mm 14.2 14.0 13.6 13.25
x- δ mm 13 13 12.6 12.25

Table 1. Varied parameters for matrix sheets;

The increase to heating surface of hot group of matrix is valued in percentages, compared to
the existing matrix hot group B, in Table 2. That increase is ΔС = 0.7 %, 3.9 % and 6.3 %.
The increase to heating surface of cold group of matrix is valued in percentages, also
 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

compared to the existing matrix cold group B, in Table 3. That increase is ΔС = - 1.5 %, 3.3
% and 5.8 %. Combining the hot and cold group of matrix resulted in four tested pairs A – D.

Nome
No. Name nclatu Unit Rotary matrix
re
Hot group A B C D
1. Type of matrix - - Double undulated
2. Equivalent matrix diameter mm 9.6 9.3 9.0 8.7
3. Rotor diameter m 12.13
4. Part of crossection for flue gas stream - 0.403
5. Part of crossection for air stream - 0.403
Coefficient of filling rotory crossection
6. - 0.932
with hub and compartments
Coefficient of filling rotory crossection
7. - 0.87 0.88 0.87 0.87
with matrix
Number of rotory air preheaters per
8. - 2
boiler unit
9. Flue gas flow section m2 75.52 76.39 75.52 75.52
10. Air flor section m2 75.52 76.39 75.52 75.52
11. Height m 1.4
Overall heating surface per 1 m3
12. m2/m3 415 412 428 438
of rotor, without hub and compartments
13. Increase of the rotary heating surface Δ - 1.007 1.000 1.039 1.063
14. Heating surface m2 118893 118034 122618 125482

Table 2. Geometrical characteristics of regenerative air preheaters – rotory hot group;

Nome
No. Name nclatu Unit Rotary matrix
re
Cold group A B C D
1. Type of matrix - - Notched plain
2. Equivalent matrix diameter mm 9.8 9.9 9.7 9.5
3. Rotor diameter m 12.13
4. Part of crossection for flue gas stream - 0.403
5. Part of crossection for air stream - 0.403
Coefficient of filling rotory crossection
6. with hub and compartments - 0.932
Coefficient of filling rotory crossection
7. - 0.80 0.83 0.83 0.83
with matrix
Number of rotory air preheaters per
8. - 2
boiler unit
9. Flue gas flow section m2 70.84 73.49 73.49 73.49
10. Air flor section m2 69.45 72.05 72.05 72.05
11. Height m 0.3
Overall heating surface per 1 m3
12. m2/m3 325 330 341 349
of rotor, without hub and compartments
13. Increase of the rotary heating surface Δ - 0.985 1.000 1.033 1.058
14. Heating surface m2 19952 20259 20934 21425

Table 3. Geometrical characteristics of regenerative air preheaters – rotory cold group;

 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

3.2. Examination of the contributions of more effective sealing

Uneaven temperature field by height and girth of the rotor leads to deformation of the massive
rotor during the operation of rotary air preheater, which results in an increase of clearance
between seals and the rotor. The analysis considers the use of more efficient sealing system of
the rotor, which is followed by a less amount of air being lost while flowing through the
heater (𝛥𝜆l). Table 4 shows heat balance of steam boiler for tested cases of rotary air heater
operation. Last column presents the boiler balance with a more efficient system for heater
sealing.

Guaranteed

Nomenclature
Coal of better quality
coal
No Name Unit Hot and cold group combination

A B C D D*

1. Lower heating value kJ/kg 7326,9 8249 8249 8249 8249

2. Furnace excess air 𝜆 - 1.20 1.20 1.20 1.20 1.20
3. Incraese of excess air in furnace 𝛥𝜆 - 0.05 0.10 0.10 0.10 0.10
4. Incraese of excess air in mill 𝛥𝜆 - 0.10 0.20 0.20 0.20 0.20
Incraese of excess air in air
5. 𝛥𝜆 - 0.09 0.20 0.20 0.20 0.09
preheater
Ratio of air quantity at the heater
6. - 1.13 1.08 1.08 1.08 0.98
inlet and stoichiometric quantity
Ratio of air quantity at the heater
7. - 1.05 0.90 0.90 0.90 0.90
outlet and stoichiometric quantity
Coefficient of air leakage from air
8. 𝛥𝜆 - 0.08 0.18 0.18 0.18 0.08
preheater into gas stream
Temperature of air preheated using o
9. C 40 40 40 40 40
external heat source
o
10. Temperature of environment air C 20 20 20 20 20
Ammount of heat imported with
11. kJ/kg 70 68 68 68 61
preheated air
12. Disposed heat quantity kJ/kg 7446 8364 8364 8364 8358
o
13. Temperature of outlet gases C 153 163 162.5 162 169
14. Excess air at the boiler outlet 𝜆 - 1.34 1.50 1.50 1.50 1.39
15. Outlet gases enthalpy kJ/kg 861 1005 1000 997 980
16. Waste gas loss % 10.20 10.57 10.51 10.47 10.36
17. Loss due to unburned gases % 0.00 0.10 0.10 0.10 0.10
Loss due to incomplete mechanical
18. % 2.4 3.0 3.0 3.0 3.0
combustion
19. Radiation loss % 0.20 0.40 0.40 0.40 0.40
20. Loss due to slag heat % 0.08 0.08 0.08 0.08 0.08
21. Boiler efficiency % 87.12 85.86 85.92 85.95 86.06
22. Superheated steam production kg/s 277.8 277.8 277.8 277.8 277.8
23. Heat quantity used in steam boiler kW 822992 822992 822992 822992 822992
24. Fuel consumption kg/s 126.872 114.604 114.523 114.480 114.421
*
With more efficient sealing of the air preheater

Table 4. Steam boiler heat balance;

 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

4. Results
Thermal calculation of rotary air preheater was performed for two different coal qualities and
four combinations of hot and cold group of matrix. Test case A refers to designed operational
conditions of steam boiler, while test cases B – D refer to real boiler conditions with varied
matrixes of rotary regenerative air preheater. Calculation is also performed optimal matrix
from aspect of heat efficiency and in operational conditions with more efficient sealing (D*).
All calculations were performed for nominal production and operational conditions without
high pressure heaters. Table 5 shows the course of thermal calculation for hot and cold group
of rotary air preheater and test cases A - D*.
Guaranteed

Nomenclature
Coal of better quality
coal
No Name Unit Hot and cold group combination

A B C D D*

Hot group
o
1. Flue gas inlet temperature C 295 295 295 295 295
2. Inlet excess air 𝜆 - 1.25 1.30 1.30 1.30 1.30
o
3. Flue gas outlet temperature C 176 189 189 189 194
4. Outlet excess air 𝜆 - 1.31 1.43 1.43 1.43 1.36
o
5. Air inlet temperature C 76 82 83 84 85
o
6. Air outlet temperature C 271 280 282 283 282
7. Avarage velocity of flue gas flow m/s 11.28 10.59 10.68 10.70 10.49
Coefficient of heat transfer from flue gases to
8. W/m2K 91.86 86.14 87.44 88.01 86.75
matrix sheet
9. Avarage velocity of air flow m/s 6.71 5.50 5.58 5.59 5.39
2
10. Coefficient of heat transfer from matrix to air W/m K 52.79 45.01 45.80 46.16 44.80
2
11. Overall coefficient of heat transfer W/m K 12.16 10.72 10.90 10.98 10.72
12. Ammount of heat absorbed by heating surface kJ/kg 628 535 536 536 548
Cold group
o
1. Flue gas inlet temperature C 176 189 189 189 194
2. Inlet excess air 𝜆 - 1.31 1.43 1.43 1.43 1.36
o
3. Flue gas outlet temperature C 153 163 162.5 162 169
4. Outlet excess air 𝜆 - 1.34 1.50 1.50 1.50 1.39
o
5. Air inlet temperature C 40 40 40 40 40
o
6. Air outlet temperature C 76 82 83 84 85
7. Avarage velocity of flue gas flow m/s 10.81 10.47 10.49 10.50 10.04
Coefficient of heat transfer from flue gases to
8. W/m2K 53.10 50.25 50.39 50.58 49.02
matrix sheet
9. Avarage velocity of air flow m/s 5.61 4.69 4.70 4.71 4.33
2
10. Coefficient of heat transfer from matrix to air W/m K 29.00 24.84 24.96 25.08 23.40
2
11. Overall coefficient of heat transfer W/m K 6.80 6.03 6.05 6.08 5.75
12. Ammount of heat absorbed by heating surface kJ/kg 117 126 130 133 131
*
With more efficient sealing of the air preheater

Table 5. Thermal calculation of rotary air preheater;

 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

Analysing the results of heat balance shown in Table 4, it is clear that the increase of the air
preheater heating surface, in test cases B – D, results in an increase of efficiency of the steam
boiler. Steam boiler has the greatest efficiency for designed operating conditions
(ηsb = 87.12 %). Designed operating conditions include the lower ammount of air breaching
into the flue gas tract. For designet – test case A, excess air at the boiler outlet is 𝜆out = 1.34.
Designed case considers the flue gas temperature at the boiler outlet to be 150°C. By
monitoring the boiler operation it was noticed that real values of air amount in flue gas, and
temperature of flue gases at the boiler outler, considerably exceed the designed values. For
this reasons, test cases B – D were performed for with measured values of excess air at the
boiler outlet, of 𝜆out = 1.50. During the real boiler work, with air preheater of unaltered
geometry of matrix profile compared to the deisgn, but an altered sheet thickness (B) and real
values of excess air, the boiler reaches efficiency of 85.86 %.
Using the matrix C leads to an increase of rotary regenerator surface, which results in an
increased increased efficiency of 85.92% in real work conditions. Examination of the
additional increase of the heating surface D, and therefore the overall matrix heat capacity,
resulted in boiler efficiency of 85.95 %.
As most favourable, from aspect of steam boiler operation, test case D was examined with
more efficient system of sealing of rotary regenerator. In real conditions of air infiltration,
with matrix D and lower amount of air leaking into the flue gas stream (Δ𝜆l = 0.08), steam
boiler operates with efficiency of 86.06 %.
By analysing the results of thermal calculation shown in Table 5, it is easy to see the changes
on profiles of matrix B – D, with identical operating conditions, lead to an increase in air
temperature at the preheater outlet. As the matrix heat capacity grows with matrix mass from
B to D, air preheater exchanges a greater amount of heat. From 661 kJ/kg for preheater with
matrix B, 666 kJ/kg for preheater with matrix C, to 669 kJ/kg for preheater with matrix D.
Lower amount of infiltrated air in the mill and furnace, during the design boiler operation
conditions, has resulted in greater amount of air flowing through the air preheater. This fact
results in greater velocity, and therefore a more intensive energy exchange in the air
preheater. Designed calculations are not directly comparable with results of other test cases,
primarily because of the idealized sealing conditions in the entire boiler. Therefore, test case
B, which represents boiler operation with current air preheater, without alterations to matrix
sheet geometry, but for real boiler operating conditions.
For matrix with optimal geometry of sheet couples (D), in case of tested, more efficient
sealing (D*), thermal calculation proves an increase in efficiency of air preheater. Greater
efficiency is a result of greater temperature differences of heat transmiter and heat reciever in
new operating conditions. Lower amount of air which flows through the preheater, becayse of
better sealing, does not present a dominant factor on intensity of the exchanged amount of
energy. During these improved operating conditions, preheater exchanges the greatest amount
of energy, 679 kJ/kg. This plant, with real operating conditions, and with better sealed air
preheater of increased matrix heat capacity (D*), has the optimal efficiency.
Selection of optimal matrix and optimal operating conditions (D*) during the reconsturction
of rotary regenerative air preheater was performed based on the represented analysis.
Measurings of the guaranteed parameters was performed on the considered heating surface
after the reconstruction [5]. Essence of performed measurings is represented in Table 6.
During the measurings, steam boiler was working at nominal production with fuel of better
quality. Measured results match the calculated values at a satisfactory level.
 PROCEEDINGS OF ECOS 2013 - THE 26TH INTERNATIONAL CONFERENCE ON
EFFICIENCY, COST, OPTIMIZATION, SIMULATION AND ENVIRONMENTAL IMPACT OF ENERGY SYSTEMS
JULY 16-19, 2013, GUILIN, CHINA

Measured Calculated
No. Name Nomencalture Unit
values values (D*)
Flue gas temperature at preheater o
1. C 296 295
inlet
Flue gas temperature at preheater o
2. C 170 169
outlet
3. Excess air at preheater inlet 𝜆 - 1,29 1,30
4. Excess air at preheater outlet 𝜆 - 1,41 1,39

Coefficient of air leakage from

5. 𝛥𝜆 - 0.10 0.08
air preheater into gas stream

Table 6. Measured and calculated values at the reconstructed steam boiler;

5. Conclusion
Analysis was performed for the operating efficiency of a steam boiler in thermal power plant
of 350 MW, for different heat capacities and sealing conditions of rotary air preheater. An
increase of air preheater heating surface was considered for minimal alterations to geometry
of matrix sheets. Represented changes enabled an increase of rotary regenerator matrix mass,
and therefore it’s heat capacity. Analysis showed that the increase of matrix heat capacity,
with identical conditions of air infiltration in the steam boiler, always results in increase
efficiency of air preheater and the steam boiler. Optimal matrix was tested in conditions of
improved sealing. Results of this test showed that the efficiency of preheater additionaly
increases, as does the efficiency of the boiler. Selected solution for increase of efficiency of
air preheater and the boiler was verified by measurings on the boiler after the reconstruction.

Acknowledgments
This work has been supported by the Republic of Serbia Ministry of Education and Science
(project: “Increase in energy and ecology efficiency of processes in pulverized coal-fired
furnace and optimization of utility steam boiler air preheater by using in-house developed
software tools”, No. TR-33018).

6. References
[1] Brkić Lj, Živanović T, Tucaković D. Steam Boilers, Faculty of Mechanical
Engineering, University of Belgrade, Serbia, 2002.
[2] Živanović T, Tucaković D, Brkić Lj Study of reconstruction of rotary air preheaters
with usage of active sealing in purpose of reducing the waste gas loss, Faculty of
Mechanical Engineering, University of Belgrade, , Innovation center, Serbia, 2008.
[3] V.K. Migai, Regenerative Rotary Air Preheaters. Energiya, Leningrad, USSR, 1971.
[4] Brkic Lj, Zivanovic T, Tucakovic D. Thermal calculation of steam boilers, Faculty of
Mechanical Engineering, University of Belgrade, Serbia, 2010.
[5] Measurings of the guaranteed parameters for rotary air preheaters Thermotechnical
examinations of boilers K1 and K2 in TPP Kostolac, Institut Vinča, University of
Belgrade, Serbia, 2011.

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