Professional Documents
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Pr esentation Plan
Air heaters Types of air heaters Materials Used Sealing arrangement for air heaters Air heater Performance Performance tests
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AXIAL SEAL
HOT INTERMEDIATE
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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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 efficiency is improved. Intensified combustion permits faster load variation and fluctuation. In the case of pulverized coal combustion, hot air can be used for heating the coal as well as for transporting the pulverized 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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Advanta ges by use of APH Stability of Combustion is improved by use of hot air.
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HOT END
AXIAL SEAL
COLD END
HOT INTERMEDIATE
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Heating Elements
Hot End Baskets Hot Intermediate Baskets Cold End Baskets
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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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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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TURN-BUCKLE
ADJUSTABLE BOLT
JACK BOLT
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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 SEALRUSSIAN
CIRCUMFERENTIAL SEAL
H.E. DIAPHRAGM
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ROTOR FLANGE
AXIAL SEAL
CIRCUMFERENTIAL SEAL
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ADJUSTABLE BOLT
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DIAPHRAGM
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RADIAL SEAL
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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
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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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O x yg e n in F lu e G a s a t A H B In le t / O u
0 0 0 0 B C D E O u tle t0 O F In le t 0P r o b e O
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CO2 measurement is preferred due to high absolute values; In case of any measurement errors, the resultant influence on leakage calculation is small.
Air Leakage Weight of air passing from air side to gas side; This leakage is assumed to occur entirely between air inlet and gas outlet Hot End / Cold End / Entrained Leakage Calculation Empirical relationship using the change in concentration of O2 or CO2 in the flue gas = CO2in - CO2out * 0.9 * 100 CO2out O2out - O2in * 0.9 * 100 (21- O2out) = 5.7 2.8 * 90 (21-5.7) = 17.1 %
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Seal Leakage Erosion Corrosion High Press Drop Across APH APH Fire
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X- RATIO = T (gas in) T (gas out) (no lkg)/ T(air out) T (air in)
Air Leakage = CO2in - CO2out * 0.9 * 100 CO2out = O2out - O2in * 0.9 * 100 (21- O2out) 00 PMI Revision
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F G T E M P (C o rr.) V s B L R E F F & G A S S ID E E F F
0. 00 0 0 0 0 0 0
0. 00
B o ile r E ffic in e c y
8 8 0 0
8. 88
G a s S id e E ffic ie n cy
8. 88 8. 88 0 0 00 0
0 0 0 0 8 8 0 0 00 0
00 0
00 0
00 0
88 8
00 0
C O R R E C T E D F L U E G A S T E M P (D e g C )
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0 0
X Ratio
Ratio of heat capacity of air passing through the air heater to the heat capacity of flue gas passing through the air heater. = Wair out * Cpa Wgas in * Cpg = Tgas in - Tgas out (no leakage) Tair out - Tair in
Say AH leakage 17.1%, Gas In Temp 333.5 C, Gas Out Temp 133.8 C , Air In Temp 36.1 C, Air Out Temp 288 C X ratio = (333.5 150.5) / (288 36.1) = 0.73
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X-Ratio depends on
moisture in coal, air infiltration, air & gas mass flow rates leakage from the setting specific heats of air & flue gas X-ratio does not provide a measure of thermal performance of the air heater, but is a measure of the operating conditions. A low X-ratio indicates either excessive gas weight through the air heater or that air flow is bypassing the air heater. A lower than design X-ratio leads to a higher than design gas outlet temperature & can be used as an indication of excessive tempering air to the mills or excessive boiler setting infiltration.
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EGT Corrected for inlet air temp and for AH leakage = AL * Cpa * (EGTcor - Tair in) + EGTcor Cpg * 100 = [13.7* (139.5 41.6)] / 100 + 139.5 = 152.9
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THANK YOU
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