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May 24, 2012 PMI Revision 00 1
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May 24, 2012 PMI Revision 00 2
• Air heaters
• Types of air heaters
• Materials Used
• Sealing arrangement for air heaters
• Air heater Performance
• Performance tests
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May 24, 2012 PMI Revision 00 3
APH is the last heatexchanger in theboiler flue gascircuit. To achievemaximum boiler efficiencymaximumpossible usefulheat must beremoved from thegas before itleaves the APH.However certainminimumtemperature hasto be maintainedin the flue gas toprevent cold endcorrosion
RADIAL SEAL
AXIAL
SEAL
BYPASS SEAL
COLD END
HOT END
HOT INTERMEDIATE
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• An air pre-heater heats the combustion air where it iseconomically 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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May 24, 2012 PMI Revision 00 5
• 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
efficiency is improved.• Intensified combustion permits faster load variation and
fluctuation.
• In the case of pulverised coal combustion, hot air can beused for heating the coal as well as for transporting thepulverised 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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Recuperative Regenerative Plate type Airheater
Steam Air Preheater Langsdorm type Rothemuhle type Tri sector Air Heater
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• 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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May 24, 2012 PMI Revision 00 10
RADIAL SEAL
AXIAL
SEAL
BYPASS SEAL
COLD END
HOT END
HOT INTERMEDIATE
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• 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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May 24, 2012 PMI Revision 00 13
• Material used Cold end in the basket is a special type of steel(corten steel (trade name)) which has high resistance to thelow temperature sulphur corrosion, thus prolongingoperational life.
• In the hot end mild steels are used
• The optimal geometric shape is usually corrugated andsizes are determined based on design modelling andexperimental data. The turbulence of air and gas flow throughthe package increases the heat transfer rate.
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• 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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• Hot End Baskets
• Hot Intermediate Baskets
• Cold End Baskets
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• RADIAL SEAL (HE & CE)
• AXIAL SEAL
• CIRCUMFERENTIAL SEAL
• ROTOR POST SEAL
• SECTOR PLATE STATIC SEAL
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May 24, 2012 PMI Revision 00 19
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%
PERCENTAGE AIR LEAKAGE
OF TOATAL LEAKAGES
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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 THEINDIVIDUAL ROTOR COMPARTMENT.
• PURPOSE: - THE PURPOSE OF RADIAL SEALS IS TO
REDUCE THE AREA AVAILABLE FOR LEAKAGE
FROM THE AIR TO THE GAS SIDE BETWEEN THEDIAPHRAGM AND THE SECTOR PLATE
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May 24, 2012 PMI Revision 00 23
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AXIAL SEALS AND
SEALING PLATES
• AXIAL SEALS MINIMIZE LEAKAGE PASSING
RADIALLY AROUND THE ROTOR SHELL. THE AXIALSEALS 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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May 24, 2012 PMI Revision 00 26
AXIAL SEAL DIAPHRAGMAXIAL SEAL DIAPHRAGM
COG RIM PINCOG RIM PIN
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May 24, 2012 PMI Revision 00 27
JACK BOLTJACK BOLT
AXIAL SEAL INSPECTION DOOR AXIAL SEAL INSPECTION DOOR
ADJUSTABLEADJUSTABLEBOLTBOLT
TURN-BUCKLETURN-BUCKLE
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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 axialseal adjustment as compared to Russian
design
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May 24, 2012 PMI Revision 00 29
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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May 24, 2012 PMI Revision 00 30
CIRCUMFERENTIAL SEAL-
RUSSIANCIRCUMFERENTIAL SEAL
H.E. ROTOR FLANGEH.E. ROTOR FLANGE2.5MM RADIAL SEAL2.5MM RADIAL SEALH.E. DIAPHRAGMH.E. DIAPHRAGM
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May 24, 2012 PMI Revision 00 31
ADJUSTABLE BOLTADJUSTABLE BOLTCIRCUMFERENTIAL SEALCIRCUMFERENTIAL SEAL
ROTOR FLANGEROTOR FLANGEAXIAL SEALAXIAL SEAL
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CIRCUMFERENTIAL SEALS
ACTUATING MECHANISM-
RUSSIANActuating 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 BETWEENTHE HOT & COLD END SECTOR PLATES AND THE
HOT AND COLD END CENTER SECTIONS.
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May 24, 2012 PMI Revision 00 34HE ROTOR POST SEALHE ROTOR POST SEAL
SECTOR PLATE STATIC SEALSECTOR PLATE STATIC SEAL
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May 24, 2012 PMI Revision 00 35CE ROTOR POST SEALCE ROTOR POST SEAL
DIAPHRAGMDIAPHRAGM
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May 24, 2012 PMI Revision 00 36
AIR SEAL HOUSINGAIR SEAL HOUSING
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ROTOR POST SEALROTOR POST SEAL
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May 24, 2012 PMI Revision 00 38
THICKNESS OF RADIAL SEALSTRIPS
• RUSSIAN MODEL : 6 MM
• BHEL DESIGN : 2.5 MM
• SOFT SEAL : 0.1 MM
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May 24, 2012 PMI Revision 00 39
• 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 CANBE GREATLY REDUCED BY INSTALLING FLEXIBLE
SEALS.
• MERIT : - SOFT SEAL IS SET TO A NEGATIVE
CLEARANCE IN COLD CONDITION, AND WHICH WILLEXTEND 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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May 24, 2012 PMI Revision 00 40
• 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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May 24, 2012 PMI Revision 00 41
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BY PASS SEAL RUSSIAN
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May 24, 2012 PMI Revision 00 44
• Boiler efficiency decreases generally on account of APH performancedegradation. This also affects ESP, ID & FD fan loadings & at times unitcapability
• 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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May 24, 2012 PMI Revision 00 45
• Higher than expected leakage would decrease the fluegas exit temperature, resulting in false sense of improvedworking.
• Higher inlet flue gas temperature is rather rare, but thiscould be one reason for high exit temperature.
• Optimum flue gas temperature is required for effectiveESP performance
• Unequal temperature at air heater exit should beinvestigated.
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May 24, 2012 PMI Revision 00 46
• FLUE GAS TEMP AT AH OUTLET IS INDICATIVE OF HEATLEAVING THE UNIT .THIS IS LOWERED ON ACCOUNT OFAH LEAKAGES.
• FGET TO BE MEASURED AT A LOCATION SLIGHTLY
AWAY FROM AIR HEATERS.
• NO OF TEMPERATURE SENSOR PROVIDED SHOULDCOVER THE DUCT ADEQUATELY.
• CORRECTED TEMP SHOULD BE USED FORCOMPARISION.
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May 24, 2012 PMI Revision 00 47
O x y g e n i n F lu e G a s a t A H A I
0
0
0
0
0
00
A B C D E F
P r o b
I n l e t O
% 0
0
0
0
0
0
00
00
O u t l e t O
% 0
In let O0 O u t l e t O0
O x y g e n i n F lu e G a s a t A H B I
0
0
0
0
0
00
A B C D E F
P r o b
I n l e t O 0
0
0
0
0
0
00
O u t l e t O 0
In le t O0 O u t le t O0
Typical Oxygen Levels at
APH Inlet / Outlet
CO t i f d d t hi h
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May 24, 2012 PMI Revision 00 48
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 = 5.7 – 2.8 * 90
(21- O2out) (21-5.7)
= 17.1 %
CO2 measurement is preferred due to high
absolute values; In case of any measurement
errors, the resultant influence on leakage
calculation is small.
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May 24, 2012 PMI Revision 00 49
• Seal Leakage• Erosion
• Corrosion
• High Press Drop Across APH• APH Fire
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May 24, 2012 PMI Revision 00 50
• APH Leakage
• Gas Side Efficiency
• X-Ratio
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May 24, 2012 PMI Revision 00 51
• GAS SIDE EFFICIENCY
= (Temp drop / Temperature head) * 100
• 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)
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May 24, 2012 PMI Revision 00 52
FG TE M P (Cor r.) V s BL R E F F & G AS
00
.888
.888
.888
.000
00
.000
000 000 000 000 888 000 000
C O R R E C T E D F L U E G A S T E M P
B O I L E R E F F I C I E N C
Y ( % )
00
88
00
00
00
88
00
00
00
G
A S S I D E E F F I C I E N C Y ( % )
Boiler Eff icin
G as S ide E f fi c ie
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May 24, 2012 PMI Revision 00 53
X – RatioRatio 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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May 24, 2012 PMI Revision 00 54
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 thandesign 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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May 24, 2012 PMI Revision 00 55
Flue Gas Exit Temperature
Flue Gas Exit Temperature is corrected for inlet air temperature
X1 = Reference Air Temp * (Gas Temp In – Gas Temp Out) +
Gas Temp In * (Gas Temp Out - Air Temp In)
X2 = Gas Temp In - Air Temp In
EGTcor. = X1/ X2= 35 * (345-143.9) + 345 (143.9 – 41.6) / (345 – 41.6)
= 139.5 C
EGT Corrected for inlet air temp and for AH leakage
= AL * Cpa * (EGTcor - Tair in) + EGTcorCpg * 100
= [13.7* (139.5 – 41.6)] / 100 + 139.5 = 152.9
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