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www.geeco.in GEECO Enercon Pvt Ltd., Energy Efficient Techniques for Air Preheater Presented by: V.Rajagopal GEECO, Trichy, India
www.geeco.in GEECO Enercon Pvt Ltd.,
Energy Efficient Techniques
for
Air Preheater
Presented by:
V.Rajagopal
GEECO, Trichy, India
www.geeco.in GEECO Enercon Pvt Ltd.,
Designation of Air Preheater
29 VI T SM RC 78 (82)
Size of APH
VI - Vertical Inverted
Tri - Sector
Element Depth, in
inches Semi Modular Future Element
Round Casing
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LAP 13494 / 1800
Ljungstrom
APH
Diameter of Rotor,
mm
Element Depth, mm
Designation of Air Preheater
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• The efficiency of boiler is increased by reduction in Gas Outlet Temperature (for every 20°C drop in flue gas temperature, the boiler efficiency increases by 1%). Leads to fuel saving.
• Reduction of APH leakage decreases Fan loading. • Reduced Gas outlet temperature reduces flue gas
volume and that results in improving ESP efficiency.
Role of Air Preheater in a Boiler
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Innovative Concepts
Resulted in • Improved Thermal Performance • Improved Fan Margin • Increased Reliability in operation • Less down time and Increased availability of
Air preheater • Less Maintenance cost • Increased Life of APH Internals
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Profiles
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Conventional Element Profiles
Double Undulated (DU)
Notched Flat (NF)
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Conventional Element Profiles
FNC
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Conventional Element Profiles
DUN
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Upgraded Heating Element Profile
Recent times the quality of coal has deteriorated – Low Calorific Value, High Ash and Sulphur.
Firing poor quality coal makes the layers of APH heating elements susceptible to fouling. Hence, there is a need to upgrade profile to minimise
fouling with consistent performance.
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Upgraded Heating Element Profile
* GEECO’s answer is the modified and improved profiles.
* The results are verified by CFD simulations & Wind
Tunnel Testing
* Implemented and the results confirms to CFD and Wind Tunnel Testing
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Upgraded Heating Element Profile
Solution for Improved Thermal Performance
GHT®
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Equal thermal performance
Lower pressure drop
6% higher heat transfer area
Reduced fouling or choking
Easy to clean under soot blowing
operation
Sustained performance
Increased life
Short Payback
MERITS of GHT® over FNC
Upgraded Heating Element Profile
FNC
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Herringbone Profiles
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AREA REDUCTION DUE TO CLEARANCE BETWEEN BASKETS & DIAPHRAGM PLATES
APH : 27 VIT DOUBLE SEALING IF GAP BETWEEN DIAPHRAGM PLATE & BASKETS IS 20mm ON BOTH SIDES:
REDUCTION IN AREA : 4.94%
IF GAP BETWEEN DIAPHRAGM PLATE & BASKETS IS 10mm ON BOTH SIDES: REDUCTION IN AREA : 2.46%
Dimensioning of Baskets
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Increase in Heat Transfer Area
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Increasing the height of APH to accommodate
Increase in Element height from 57.5’’ to 67.5” (1460 to 1715 mm)
Increasing the Size of APH
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Increasing the Size of APH
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Increasing both diameter and
height of Rotor
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Solution for Improved Thermal Performance @ lesser DP
MAXTRA®
Increasing the Size of APH
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Maxtra resulted in improving the boiler efficiency from 1.5 to 2%
Maxtra resulted in reducing the leakage level
Maxtra
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Placement of Bigger Size APH in
3rd Pass of the Boiler
Maxtra
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Maxtra
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CFD
Computational Fluid Dynamics
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Even distribution Gas and Air
at Entry
CFD
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CFD
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Flue Gas Inlet – Velocity Magnitude
Large flow Separation downstream of the
ash hopper that creates an uneven
flow distribution
Reduced the flow Separation
downstream of the ash hopper by addition of a
guide deflector vane
Added Vane
47
CFD
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Introduction of Sacrificing
Baskets at Gas Entry
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Sacrificing Element
Hot Intermediate
Hot End
Cold End
Sacrificing Baskets
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Soft Touch Seal
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Soft Touch Seal
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Liner Plate on Sealing Surface
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Liner Plates
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Single Sealing
----
Double Sealing
----
Triple Sealing
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Solution for Reduced Leakage and Improved Fan Margin
DOUBLE / TRIPLE SEALING
MODIFIED RADIAL AND AXIAL SEALING
ARRANGEMENT WITH MODULAR ROTOR
Improvements
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Before Typical 12 sector rotor design
After Rotor modified to 24 sectors
New axial seal carrying bars fitted
Improvements
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Modular Rotor
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Modular Rotor
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Leakage Control System
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Solution for Reduced Leakage and Improved Fan Margin
GLRS®
LEAKAGE CONTROL SYSTEM
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Talcon Seal
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Solution for Increased Reliability
PERIPHERAL DRIVE SYSTEM
INTRODUCTION OF PERIPHERAL DRIVE SYSTEM
FOR AIR PREHEATERS
Reliability
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Solution to prevent more ash carry over to Air Preheater
ECO - HOPPER
Reliability
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Solution for Increased Reliability
APH MONITORING SYSTEM
SCADA BASED ONLINE APH PERFORMANCE
MONITORING & FIRE SENSING SYSTEM
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Solution for Increased Reliability
Conversion of TAPH to RAPH
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Thank You
