AIR HEATER PERFORMANCE

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Role of Regenerative Air Heaters

To recycle the heat of exit flue gas back in the combustion process Enabling efficient coal combustion by raising secondary air temperature.

Enabling efficient pulverization process by optimizing pulverized output temperature.

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What can go wrong ?

Partly ingress of air in flue gas at air heater entry due to leakage causing lowering flue gas temperature and thereby inefficient heat transfer. It increases the required fan power and can eat away the fan margin.

Choking of air heater basket resulting high dp across air heater, low heat transfer and high exit temperature. Low gas side efficiency.
Low X-ratio indicating bad operating condition
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Therefore..

The Performance Indicators are

Air Leakage Gas Side Efficiency X - ratio Gas & Air side pressure drops

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Data required
O2 & CO2 in FG at APH Inlet

O2 & CO2 in FG at APH Outlet

Temperature of air entering air heater Temperature of air leaving air heater Diff. Prsr. Across APH on air & gas side

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Sampling Ports in Flue Gas Ducts (Typical )

100mm

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Gas Side Probes

l/6 l/2

5/6 l

Air Side Probes

Thermocouples

Traverse Ports

Ports

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Flue Gas Sampling Train

FG Sample from probes Desiccant Jar Bubble Jar Condenser

Datascan Boxes

Gas Analysers Vacuum Pump

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Temperature Stratification in APH Outlet FG Duct

170 160
Temp C

150 140 160.0-170.0 130 A B

S2 S3

150.0-160.0 140.0-150.0 130.0-140.0

9

C Probes

E
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S1

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O2 Stratification at APH Outlet FG Duct

8 7

7-8
6

%
5 4
S3 S2 S1

6-7 5-6 4-5 3-4

10

3 A B C D
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Probe

Oxygen in Flue Gas at AH inlet (Test x/xx)

D 2.8 C B A 2.3 2.8 2.5 2.0 N 1.9 M 2.3 L 2.6 K 4.2 E 2.8 F 2.9 4.2 G 2.7 2.7 H I J

Average Oxygen values in Test x from the fourteen probe grid in Flue Gas Duct at Air Heater Inlet

2.6 2.6

'On line' Zirconia probe

D 3.3 C B A 2.8 2.8 3.0 2.5

4.6

E 2.7

F 3.1

4.2

G 3.2 3.0 H I J
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Average Oxygen values in Test xx from the fourteen probe grid in Flue Gas Duct at Air Heater Inlet
2.1 PMI Revision 00 2.4 2.6

3.0 2.9

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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. Almost 65% leakage is from radial seals, 30 % from circumference bypass seals and rest from axial, rotor post seals Hot End / Cold End / Entrained Leakage Empirical relationship using the change in concentration of O2 or CO2 in the flue gas
= CO2in - CO2out * 0.9 * 100 CO2out

Calculation

% AL

O2out - O2in * 0.9 * 100 (21- O2out)

Calculation using CO2 values is preferred because of higher absolute values and lower errors. The method of determination of O2 or CO2 should be the same at inlet and outlet - wet or dry (Orsat).
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Gas Side Efficiency

Ratio of Gas Temperature drop across the air heater, corrected for no leakage, to the temperature head.

= (Temp drop / Temperature head) * 100

where Temp drop = Tgas in -Tgas out (no leakage) Temp head = Tgasin - T air in Tgas out (no leakage) = The temperature at which the gas would have left the air heater if there were no air heater leakage Now Tgas out (no leakage) = AL * Cpa * (Tgas out - Tair in) + Tgas out Cpg * 100 Where Cpa Specific heat of air & Cpg- Specific heat of gas.
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Flue Gas Exit Temperature

Flue Gas Exit Temperature is corrected for deviations of inlet air and inlet gas temperatures from design values.

Temp corrected for leakage and temperature of entering air is

Tgasoutla = Tairind (Tgasin Tgasoutnl) + Tgasin(Tgasoutnl Tairin) Tgasin Tairin

Temp corrected for leakage and temperature of entering flue gas is

Tgasoutlg = Tgasind (Tgasoutnl Tairin) + Tairin(Tgasin Tgasoutnl) Tgasin Tairin Flue gas exit temp corrected for deviations from design = Tgasoutla + Tgasoutlg - Tgasoutnl

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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

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4) Air In / Air Out Temperatures For air inlet and outlet temperatures, weighted averages of primary and secondary air temperatures are used as below. Fraction of PA flow = F1 = PA flow / Total Air Flow Fraction of SA flow = F2 = SA flow / Total Air Flow Weighted Air Temp In = F1 * PA Temp In + F2 * SA Temp In Wghted Air Temp Out = F1 * PA Temp Out + F2 * SA Temp out

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5) The specific heat of the air is calculated at the average air temperature in the AH (Inlet Temperature + Outlet Temperature) / 2. This is done by using ASMEs PTC 4.1 Steam Generating Units, Figure 3. = CpAIR (kcal/kg/K) Formula: Cp_air = 9.798958E-19 * X5 2.76786E15 * X4 7.42842E-12 * X3 +0.00000002654212 * X2 +.000006479326 * X +0.2389161 Where X = Average air temperature in AH. 6) If a CO2 analyser is not available, the amount of CO2 in the flue gas can be calculated by subtracting the O2 percentage from the constant for (O2 + CO2). CO2 (%) = (O2 + CO2) - O2 = BO2CO2 - O2
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7) The specific heat of the flue gas is calculated using average gas temperature (Gas inlet and no-leakage gas outlet), carbon content of fuel, hydrogen content of fuel, and amount of CO2 in the flue gas. See ASMEs PTC 4.1 Steam Generating Units, Figure 7. = CpGAS (kcal/kg/K) 8) Air Heater Leakage (%) is defined as 100*the mass of wet air leaking to the gas side divided by the mass of wet gas entering the air heater. However, it is usually approximated by one of the two equations using measurements of gas analysis, by volume, on the gas side: % Leakage = 90* (%CO2 entering - %CO2 leaving) / %CO2 leaving % Leakage = 90* (%O2 leaving - %O2 entering) / (21%O2 leaving)
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9)

AH Gas Side Efficiency is calculated as below. AHE = 100 * (Gas Temp In NL Gas Temp Out) / (Gas Temp In Air Temp In) Or AHE = 100 * (AHGIT - EGTCorTNL) / (AHGIT AirT)

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THANK YOU

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