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GREENS

Steel H Economizer And Gas Heat Exchanger

Steel H Tube is extended surface tube with H shaped Plate Fins fused to the tubes
Extended surface assists improved heat transfer rates

About 2 to 4 times increased Heating Surface Area than plain surface in unit volume of Space

Advantages of Steel H
Compact Size Low Pressure Loss Less Tubes and Weight Lower Costs Proven Heat Transfer Rates Double H Inherent Stiffness

Low Temperature Economizers are the Steel H Economizers used at Up or Downstream of ESP
Generally called as GAS HEAT EXCHANGER (GHE) for Power Station Boilers GHE are used to enhance the system efficiency

Objectives of GHE
Reduces the exhaust gas temperature from 160 ~ 170 Deg C to about 120 Deg C
GHE shall assist to reduce the inlet gas temperature of
1. Desulphurization / Denitrification equipment 2. Next generation ESPs

Methods of Incorporation

TO DRIVE VAHP FOR CENTRAL AIR CONDITIONING


APH ESP ID Fan FGD

GHE

Stack

FD Fan

Placed between ID Fan and FGD Heat from the flue gas is used to heat water Hot water drives Vapour Absorption Heat Pump VAHP produces chilled water for central air conditioning

TO DRIVE VAHP FOR PRODUCING CHILLED WATER GHE 2


FGD ESP ID Fan

APH FD Fan

GHE 1

Stack

GHE 1 is Placed between ID Fan and FGD GHE 2 is Placed before ESP Heat from the flue gas is used to heat water by GHE 1 and then by GHE 2 Hot water is used to drive VAHP VAHP provides chilled water for Central Air Conditioning Hot water can also be sent directly to main economizer

TO PREHEAT THE AIR


ESP ID Fan GHE FGD

APH

Stack

FD Fan

Placed between ID Fan and FGD Heat from the flue gas is used to heat water Hot water then heats the air from Primary Air Fan

TO MAINTAIN THE TEMP IN STACK


APH ESP ID Fan FGD

GHE FD Fan

Stack

Placed between ID Fan and FGD Heat from the flue gas is used to heat the over cooled flue gas after FGD The temperature of the flue gas is controlled to maintain the temperature in stack

TO HEAT THE STEAM CONDENSATE


Steam Turbine FD Fan LP Heater
Steam Condensate Outlet Condensate Outlet

Steam Extracted from Turbine Condensate Inlet

APH

FD Fan

ESP

ID Fan

GHE

FGD

Stack

Placed between ID Fan and FGD Heat from the flue gas is used to condensate from turbine Hot condensate is then joined with the outlet of LP Heater

GREENS Steel H Economisers


Supplied

IN INDIA

BALCO
KORBA

270 MW BCPP (4 X 67.5 MW) 4 x 275 TPH Boilers 3 units installed 1 unit to be installed in next shutdown Performance of proposed design provides additional 10% duty

Existing Economiser
Type of Surface
Number of Plain Tubes Number of Finned Tubes Finned Length Tubes High Tubes Wide Water Paths No. of Tiers Tube diameter Tube thickness Tube material Fin thickness mm mm mm Mm

Greens Economizer
Combination of Finned & Plain Tube 112 1232 4250 24 56 56 2 44,5 4.5 min ASME SA210-C 3

Unit

Finned Tube
0 896 4280 16 56 56 3 51 4.5 avg (assumed) BS3059-2, Gr 440 2

Fin pitch

mm

18

25 (50 top bank)

Existing Economiser
Flue Gas Temperature Economiser inlet Economiser outlet Flue Gas Flow rate Flue Gas Velocity, Eco Inlet, (avg) Gas Draft Loss (over heating surface only) Feed Water Flowrate Economiser inlet Feed Water Pressure Loss (friction only) Feed Water Temperature Economiser inlet Economiser outlet Heat Duty C C MW 209 300 23.6 C C t/h 529 398 565.2

Greens Economiser

529 384.5 565.2 18.5 (inlet to bottom bank) 53 190 107 0.6

m/s

21

mm WG t/h bar bar

54 190 107 0.2

209 308 26

Essar
ESSAR, VADINAR 77 MW COGEN PLANT Total 3 units. 1 unit under installation Next 2 units will be installed in Next shut downs
Boiler OPERATING PRESSURE TEST PRESSURE WATER Inlet Temperature Outlet Temperature FLUE GAS Inlet Temperature Outlet Temperature TOTAL HEAT DUTY 500 C 210 C 17900 KW 175 C 256 C 175 TPH Babcock Make 81.5 KG/Cm2 122.25 KG/Cm2

Size

Material

TUBE

DIA 38.0 MM OD X 3.2 MM THICKNESS

DIN 17175 St 35.8 III (EQUIVALENT SA 210 A-1)

HEADER

PIPE DIA 219.1 OD X 14.2 MM THICKNESS

DIN 17175 15Mo3 (EQUIVALENT SA 335- P1)

FINS 44 NOS OF FINNED COILS

SIZE 150 MM LONG X 2 MM THICKNESS


PITCH 75 MM

DIN StW 22

Economizer at our factory

Economizer at our factory

Hindalco RENUSAGR POWER DIVISION

RENUSAGAR Thermal Power Station 740 MW 1 unit 70 MW under OPERATION


Heating Surface 2840 m2 No of coils 57 Fin pitch 25 mm Material
Tubes Fins SA 210 Gr C JIS 3131 Gr SPHC

Unit Feed Water Economizer Inlet Economizer Outlet Pressure Total Pressure Drop (friction) Flue Gas Flow rate Flue Gas Temperature Economizer Inlet Economizer Outlet Flue Gas Velocity t/hr C C Kg/cm (g) Kg/cm T/hr

Existing 275 230 285 107 2.1 388 550 375

Modified 275 230 295 107 1.8 388 550 340

Maximum Gas Velocity


Total Draft Loss (Over Heating Surface Only) Heat Duty

m/s

10

10

mm WG MW

24 20.5

24 24.5

Hindalco Industries Ltd.


Renukoot

Unit Feed Water Flow Rate Feed Water Temperature Economizer Inlet Economizer Outlet Feed Water Pressure Total Pressure Drop (friction) Flue Gas Flow rate Flue Gas Temperature Economizer Inlet C C Kg/cm (g) Kg/cm T/hr t/hr

Existing 90 99 117 66

Modified 90 99 135-145 66 0.5

142.7 242

142.7 242

Economizer Outlet
Flue Gas Velocity Economizer, Average Total Draft Loss (Over Heating Surface Only) Heat Duty m/s mm WG MW

174

135-140

8-9 25 2.0 3.7-4.7

ECO 1 to be replaced by Greens Steel H Economizer

Eco 1 is used to heat the feed water

VEDANTA
Talwandi Sabo Power Ltd.
3 x 660 MW thermal power plant Plant at District Mansa, Punjab Talwandi Sabo Power Limited is a subsidiary of Sterlite Energy Ltd. Boiler supplied by Harbin Boiler Co Ltd.

Gas Heat Exchanger


Supplied by Greens Power Equipment India Pvt Ltd

R.K.M.
Powergen Pvt Ltd.
Uchpinda, CG

4 X 360 MW Thermal Power Plant 4 Units of Gas Heat Exchanger is Supplied GHE will be used to drive Vapour Absorption Machine of capacity 4 x 200 TR GHE is under installation phase

Greens Offers
Process and Design analysis for feasibility Waste Heat Recovery Techniques without hindering in current operation Cost saving methods by conserving the valuable resources Participation in making the plant environment friendly

Thank You