W

P
C
A
Worldwide Pollution
Control Association
WPCA-Entergy
Increasing Energy
Efficiency of Existing
Units Seminar
J anuary 22, 2014
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Louis Bondurant
J anuary 22, 2014
Approaches to Improve
Air Preheater
Thermal Efficiency
Alstom Air Preheater
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 2
LGOT R&D Program
(Low Gas Outlet Temperature)
Objective of the LGOT Program
Develop the design of the Ljungstromair preheater for operation at gas outlet temperatures
down to 220F (105C) on coal fired boiler applications.
The Potential Benefits of LGOT
Significant reduction in Dry Gas Loss a key metric in unit heat rate
Reduced volumetric flow rates for downstream FGD, CO2 capture, etc.
ESP can benefit from reductions in both volumetric flow and fly ash resistivity
Potential Issues for LGOT
Enhanced risk of air preheater acid dew point fouling problems
Added potential for low temperature corrosion from halogen acids near the H
2
O dew point.
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 3
Bench-Scale Test Apparatus
Fouling Test Apparatus Soot Blowing Simulator
Simulated gas flow included controlled amounts of
SO3
Water vapor
Solid particulate
Cleaning cycle
Duration of tests mimicked typical sootblowing interval
Translational movement in the path of the cleaning
nozzle mimicked rotor rotation
Tube removal required in order to clean
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 4
Pilot Scale Test Apparatus
Air
Side
Fan
Tower
#1
To atmosphere
Preheat
Burner
Natural Gas
Gas
Side
Fan
Catalyst
SO
2

Particulate Feeder
Water
Flyash
Soot blower
Tower
#2
Soot blower
Broken =Gas side flow
Solid =Air side flow
To atmosphere


Heat Exchanger
Baghouse
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 5
Pilot Scale Test Apparatus
Gas Inlet Ducting: SO
3
, H
2
O,
Flyash Injection
Preheat Burner
System
Instrumentation Panel
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 6
Simulated URS SBS Injection Technology
Full Mitigation (5ppmv SO
3
+ Na
2
SO
4
By-Product)
Stable Pressure Drop Response for ~2 Months
Tower 1 Gas Side Pressure Drops
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0 200 400 600 800 1000 1200 1400 1600 1800 2000
El apsed Operati ng Ti me (hrs)
P
r
e
s
s
u
r
e

D
r
o
p

(
i
n
w
g
)
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
F
l
u
e

G
a
s

F
l
o
w

(
l
b
/
h
r
)
Total Cold End Flue Gas Flow
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 7
Simulated URS SBS Injection Technology
Full Mitigation (5ppmv SO
3
+ Na
2
SO
4
By-Product)
No Significant Deposit Thickness Was Found
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 8
Conclusions from Pilot Scale Testing
Simulated URS SBS Injection Technology
With SO
3
levels reduced to 5 ppmv
Cold layer pressure drop did not increase
No significant deposit thickness was found

With SO
3
levels at 10 ppmv
Rapid increases in cold layer pressure drop occurred
Significant sodium bi-sulfate deposit was found


Note: Sodium based SO
3
mitigation must reduce SO
3
concentrations to 5
ppmv or less entering the air preheater


ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 9
RGOT Vs LGOT Operation
(Reduced Gas Outlet Temperature)
Simple modifications to an existing air heater typically cannot achieve a
220F gas outlet temperature
An increase in airflow can provide a significant reduction in gas temperature.
Co-benefit, if this this incremental hot air can be used elsewhere in the plant.
Reduced gas outlet temperature (> 220F) can be pursued in lieu of LGOT.
Basic benefits retained, implementation cost lowered significantly.
Reduced potential for corrosion, but need to stay above H
2
O dewpoint
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 10
RGOT Operation
Means to Accomplish
Fill empty voids in APH rotor with additional
basket layers
Utilize special basket designs to maximize
useable space for heat transfer surface
Consolidate shallow basket layers into
single deeper layers
Modify APH rotor to more efficiently support
basket layers
Switch to more efficient types of heat
transfer surface
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 11
RGOT Operation
Considerations
Fuel compatibility
Thermodynamic limitation
Available space within the existing APH rotor
Load bearing limits on rotor bearings, rotor drive and APH structure
Ability of draft fans to accommodate expected pressure drop levels
Ability of APH sealing system and structure to operate at higher
pressure levels
Ability to maintain temperature levels above H
2
O dew point at all load
and ambient conditions
ALSTOM 2013. All rights reserved. Informationcontainedinthis documentis indicative only. No representationor warrantyis givenor shouldbe reliedon
that it is complete or correct or will applyto anyparticular project. This will dependon the technical and commercial circumstances. It is providedwithout
liabilityand is subject to change without notice. Reproduction, use or disclosure to thirdparties, without express writtenauthority, is strictlyprohibited.
Presentation title - 23/01/2014 P 12
Benefits Derived from RGOT
Reduced coal consumption (potentially as much as 3%)
Significant reduction in activated carbon required for mercury capture
Enhanced ESP performance (due to fly ash resistivity)
Reduced O&M costs associated with steam coil air preheaters
Reduced CO2 emissions resulting from improved boiler efficiency
Co-benefit if additional hot air can be used elsewhere on site
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