Академический Документы
Профессиональный Документы
Культура Документы
Stephen K. Storm
Storm Technologies, Inc. (USA)
John Guffre
Paragon Airheater Technologies (USA)
GAS Side
Circumferential leakage through an air heater
Sample Grid Considerations
• Test grid should be reasonably spaced with 1 point per 0.6 – 0.8 square meters
(or 7-9 per sq ft)
• More test points do not substitute for insufficient number of test ports.
• Fan efficiency:
Flow(ACFM) Static Pressure(" w.c.)
Power Consumption 6356 HP
Fan Efficiency Motor Efficiency
Measuring Air Heater Leakage
• Approximate leakage rates:
0.5
2
Q C d A
Discharge Coefficient
(=0.61 for a “Flat Air Density (kg/m3)
Cross Sectional Area of
Plate” Orifice) Opening (m2)
Testing Locations
Theoretical vs. Measured Airflow
Theoretical airflow vs. Actual combustion airflow audits should be considered
1,200,000
1,000,000
800,000
600,000
400,000
200,000
0
Total Secondary OFA Primary
Theoretical Measured
Theoretical vs. Measured Airflow on a 460 MW unit
Direct Effect of the APH on Fuel
Consumption and CO2 Emissions
• Air heater responsible for at least 10% of a units thermal efficiency
• Excessive leakage can deteriorate net unit efficiency as well as reduce
power generation
• Air Heater Performance correlates directly with excess CO2 emissions
Design Considerations
(5) Key Points:
1. Leakage Reduction
2. Power Savings
3. Erosion & Abrasiveness
4. Corrosion
5. Heat Transfer
Air Side Flue Gas Side
Bypass
Seals
Radial
Seals
Bypass
Seals
Leakage Overview
Air Heater Leakage
• Major draw back of regenerative air heater
– Undesired leakage inherent to design
– Difficult to seal
– Inherent thermal distortion
Hot End of Rotor
Thermal Turn-down
Leakage Solutions
• Replace original seals with newer high performance radial seals
• Reinforce circumferential/bypass seals
Continuous Contact DURAMAX Seal (before & after sector plate contact)
OEM Circ/Bypass Seal
Air Flow
Leakage Solutions
DuraMaxTM Radial Seal
23% Reduction in total fan amps with full contact radial seals
Air Heater Leakage
Power Consumption vs Volumetric Flow
100
Power Consumption (%)
80
60
40
20
0
0 20 40 60 80 100
Volumetric Flow (%)
Design Considerations
• Erosion / Abrasiveness
• Ash Velocity Basic erosion equation: Erosion Equation CxMxV n
• Turbulence
• Basket Element Type
Outer ring basket erosion Heavy gage NF-6 element (right) and Lighter gage
typical hot end element
Design Considerations
• Reducing Air Heater Outlet Gas Temperature
– Recommended air heaters operated at low exit gas temp
– Cold end element layer is intended as sacrificial layer
• Increased Element Depth
– Added during basket replacement
– Supplier calculate temperature changes
• Environmental Control Equipment Relationships to Consider
– SCR Performance
– ABS plugging
– ESP Velocity
– FGD Performance