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PRESENTATION PLAN
Air heaters Types of air heaters Materials Used Sealing arrangement for air heaters Air heater Performance Performance tests
RADIAL SEAL
AXIAL SEAL
HOT INTERMEDIATE
AIR PRE-HEATER-FUNCTIONS
An air pre-heater heats the combustion air where it is economically feasible. The pre-heating helps the following: Igniting the fuel. Improving combustion. Drying the pulverized coal in pulverizer. Reducing the stack gas temperature and increasing the boiler efficiency. There are three types of air heaters: Recuperative Rotary regenerative Heat pipe
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DESIGN PARAMETERS
Tubes are generally arranged in staggered pattern. Steel tubes of Dia: 37 63 mm. Transverse pitch: S1/d = 1.5 1.9 Longitudinal pitch: S2/d = 1.0 1.2 The height of air chamber:1.4 4.5 m. Gas and Air flow velocity : 10 16 m/s. Plate Recuperators: Instead of tube, parallel plates are used. The gas passage is 12 16 mm wide. The air passage is 12 mm wide.
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RADIAL SEAL
HOT END
AXIAL SEAL
COLD END
HOT INTERMEDIATE
HEATING ELEMENTS
Hot End Baskets
TYPES OF SEALS
RADIAL SEAL (HE & CE) AXIAL SEAL CIRCUMFERENTIAL SEAL ROTOR POST SEAL SECTOR PLATE STATIC SEAL
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TURNBUCKLE
ADJUSTABLE BOLT
JACK BOLT
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Curved axial sector plate adjustable from outside Seal strips are attached to the rotor. The thickness of seal strips : 6 MM straight strips in Russian. 2.5 mm thick and bend backward in BHEL.
BHEL APH has better accessibility of axial seal adjustment as compared to Russian design
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CIRCUMFERENTIAL SEALS
THE CIRCUMFERENTIAL SEALS PREVENT AIR AND GAS FROM BYPASSING THE HEATING SURFACE THROUGH THE SPACE BETWEEN THE ROTOR AND THE HOUSING SHELL. THEY ALSO PREVENT AIR AND GAS FROM FLOWING AXIALLY AROUND THE ROTOR.
CIRCUMFERENTIAL SEALRUSSIAN
CIRCUMFERENTIAL SEAL
H.E. DIAPHRAGM
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ROTOR FLANGE
AXIAL SEAL
CIRCUMFERENTIAL SEAL
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ADJUSTABLE BOLT
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DIAPHRAGM
RADIAL SEAL
APH PERFORMANCE
Boiler efficiency decreases generally on account of APH performance degradation. This also affects ESP, ID & FD fan loadings & at times unit capability
APH PERFORMANCE
Higher than expected leakage would decrease the flue gas exit temperature, resulting in false sense of improved working. Higher inlet flue gas temperature is rather rare, but this could be one reason for high exit temperature. Optimum flue gas temperature is required for effective ESP performance Unequal temperature at air heater exit should be investigated.
CO2 measurement is preferred due to high absolute values; In case of any measurement errors, the resultant influence on leakage calculation is small.
Air Leakage and gas outlet Weight of air passing from air side to gas side; This leakage is assumed to occur entirely between air inlet
Seal Leakage Erosion Corrosion High Press Drop Across APH APH Fire
X- RATIO = T (gas in) T (gas out) (no lkg)/ T(air out) T (air in)
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
Say AH leakage 17.1%, Gas In Temp 333.5 C, Gas Out Temp 133.8 C , Air In Temp 36.1 C, Air Out Temp 288 C X ratio = (333.5 150.5) / (288 36.1) = 0.73
X-Ratio depends on
moisture in coal, air infiltration, air & gas mass flow rates leakage from the setting specific heats of air & flue gas X-ratio does not provide a measure of thermal performance of the air heater, but is a measure of the operating conditions. A low X-ratio indicates either excessive gas weight through the air heater or that air flow is bypassing the air heater. A lower than design X-ratio leads to a higher than design gas outlet temperature & can be used as an indication of excessive tempering air to the mills or excessive boiler setting infiltration.
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