1

PERFORMANCE EVALUATION OF AIR PRE HEATER

AT OFF DESIGN CONDITION

Rakesh Kumar
1
, Sanjeev Jain
2


1
Project Engineering- Mechanical Design, Engineering office complex, NTPC, Sector 24,Noida U.P, India
2
Department of Mechanical Engineering, Indian Institute of Technology, Hauz Khas, New Delhi, India.

Abstract
The poor performance of air pre heaters in the modern power plants is one of the
main reasons for higher Unit Heat rate and is responsible for deterioration in boiler
efficiency. The main problem of Air Pre heater is the leakage of air to the flue gas
side and thereby poor thermal performance. The experience of automatic sealing
system used in rotary regenerators has proved to be a failure and the designers are
reverting back to fixed sector plate design. The higher ash content in Indian coal also
adds to the problems associated with rotary regenerators.

In the present work the performance of regenerative air pre heater has been
evaluated at off design conditions. To assess the performance at different operating
conditions and leakage rate, a regenerator leakage model is proposed. The model can
also be used while selecting a new type of surface geometry for improving the existing
heat transfer surface by replacement.

Key Words: Air pre heaters, Flue gas, Leakage, Performance, Element profile.

NOMENCLATURE
A Surface area of heat transfer element
C
w
Specific heat of wall material

C Flow stream heat capacity
C
r
*
Total matrix heat capacity ratio
(C
r
/C
min
)
Cr Matrix heat capacity rate
C
*
Heat capacity ratio (C
min
/C
max
)
f Friction factor
h Heat transfer coefficient
I
n
Modified Bessels function of n
th

order.
j Colburn modulus
K Thermal conductivity
n Fraction of leakage at cold end
N
u
Nusselt number
p partial pressure of gas
P Pressure of gas
Re Reynolds number
V
*
Ratio of header volume to matrix total
volume
W Fluid flow rate (Kg/s)
P
W Pressure leakage (Kg/s)
a
W Mass of air leakage (Kg/s)
g
W Mass of gas leaking to airside (Kg/s)
X
p
Pressure leakage and carry over
factors
X
a
Air carry-over factor
X
g
Gas carry-over factor

Greek symbols

Effectiveness of regenerator
Density of fluid
Porosity of heat transfer element.
Viscosity



2
Introduction

Modern high capacity boilers are always provided with an air pre heater. The role of
the air pre heater, which can be used to preheat the combustion air increases with the
unit power of a plant. The flue gases from coal-fired boiler contain significant amount
of thermal energy at the exit of economizer. Apart from the need to preheat air to dry
coal and improve combustion efficiency the benefit from preheating combustion air
can be shown to be 1% improvement in boiler efficiency, for each 22
o
C rise in the
combustion air temperature [1]. By utilizing the air pre heater the temperature of the
combustion product can be reduced from 370- 450
o
C to 120-135
o
C [2].

The cold end flue gas temperature of an air pre heater is designed for acid due point.
Generally with coal firing there is sufficient alkaline fly ash available to absorb the
acid (H
2
SO
4
) and prevent the fouling and corrosion of air pre heater and ducting. If
the ash to sulphur ratio in the coal is more than 7:1, then cold end fouling does not
occur even at temperature below 120
o
C [3].

The main requirements of an air pre heater are high heat transfer rate, low-pressure
drop and low sensitivity to fouling. These depend mainly on heat transfer element
geometrical design.

Air Heater Performance

There are many factors, which contribute to the deterioration of air pre heater
performance like high seal leakage, deterioration of heat absorption characteristics of
basket elements due to fouling or plugging. Air pre heater performance can be
substantially affected by upstream parameters as well. Exact reasons of air heaters
performance deterioration needs to be investigated before planning for overhaul or
up-gradation.

The primary air temperature is normally controlled either biasing share of flue gas or
economizer bleeding to suit varying coal. Many air pre heaters are designed for
different coals, which were never received in actual operations. Both the extremes in
terms of moisture in coal have been noted in NTPC (India) stations [4]. In one case
operating efficiency was lower due to actual moisture being less than designed and in
other case, actual moisture was higher than design and this affected grinding
capability of coal mill. Increasing the temperature of the air entering the pre heater by
steam preheating can also increase air exit temperature by maintaining cold end metal
temperature.

Ash carry over from economizer hopper can also contribute to degradation of air pre
heater performance. Erosion of ducting and expansion joints upstream and
downstream of air pre heaters can also contribute to loss of margin in draught system
and poor air pre heater performance. Close monitoring of air pre heater performance
& proper instrumentation would enable timely detection of performance degradation.


3
Regenerator Model

In this paper a simple flow model of the rotary regenerator has been analyzed. In
rotary regenerator fluid leakage can be classified in to two categories.

i) Pressure Leakage: due to part of higher-pressure gas stream passing
through the sealing system mixes with low-pressure fluid stream.
ii) Carry over leakage: When a part of gas stream trapped in void volumes of
the rotor element is carried to the other gas stream during rotation. The
carry over leakage can occur in both the direction.

It has been idealized that the air leakage flows only at faces of the regenerator rotor.
The intermixing of the fluid occurs only at the outside the matrix. Air is at higher-
pressure side. The fluids have a perfect gas behavior. "#$%&!

Fig. 1. Regenerator model with fluid bypass and carryover.

A regenerator leakage model having finite fluid bypass and carryover leakage is
shown in Fig 1. Let the total mass flow leakage rate from the high-pressure airside to
low-pressure gas side is
P
W . It is assumed that the amount of fluid by pass at the air
(cold) inlet side and gas (hot) inlet side will be
p
nW . Where n is a fraction indicating
leakage distribution at cold and hot end. Let the mass of air contained in the matrix
void volume and carried over to the gas (hot) side during one rotation is
a
W and the
hot fluid carry over is
g
W . The pressure leakage and carry over factors X
p
, and carry
over leakage factors X
a
and X
g
are defined as
P
p
a
W
X
W

= ,
a
a
a
W
X
W

= ,
g
g
a
W
X
W

= (1)
4
The fractional carry over factors
a
X and
g
X can be calculated as [5]:
*
, *
( )
1
a p a
a r
w w
C
V
X C
C

+
=

(2)
*
, * *
( )
1
g p g
g r
w w
C
V
X C C
C

+
=

(3)
The effectiveness is calculated using Galerkin method [6] for solving balanced,
symmetric counter flow regenerator effectiveness.
2 1 1 1
2
1 7 24{ 2[ 90( 2 )]}
1 9 24{ 6[ 20( 3 )]}
r
B R A N E
C
B R A N E

+ +
=
+
(4)
Where
3 4
1
1
1
3 13 30( )
)]
)]
B
R
E
N
A
R
5 6
2 4 5 6
3 3 4 5 6
2
4 4 5 6 5
2 2 3
2 4 6 2 5 3 6 3 4 5 4
2
4 4 5 6 5
3 3 4 5 6
2 4 5 6
= +
= [3 5(3 4 )]
= [3 5(3 + 4 12 )]
= [2 3( + )] + 3
= + 2
= [ 2( + )] + 2
= [ 15( + 4 12
= [ 15( 2

*
1
2
( , 2 )
(2 )
O
i O
r
i i
O
NTU
V NTU
C
NTU

=
Where i=2,3,4....6... (5)
2
i 1
1
V( , ) exp[ ( )] ( ) (2 )
n
n
m n
n m
y
x y x y C I xy
x

=
= +

(6)
eq. (4) is valid for C
*
=1 and (hA)
*
=1.
The effectiveness of unbalanced regenerator can be calculated as follows:
Computing
, o m
NTU and
*
, r m
C for an equivalent balanced regenerator from the specific
value of
o
NTU ,
*
C and
*
r
C as
*
, *
2
1
o
o m
NTU C
NTU
C
=
+
(7)
* *
*
, *
2
1
r
r m
C C
C
C
=
+
(8)
5
Then the equivalent balanced regenerator effectiveness
r
is calculated using
, o m
NTU ,
*
, r m
C for
o
NTU and
*
r
C in equation (4). The actual regenerator effectiveness is then
calculated using equation.
*2
*
*2
*
*
( 1)
1 exp{ }
2 (1 )
( 1)
1 exp{ }
2 (1 )
r
r
r
r
C
C
C
C
C

(9)
The performance evaluation is normally done either to verify venders specification or
to determine the performance in off design condition. The objective of the
performance evaluation is to determine fluid outlet temperatures heat transfer rate and
pressure drop of both the streams. The method given in Shah [5] has been used to
calculate heat loss, pressure drop and outlet temperatures of air and gas streams.

Correlation for Heat Transfer and friction factor

For heat transfer coefficient average Nusselt number Vs Reynolds number plot for 30
o
undulation angle [7] has been taken and a fit to a polynomial curve fit equation.

-03 -03 -06 2 -10 3 -14 4 -19 5
av
Nu =-10.3E +14E Re-4.8363E Re +9.2369E Re -5.724E Re -4.1538E Re (10)

For corrugated undulated surface geometry combination and inclination angle 30
o
, the
correlation is [7]
0.722
26.57 Re for Re range 1300 - 3000 f

= (11)
0.411
2.203Re for Re range 3000 - 10000 f

=

For notched plate geometry of cold end elements correlations given in shah [5] has
been used to calculate colburn j factor and friction factor f.

Physical properties of fluid

The heat transfer rate and fluid pumping power are dependent upon the fluid thermo
physical properties. Hence it is essential that the fluid properties to be calculated
accurately at each section corresponding to the temperature. Fluid properties required
for analysis are density, specific heat, viscosity, thermal conductivity and Prandtl
number. Correlations [8] have been used to calculate thermal conductivity (K) &
viscosity ( ) of flue gas as follows, depending upon the volumetric constituent of
flue gas.
1
( 1/ )
2
i i i i i
i
p K p
K
P K P

= +
(12)
Where K
i
& p
i
are the thermal conductivity & partial pressure of individual
constituent of mixture, and
i
are correction factors to account for molecular kinetic
theory of gases.
6
1/ )
i i
i
p
P

=
(13)
Where, !
i
is viscosity of individual constituent of mixture, and "
i
are correction
factors. The curve fit equations of thermo physical properties of constituent of gases
and other working fluids taken from Yaws [8].

Results and Discussion

To validate the design model performance prediction computer programs run for
various loading conditions for Air Pre heaters of a typical 500 MW by varying
leakage distribution at cold end and hot end from 30 % to 70 %. The input data at off
design conditions like flow rate, fouling, chocking of the air pre heater baskets,
leakage distributions etc. are not available. Hence it is very difficult to evaluate the
performance of air pre heater at off design conditions. However the effect of various
parameters likes leakage, fouling, chocking of elements and change in flow and
change in inlet air or gas temperature can be analyzed using this performance
evaluation program.

Leakage drift and its effect on air pre heater performance

Leakage is an unavoidable feature of regenerative air pre heater. Air pre heaters are
designed with a certain percentage of leakage. Leakage drift is increase in leakage
over a period of time due to deterioration of sealing system. The effect of leakage
with variation in leakage distribution at hot and cold end for primary air pre heater of
a typical 500 MW power plant are shown in Table 1. In this analysis flow parameters
for BMCR are taken and air outlet flow from air pre heater has been kept constant.
7

Outlet Temperature
o
C
Heat Transfer rate
MW
Effectiveness
%
Leakage
fraction at
CE
% Leakage
Gas Air Actual Loss Ideal Actual
0.3 6 152.49 277.90 33.69 4.28 71.71 63.638
0.3 8 151.35 276.46 32.46 5.92 70.95 60.011
0.3 10 150.18 274.97 31.18 7.61 70.16 56.389
0.3 12 148.99 273.44 29.84 9.37 69.35 52.775
0.3 14 147.77 271.87 28.44 11.19 68.52 49.167
0.3 16 146.47 270.31 26.99 13.09 67.68 45.581
0.4 6 152.10 278.39 33.77 4.21 71.71 63.772
0.4 8 150.82 277.15 32.56 5.82 70.95 60.196
0.4 10 149.50 275.87 31.31 7.49 70.16 56.625
0.4 12 148.17 274.54 30.00 9.22 69.36 53.058
0.4 14 146.81 273.18 28.63 11.01 68.52 49.496
0.4 16 145.40 271.81 27.21 12.87 67.68 45.949
0.5 6 151.72 278.88 33.84 4.14 71.72 63.907
0.5 8 150.28 277.84 32.67 5.72 70.95 60.383
0.5 10 148.82 276.77 31.44 7.36 70.17 56.862
0.5 12 147.34 275.66 30.16 9.06 69.36 53.344
0.5 14 145.84 274.51 28.83 10.82 68.53 49.83
0.5 16 144.314 273.337 27.437 12.651 71.72 46.323
0.6 6 151.33 279.38 33.91 4.07 71.72 64.043
0.6 8 149.74 278.55 32.77 5.62 70.96 60.571
0.6 10 148.13 277.68 31.58 7.23 70.17 57.102
0.6 12 146.50 276.79 30.33 8.90 69.37 53.634
0.6 14 144.86 275.86 29.03 10.63 68.54 50.169
0.6 16 143.20 274.90 27.67 12.43 67.69 46.707
0.7 6 150.94 279.88 33.99 4.00 71.72 64.179
0.7 8 149.19 279.25 32.87 5.52 70.96 60.761
0.7 10 147.43 278.60 31.71 7.10 70.18 57.344
0.7 12 145.65 277.93 30.50 8.74 69.38 53.928
0.7 14 143.86 277.23 29.23 10.44 68.55 50.513
0.7 16 142.06 276.51 27.90 12.20 67.70 47.1

Table 1. Primary APH performance data with variation in leakage & its distribution.


Air Pre heater Performance Improvement

In some of the air pre heaters space is provided to permit the addition of extra element
at a latter stage if under performance is observed. But many under performing air
preheaters are not equipped with this provision of additional space. In such air
preheaters performance can be improved by substituting old element with new
element profile of better thermal performance. In NTPC (India) air pre heaters are
provided with Double Undulated, Corrugated Undulated elements at hot end and
Notched plate at cold end. However now a day many more element profiles with
better thermal performance & with higher undulation angle are available.

The performance evaluation program can be used to predict the performance of air pre
heaters with change in element profile or element height. This can also help in
selecting a particular element profile for the air pre heater while going for
performance improvement. The performance evaluation program output has been
shown in Table 2 for a typical primary air pre heater with same element profile
(Double Undulated) at both hot & cold end. It is observed that modifying element
profile yields appreciable temperature rise in air side without much rise in pressure
drop. This temperature rise will be much pronounced if economizer by pass is open
and high temperature flue gas is allowed to pass through the APH.
8

SN Performance Parameter Unit Existing
Prediction
Modified
Prediction
Change
1 Gas outlet temperature (
o
C) 146.8 139.1 -8.5
2 Air out let temperature (
o
C) 278.3 287.8 10.2
3 Gas side Pressure drop (mmwc) 88 109 21
4 Air side pressure drop (mmwc) 96 124 28
5 Actual Heat transfer rate MW 31.3 32.57 1.27
6 Heat loss rate MW 7.7 6.5 1.2
7 Effectiveness of APH % 56.2 58.43 2.23

Table 2. Performance Parameter after Modification
Conclusion

The regenerator leakage model has been briefly discussed in this paper. The
Performance of rotary regenerator with leakage and its distribution at hot & cold end
has been analyzed. It is observed that leakage at cold end does not contribute to any
heat loss but it only dilutes the flue gas outlet temperature. The effectiveness of a
regenerator considerably reduces due to increase in leakage, especially if leakage is
more at hot end.

The performance improvements of existing non-performing air preheaters are
discussed in brief. The performance improvement by improving element profile at
cold end of an existing air preheater has been presented. With the change in element
profile at cold end airside temperature can be increased up to 10
o
C and gas side
temperature can be reduced up to 8.5
o
C.

REFERENCES
1. British Electricity International, Modern Power Station Practice, Pergamon
Press London, Vol. B, 3
rd
edition, (1991).
2. Reznikov M.I., Lipov Yu. M., Steam Boilers of Thermal Power stations, Mir
Publication Moscow (1985).
3. Howden Power Ltd, Product Information air pre heater customer manual,
(2000).
4. Singh, B.M. Air pre heater Performance and its effect of Boiler efficiency,
Workshop on Maintenance Practice of air pre heater, ducts, dampers at NTPC
(India) Ramagundam, (1999).
5. Shah, R.K., Counter flow rotary regenerator Thermal Design procedure (pp
267-269), Heat transfer equipment design, Hemisphere, Washington D.C.,
(1988).
6. Ballic, B.S., Application of the Galerkin Method to the solution of the
symmetric and Balanced Counter flow Regenerator problem, J. Heat Transfer,
Vol. 107, pp. (214-221). (1985)
7. Staseik J.A., Experimental studies of heat transfer and fluid flow across
undulated heat exchanger surfaces. Int. J. Heat Transfer. Vol. 41 Nos. 6-7, pp.
899-914, (1998).
8. Yaws, Carl L., Chemical Engineering Handbook, McGraw- Hill, (1999).