NEXT

XV. AIRHEATERS
Go To Contents
Contents
1. INTRODUCTION
2. TYPES OF AIRHEATERS
3. REGENERATIVE Vs. RECUPERATIVE
4. TROUBLE SHOOTING WITH AIRHEATERS
5. OPERATION AND MAINTENANCE
6. CONCLUSION
FIG. XV-1 GENERAL ARRANGEMENT OF 120 MV BOILER WITH
TUBULAR AIRHEATER
FIG. XV-2 AIR PREHEATER
FIG. XV-3 EXPLODED VIEW OF AIR PREHEATER
FIG. XV-4 REGENERATIVE AIR PREHEATER TYPE - R
FIG. XV-5 EXPLODED VIEW OF THE R TYPE AIR PREHEATER
FIG. XV-6 ROTHEMUHLE REGENERATIVE AIRHEATER
NEXT
B A C K
Go to Manual index
Go To Contents
BACK
XV. AIRHEATERS
1. INTRODUCTION
Airheater is a heat exchanger in which air temperature is raised by transferring has from other
fluid such as flue gas. Since airheater can be successfully employed to reclaim heat from
flue gas at lower temperature levels than is possible with economiser, the heat rejected to
chimney can be reduced to a great extent thus increasing the efficiency of the boiler. for
every 20
0
c drop in flue gas exit temperature, the boiler efficiency increases by about 1%.
1.1 Advantages of Airheaters
In addition to increase in boiler efficiency the other advantages that may result in are listed
below:
i) Stability of combustion is improved by use of hot air.
ii) Intensified and improved combustion.
iii) Burning poor quality fuel efficiently.
iv) High heat transfer rate in the furnace and hence lesser heat transfer area require-
ment.
v) Less unburnt fuel particle in flue gas thus complete combustion is achieved.
vi) Intensified combustion permits faster load variation.
vii) In the case of pulverised coal combustion, hot air can be used for drying the coal
as well as for transporting the pulverised coal to burners.
viii) This being a non-pressure part will not warrant shut-down of units due to corro-
sion of heat transfer surface which is inherent with lowering of flue gas tempera-
ture.
2. TYPES OF AIRHEATERS
Airheaters can be classified as Recuperative and Regenerative types based on their
operating principle.
In Recuperative type heating medium is on one side and air is on the other side of tube or
plate and the heat transfer is by conduction through the material which separates the media.
These are of static construction and hence there is only nominal leakage through expansion
joints, access doors, casings etc.
In Regenerative type the heating medium flows through a closely packed matrix to raise its
temperature and then air is passed through the matrix to pick-up the heat. Either the matrix or
the hoods are rotated to achieve this and hence there is slight leakage through sealing
arrangements at the moving surfaces.
NEXT
Go To Contents
2.1 Tubular Airheater (Recuperative) (Figure XV-1).
This usually consists of large number of steel tubes of 40 to 65 mm dia either welded or
expanded into the tube plates at the end. Either gas or air may be allowed to flow through the
tube. Gas through the tube normally requires higher size tube and vertical flow to reduce
fouling. Single or more passes on the gas side and multipass cross flow on the air side usually
fits in with the overall plant design. The portion of airheater at low temperature zone is designed
normally with a shorter tube length so as to facilitate maintenance of surfaces due to corrosion
and fouling. In some cases instead of using boiler flue gases, separate external firing is used
particularly during starting.
2.2 Plate Type Airheater (Recuperative).
These comprise of parallel plates which provide alternate passage for gas and air. This type
is simple and compact compared to that of tubular type. The narrow passes between plates
make the cleaning tedious but with shot cleaning method it is improved. But replacement is
a major task.
2.3 Steam Air Preheater (Recuperative)
This does not utilise the heat from boiler flue gas and hence does not improve boiler efficiency.
Normally this is used only during starting when flue gas entering the regular airheater is low
and hence further heat extraction is not possible and low temperature corrosion prevails.
Several designs are there with oval or round tubes carrying the steam to be condensed.
Condenser for this should be provided with air removal system so that any air entering with
steam will not lock and prevent the operation of airheater. Air outlet temperature can be
controlled easily.
2.4 Ljungstrom Type (Regenerative) (Figures XV-2, 3, 4 and 5)
The heat transfer elements are rotated at a constant speed and they pass alternately through
gas and air passes. The axis of rotation may be horizontal or vertical. The drive is normally
electrical operated through reduction gear with compressed air motor as stand-by.
The plates forming the elements (matrix) may be varied in spacing and thickness and cold
ends are made of special corrosion resistance alloy such as corten or enamelled to achieve
corrosion resistance. This type is very compact and lends easily for ducting arrangement.
Effective cleaning of heat-transfer surface by soot blowing is possible.
2.5 Rothemuhle Type (Regenerative) (Figure XV-6)
This type is the same as the Ljungstrom type -except that the matrix element is stationary
and the air gas hoods rotate. Again axis of rotation may be horizontal or vertical.
3. REGENERATIVE Vs. RECUPERATIVE
3.1 Regenerative airheaters have the following advantages over recuperative ones
(tubular):
i) Compact and hence save space and structure cost. Since this type of airheater can be
effectively cleaned when in service the elements can be closely packed, hence they
are compact.
BACK NE XT
Go To Contents

B A C K
(ii) This is the type that can be economically used for high capacity boiler. As the
boiler size increases heat transfer area required in airheater also increases and if
the pressure drop on air and gas side is to be kept constant to limit the fan capaci-
ties and operation cost the recuperative airheater size assumes even greater pro-
portions than boiler.
(iii) From the above two reasons, it is clear that initial cost as well as the operating
cost can be kept minimum with regenerative airheaters for higher size boilers.
(iv) Less weight of metal permit economic usage of alloy steel like corten steel elements
in the low temperature section thus corrosion problem is combated to a great extent.
(v) Normally the cold end element packs are separate and handy and because of the
nature of this arrangement (possible only with regenerative type) the replacement
cost and downtime is very low.
(vi) Minimum metal temperature at the cold end of a regenerative heater is slightly higher
than in a recuperative design operating under the same condition. This is because
regenerative type works very close to the counter flow, while that of recuperative is
on cross flow where metal reaches the air inlet temperature.
(vii) Holes in the elements due to corrosion etc.. will not materially affect the perform-
ance of the heater.
(viii) Deposit on the heat transfer surface does not reduce the heat transfer. Deposit will
reduce heat transfer in the case of recuperative exchangers due to their poor heat
conduction.
(ix) Ducting arrangements are neat, streamlined, simple and less costly.
(x) Pressure drop across the elements can be kept nearly constant throughout the operat-
ing period with onload cleaning arrangement. Off-load cleaning also helps.
(xi) Hot primary air for coal drying in mill is possible with single airheater of tri-sector
design. This also helps to make use of a cold primary air fan.
3.2 Disadvantage of Regenerative Airheater when compared to Tubular
Recuperative Type
Moving parts need operators attention.
4. TROUBLE SHOOTING WITH AIRHEATERS
4.1 Fouling, Plugging and Corrosion
Deposits in airheaters are initiated by condensation of acid or moisture from flue gas on metal
surface operating at temperature below dew point. Other things remaining same, degree of
fouling depends on airheater heating element metal surface. Minimum metal temperature
occurs at the cold end, where, as a result, most fouling and corrosion occur.
NEXT
Go To Contents

As coal contains less sulphur, corrosion is not normally as much a problem as fouling and
hence lower exit gas temperature to a level of 120
0
C is permissible. But in the case of oil
firing, the corrosion and plugging due to corrosive products of combustion are very common.
The gas outlet temperature and/or air inlet temperature has to be raised to restrict the corrosion
to the permissible level. Operating the oil fired boiler at very low excess air reduces the acid
formation and hence corrosion.
During starting and at low loads the flue gas exit temperature falls to a low value that will
lead to corrosion. One or some of the following method is used to combat the problem:
i) Use of low sulphur oil during the above condition.
ii) By-pass cold air so that gas temperature can be kept at a higher level.
iii) By-pass of gas so that acid condensation on airheater does not occur at all.
iv) Increase the air inlet temperature by having steam coil air preheater.
v) Recirculate the hot air.
The recirculation of part of hot air can be utilised in normal operation also if the F.D, fan is
designed for the same.
During the normal operation to minimise the corrosion one or some of the following method
is used:
i) Air inlet temperature is increased mostly by steam air heating to maintain the recom-
mended cold end average temperature for the installation.
ii) Corrosion resistant alloys like corten steel can be used for cold end.
iii) Easily and economically replaceable cold end portion of airheater without much
outage period.
iv) Design the boiler for high flue gas exit temperature which means lesser efficiency of
boiler.
v) Effective on-load blowing of airheaters with superheated steam as moisture in steam
accelerates fouling and corrosion.
4.2 Cleaning of Airheaters
(i) On-load Cleaning:
(a) Recuperative Type
Proven practical method is by shot cleaning.
(b) Regenerative Type
BACK NEXT
Go To Contents

Fixed or moving type soot blowers with multinozzle thoroughly cleans the airheater.
(ii) Off-load Cleaning:
(a) Recuperative Type:
if not provided with on-load cleaning, this has to be cleaned at intervals during shutdown by
hand or mechanical method. Large quantity of cold or warm water can also be used for this
purpose. Small quantity of water will actually do harm by making deposit compact and hard.
(b)Regenerative Type:
Normally on-load cleaning devices keep them clean and if it is needed to clean during
shut-down large quantities of water may be used. It deposit is severe, sometimes soda-ash
solution may assist in dissolving it. Water requirement for cleaning is less when compared to
static type.
4.3 Erosion
This problem is normally encountered in tubular type airheaters. If the airheater is not cleaned
at frequent intervals the fouling increases to a stage of plugging of tubes and velocity increases
in other tubes. in case of coal fired boiler due to erosive nature of ash, erosion of tube particularly
in the lower temperature airheaters at the entry side may occur. This problem can be obviated
by frequent cleaning of airheater and/or by using replaceable inserts at the erosion prone
areas.
4.4 Fire
All types of airheaters are a potential fire hazard particularly at start-up of the boiler and
shut-down especially if the heater is having a thick deposit of soot. Finely divided particles of
combustible matter is deposited on the low temperature airheater surface when the combustion
is not satisfactory in the furnace due to various reasons. if the ignition temperature at
combustible matter is reached and sufficient oxygen is available, fire occurs and may sometime
destroy the whole airheater, duct etc., if not noticed earlier and put off A clean airheater will
never be the cause of such a major fire. In addition to keep watch on the combustion in the
furnace, early warning of fire and fire fighting equipments are essential. The outlet gas and air
temperatures from the airheater will rise above normal in case of fire and is the best indication
to detect fire and to take necessary step, for fire fighting. Fuel firing and fans are stopped and
airheater is flooded with water for which fire hose and fire main will be located nearby or
permanent installation by the side of airheater. Water from ducts and flues to be drained to
avoid collapsing due to waterload.
Most of the fire in airheater occurs either during starting, at low load or during shutting down.
This is due to the fact that combustion regime is poor during the above period and could not
be completely monitored due to varying conditions. Use of on-load cleaning at frequent
intervals during the above period will reduce the hazard to a great extent. Cutting out of fuel
automatically on fire out, and automatic combustion monitoring at all loads of operation are
essential features of modern boiler which may eliminate this hazard. Passing of oil isolating
valves, poor atomising oil tips are to be attended to immediately to avoid this hazard.
IMPORTANT :- Airheater by itself is not the cause of any fire and airheater fire can
be extinguished only by large quantity of water. Foam, CO, etc. will
not be effective.
BACK NEXT
Go To Contents
BACK
5. OPERATION AND MAINTENANCE
During operation the degree of fouling is reflected on the pressure drop across the airheater
for a particular loading condition. On-load cleaning if provided can be done at suitable intervals
to keep the fouling to the admissible level. Otherwise it is essential to plan a shut-down of the
unit for off-load cleaning. The cleaning of airheater to keep down the fouling is essential as
this is the primary cause for all the airheater problems i.e. plugging corrosion, erosion and
fire. Use of low sulphur oil, air by-pass, gas by-pass, steam coil airheaters, hot air recirculation
if any provided should be resorted to at low loads and starting to reduce the fouling and
corrosion. Low excess air will also reduce the corrosion. During shut-down at regular intervals
the airheater has to be inspected for the rate of fouling and corrosion. From the rate of corrosion
the length of life may be predicted and replacement can be planned accordingly, on an outage.
During annual overhauls airheaters should be thoroughly cleaned and water-washed. During
other shut-down it can be cleaned depending upon the fouling. Where erosion is experienced
(mostly) in P.F. fired boilers) cleaning of airheater at all possible shut-downs will yield good
results. Leakage in airheaters can be checked during operation by analysing flue gas for CO,
drop across the airheater. This leak age is through the tube joints, corrosion, erosion holes etc.
in case of tubular airheater while through seals and entrainment in the case of regenerative
airheaters. Seal design and adjustments provided now offer drop of CO, to around 0.5%. This
may rise upto 1.0% for 12 months operation. The CO, drop is checked before shutting down
for overhaul and during the overhaul the seals are to be adjusted or replaced in the case of
regenerative airheater and tube replacement, leakage arresting etc. are done in the case of
tubular type. Since regenerative airheaters are of rotary type, it is necessary to have a preventive
maintenance programme, to check the drives, bearings, cleaning devices, oil circulation system
etc.
6. CONCLUSION
Airheater is used for low as well as high capacity boiler not only because it raises the efficiency
of boiler but also due to many other advantages. Even though the recuperative or regenerative
airheaters can be used for any boiler, economy and ease of maintenance dictate the use of
regenerative airheater for low as well as high capacity pulverised fuel and oil/gas fired boilers.
The common problems faced with airheaters were taken into account during the design stage
itself but planned maintenance and careful operation is essential to counteract the problems
successfully so that total economy in steam generation can be achieved.
NEXT
Go To Contents
FIG. XV-1 GENERAL ARRANGEMENT OF 120 MV BOILER WITH
TUBULAR AIRHEATER
BACK NEXT
Go To Contents
FIG. XV-2 AIR PREHEATER
NEXT BACK
Go To Contents
FIG. XV-3 EXPLODED VIEW OF AIR PREHEATER
NEXT BACK
Go To Contents
FIG. XV-4 REGENERATIVE AIR PREHEATER TYPE - R
NEXT
BACK
Go To Contents
FIG. XV-5 EXPLODED VIEW OF THE R TYPE AIR PREHEATER
NEXT
BACK
Go To Contents
FIG. XV-6 ROTHEMUHLE REGENERATIVE AIRHEATER
NEXT BACK
Go to Manual index