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Air Heater Pluggage

Economizer Hopper Ash Capture
 
Problem: Heat heater pluggage photo
Photograph of Air Heater Flyash Fouling
Red Ball A 600 MW coal-fired power plant was experiencing significant flyash fouling of the rotary air heater
Red Ball Forced unit shutdown every 2-3 months for air heater cleaning
Red Ball Estimated lost revenue of $50,000 per outage; air heater wash cost of $17,000 per wash
Red Ball Total cost $67,000 per outage
 
Baseline velocity plot
 Solution:
Red Ball Using computer flow model, evaluate numerous design scenarios and operating conditions.
Red Ball Determine final design that optimizes ash capture with minimum pressure loss and installation cost.
Red Ball The final design captured 100% of ash particles greater than 500 microns in diameter.
 
Baseline particle track plot
 Results:
Red Ball After installation of recommended modifications, forced outages for air heater cleaning were eliminated.
Red Ball Cost savings of $200,000 per year were realized by eliminating a minimum of 3 forced outages per year.
 
Heat Exchanger Systems
 
Original Condition Plots
Original Condition		   Illinois Power Company Cross-flow Tubular Air Heater

Project Goals:
Red Ball Alleviate Pluggage
Red Ball Maximize Heat Transfer
Temperature Scale
After Modification Plots
After Tube Modifications
A local cool spot in the gas flow resulted in temperatures below the sulfuric acid dew point. Acid condensation initiated flyash pluggage of the air heater.   The air heater was modified to improve flow and temperature uniformity. Temperatures are maintained above the acid dew point.
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