Economizer Hoppers

Economizer Hopper Ash Capture
Problem:		Photograph of Air Heater Flyash Fouling
	A 600 MW coal-fired power plant was experiencing significant flyash fouling of the rotary air heater
	Forced unit shutdown every 2-3 months for air heater cleaning
	Estimated lost revenue of $50,000 per outage; air heater wash cost of $17,000 per wash
	Total cost $67,000 per outage

	Solution:
		Using computer flow model, evaluate numerous design scenarios and operating conditions.
		Determine final design that optimizes ash capture with minimum pressure loss and installation cost.
		The final design captured 100% of ash particles greater than 500 microns in diameter.

	Results:
		After installation of recommended modifications, forced outages for air heater cleaning were eliminated.
		Cost savings of $200,000 per year were realized by eliminating a minimum of 3 forced outages per year.