AIR HEATER PERFORMANCE

• GAS OUTLET • GAS OUTLET

TEMPERATURE TEMPERATURE
LOWER THAN HIGHER THAN
OPTIMUM OPTIMUM
– LEADS TO COLD – MORE DRY GAS LOSS
END CORROSION – RISE OF 220C ABOVE
• LOSS OF HEAT OPTIMUM REDUCE
TRANSFER BOILER EFFICIENCY
ELEMENTS
BY 1%
– 20C RISE ABOVE
OPTIMUM RESULTS
LOSS OF 600Kcal HEAT
IN 1 TONNE OF F.G.
 FACTORS AFFECTING A.H. GAS
OUTLET TEMPERATURE
• LOWER THAN • HIGHER THAN OPTIMUM
OPTIMUM – QTY. OF AIR PASSING THROUGH
– LIGHTING AND A.H.
FIRING COLD • TEMPERING AIR
• SETTING INFILTRATION
BOILER
• BYPASS DAMPERS PASSING
• USE SCAPH
– TEMP.OF GAS ENTERING A.H
– AIR LEAKAGE
• DEPOSITS ON BOILER HEAT TRANSFER
• SEALS CONDITON AREAS
• DIFF. PR. • DELAYED/SY.COMBUSTION
BETWEEN AIR AND
• FEED WATER TEMP
F.G
– FOULED / CORRODED ELEMENTS
– DEFECTIVE BAFFLES
– QTY.OFGAS PASSING THROUGH
A.H.
AIR HEATER PERFORMANCE TESTS
• REQUIREMENTS
– CHECKING ACTUAL PERFORMANCE
AGAINST MANUFACTURER’S GUARANTEE
– COMPARISON WITH A STANDARD OF
OPERATION
– COMPARING PERFORMANCE WHEN FIRING
DIFFERENT FUELS
– DETERMINING THE EFFECTS OF CHANGES
TO EQUIPMENT
– DETERMINING CORRECTIONS TO A.H.
EXITGAS TEMP. CAUSED BY VARIATIONS IN
INLET TEMP. IN AN EFFICIENCY TEST OF A
BOILER
 AIR HEATER PERFORMANCE
TESTS
• PERFORMANCE ITEMS DETERMINED
– GAS SIDE EFFICIENCY
– AIR LEAKAGE
– X-RATIO
– GAS AND AIR TEMPERATURE
CORRECTIONS
– GAS AND AIR PRESSURE LOSS
 DATA REQUIRED FOR A.H.
PERFORMANCE TESTS
• TEMP.OF AIR ENTERING
• TEMP.OF AIR LEAVING
• TEMP.OF GAS ENTERING
• TEMP.OF GAS LEAVING
• QTY. OF AIR ENTERING
• QTY. OF HEATED AIR LEAVING
• AIR SIDE INLET AND OUTLET STATIC PRESSURE
• AIR SIDE INLET AND OUTLET VELOCITY PRESSURE
• GAS SIDE INLET AND OUTLET STATIC PRESSURE
• GAS SIDE INLET AND OUTLET VELOCITY PRESSURE
• GAS ANALYSIS OF F.G.ENTERING AND LEAVING A.H
• HUMIDITY OF INLET AIR
 DATA REQUIRED FOR A.H.
PERFORMANCE TESTS
• QTY. OF GAS ENTERING A.H.
• QTY. OF GAS LEAVING A.H.
• QTY. OF FUEL MEASURED OR COMPUTED
• ULTIMATE ANALYSIS OF COAL
• QTY. OF ATOMISING STEAM IF BURNING OIL
 AIR HEATER CALCULATIONS
GAS SIDE EFFICIENCY
G = {(tG14-tG15(NL))/(tG14-tA8)}*100

WHERE tG14 - MEASURED GAS TEMP. ENTERING A.H.

tA8 - MEASURED AIR TEMP. ENTERING A.H
tG15(NL) - CALCULATED GAS TEMP LEAVING
A.H. CORRECTED FOR NO AIR
LEAKAGE
 HEAT BALANCE FOR LEAKING AIR IN
AIR HEATER
HEAT GAINED BY LEAKING AIR=HEAT LOST BY F.G
HEAT GAINED BY LEAKING AIR=HEAT REQUIRED TO
RISE TEMP. OF
LEAKING AIR (tA8)
TO GAS OUTLET
TEMP.( tG15)

=A (L)*CpA*(tG15- tA8)

WHERE A (L) - % AIR LEAKING

CpA - Sp.HEAT OF AIR
 HEAT BALANCE FOR LEAKING AIR IN
AIR HEATER
HEAT LOST BY F.G =HEAT LOST TO BRING
DOWN THE GAS TEMP.
FROM IF THERE IS NO
LEAK (tG15(NL)) TO
ACTUAL GAS TEMP. ( tG15)

=100*CpG*( tG15(NL) - tG15 )

WHERE CpG - Sp.HEAT OF F.G.

100*CpG*( tG15(NL) - tG15 ) = A (L)*CpA*(tG15- tA8)

tG15(NL) = [{A (L)*CpA*(tG15- tA8)}/ 100*CPg ] + tG15

 AIR HEATER LEAKAGE

A(L) =[WET AIR LEAKAGE/WET GAS ENTERING A.H]*100

=[{WG15-WG14}/WG14]*100

BY EMPRICAL APPROXIMATION

A(L) =90*{%CO2 ENTERING A.H.-%CO2 LEAVING A.H.}/

%CO2 LEAVING A.H.

A(L) =91*{%O2 LEAVING A.H.-% O2 ENTERING A.H.}/

(21- %O2 LEAVING A.H.)
 EFFECT OF VARIOUS
PARAMETERS ON A.H. GAS SIDE
EFFICIENCY
• AIR INLET TEMP.IN ALL CASES 300C
GAS GAS
INLET OUTLET LEAKAGE EFFICIENCY
CASE
TEMP. TEMP. % %
0 0
C C
IDEAL 400 140 13 66.5

1 400 155 13 62.2

2 400 140 20 64.6

3 400 155 20 59.7

4 430 165 20 59.8

 EFFECT OF COMPONENT ON DRY GAS
LOSS / EFFICIENCY

Gcv Gross calorific value Kcal/kg 3689.10 3689.10 3689.10

of fuel
C Carbon in fuel % 36.92 36.92 36.92
S Sulphur in fuel % 0.28 0.28 0.28
U Unburnt carbon/kg Kg 0.0066 0.0066 0.0066
fuel
CO2 Carbon di oxide in % 13 12 13
flue gas
Wd Dry gas wt. Per kg Kgmol/kg 0.2331 0.2525 0.2331
of fuel
Sp.ht Specific heat Kcal/kgmol 7.31 7.31 7.31
/0c
0
Tg Gas temperature C 155 155 165
leaving boiler
0
Ta Ambient C 35 35 35
temperature
0
DT Tg-Ta C 120 120 130
L1 Dry gas loss % 5.54 6.00 6.00
Change in loss for
1% CO2 % -0.46
100C -0.46
 EFFECTS OF TRAMP AIR
TO BOILER
• NOT CONTRIBUTING TO
COMBUSTION
• OFTEN IT IS COLD
• INCREASE GAS VELOCITY
THROUGH E.S.P
• BYPASSING A.H. INCREASED GAS
OUTLET TEMPERATURE
SOURCES OF AIR INGRESS
• ASH HOPPER SEALS
• ASH HOPPER DOOR LEFT OPEN
• DEFECTIVE EXPANSION JOINTS
• DUCT OPENINGS UNCOVERED
• BOILER ROOF SEALS DEFECTIVE
• ATTEMPERATING AIR DAMPERS
PASSING
• A.H.AIR BYPASSING DAMPERS PASSING
• SUCTION MILLING PLANT
• WORN SHAFT SEAL ON EXHAUSTERS
 X RATIO
HEAT CAPACITY OF AIR PASSING THROUGH A.H.
X RATIO = --------------------------------------------------------------------------
HEAT CAPACITY OF GAS PASSING THROUGH A.H.

WA9*CpA*(tA9 - tA8) = WG14*CpG*(tG14 - tG15(NL))

WA9*CpA (tG14 - tG15(NL))

X RATIO = ------------- = ------------------
W G14*CpG (tA9 - tA8)

CpA / CpG = 0.95

INDICATION OF AIR BY PASSING A.H

EFFECT OF BYPASSING AIR ON F.G. TEMP.
LEAVING A.H
EFFECT OF AIR BYPASSING AH ON X RATIO AND GAS TEMP.

Qg Gas quantity entering T/hr 700 700 700

A.H.
Qa Air quantity leaving A.H. T/hr 500 475 525
Xr X ratio Qa*95/Qg 0.68 0.64 0.71
0
Tgi Gas temp. entering A.H. C 330 330 330
0
Tai Air temp. entering A.H. C 35 35 35
0
Tao Air temp. leaving A.H. C 310 311 309
0
Tgo Gas temp. leaving A.H. C 143.39 152.08 134.78
without leakage
Tgi-[ Xr*( Tao- Tai )]
VARIATION 8.69 - 8.62
Aef A.H.Efficiency % 63 60 66
 CALCULATING AIR INGRESS %
Qg Gas quantity at A.H.inlet T/hr 700
Qaf Air quantity based on T/hr 650
excess air at A.H.inlet
Xr A.H.Xratio 0.7
Qa Air quantity leaving A.H. T/hr 515.79
Xr*Qg/0.95
Qat Tempering air quantity T/hr 100
from mill heat balance
Qi Air ingress quantity T/hr 34.21
Qaf-Qat-Qa
% Air ingress 5.26