Applied Mechanics and Materials Submitted: 2015-02-05

ISSN: 1662-7482, Vol. 787, pp 238-242 Revised: 2015-03-23

doi:10.4028/[Link]/AMM.787.238 Accepted: 2015-04-22
© 2015 Trans Tech Publications, Switzerland Online: 2015-08-28

IMPROVING THE BOILER EFFICIENCY BY OPTIMIZING THE

COMBUSTION AIR
R.Pachaiyappan1, a*, J. Dasa Prakash2, b
1
Assistant professor, 2 M.E. Final year (Thermal Engineering)
1,2
Department of Mechanical Engineering, Adhiparasakthi Engineering College,
Melmaruvathur-603319, Tamil Nadu, India.
a
rp00212@[Link], b dasaprakash3@[Link]

Keywords: Air Preheater, Heat Exchangers, Economizer, Seal Leakages, Heat Conductivity, Flue
Gas, Optimum Air.

Abstract. Air pre-heater and economizer are heat transfer surfaces in which air temperature and
water temperature are raised by transferring heat from other media such as flue gas. Hot air is nec-
essary for rapid combustion in the furnace and also for drying coal in milling plants. So an essential
boiler accessory which serves this purpose is air pre-heater. The air pre-heater is not essential for
operation of steam generator, but they are used where a study of cost indicates that money can be
saved or efficient combustion can be obtained by their use. The decision for its adoption can be
made when the financial advantages is weighed against the capital cost of heater. The efficiency of
the boiler increases with the increase in the temperature of the combustion air used in the furnace.
This is achieved by the increased temperature of the flue gas in the air preheater and economizer
zone. This paper deals with the different ways to obtain the maximum heat from the flue gas travel-
ling through the air preheater and the economizer zone to improve the boiler efficiency.
Introduction
Air is a primary component in furnaces and boilers. In each of these equipments, the ambi-
ent air needs to be heated up to high temperatures. Preheating the incoming air largely improves the
thermal efficiency of the system, thereby increasing the energy savings of the industry and results in
lower operating costs. In fact, every 220C rise in combustion air temperature increases the boiler
efficiency by nearly 1%. Heat exchangers can be used to recover the heat from various processes to
preheat the air. However, the heat transfer coefficient of air is low and hence, fins or extended sur-
faces are used to enhance the heat transfer [1]. It is a common industrial practice to utilize the heat
of exhaust gases or flue gases and process steam to preheat ambient air. Air pre-heater is the most
common equipment responsible for deterioration in boiler efficiency and increase in auxiliary pow-
er consumption in ID (Induced draft), FD (Forced draft), and PA (Primary air) fans. In this paper
different aspects of air pre-heater performance has been discussed such as, the parameters to be
monitored, causes and effects of poor performance of the air pre-heater and how the air pre-heater
performance affects the boiler efficiency. Some suggestions to improve the air pre-heater perfor-
mance are also discussed in this paper.
Specification of air preheater

Type: 27-VI-72 (T) 74

Where, 27 is the nominal diameter of rotor in feet
VI stands for vertically erected down flow air pre-heater
72 is the height of rotor in inches
74 is the height of casing in inches

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 Applied Mechanics and Materials Vol. 787 239

Fig. 1, Air preheater [2]

This air preheater is divided into 3 sectors of 72, 108 and 180 degrees. Flue gas is allowed to pass
from top to bottom vertically through the 180 degree sector. Primary air is allowed to pass from bot-
tom to top upward through the 72 degree sector and similarly secondary air passes upwardly
through 108 degree sector. The rotor is divided into 12 sectors by vertical diaphragm plates. Heat-
ing elements are arranged in these sectors in 3 layers, the top layer hot end, intermediate and the
bottom layer-cold end. Heating elements at hot end and intermediate end are identical. The top and
bottom sides of the diaphragm plates are mounted with 12 sets of radial seals each and the vertical
sides of the rotor are mounted with 12 sets of axial seals.

Seal leakages

Seals are provided at both ends of the air preheater to minimize leakage between the air side
and the gas side of the pre heater. The seal plates are made up of special corrosion resistant alloy
known as Corten steel. Primary and secondary air escape in so many ways to the flue gas side like
axially, radially and circumferentially.
The seal leakages are caused by different reasons. The primary air pressure is the highest of
the three streams and being the high pressure stream, there is direct leakage from the primary air
section to the gas and secondary air side. There is also direct leakage from the secondary air side to
the gas side. The quantity of air leakage from the primary air side to the secondary side is merely a
transfer from a higher pressure source to a lower pressure source [2]. The leakage leads to the air
ingression which reduces the air required for combustion of fuel and high oxygen content in the flue
gas [3].

Effects of increased seal leakage

If the seal leakage at the hot end increases

 Air outlet temperature decreases.
 PA and FD fan power consumption increases.
 ID fan power consumption increases.
If seal leakage at the cold end increases
 Flue gas outlet temperature decreases.
 PA and FD fan power consumption increases.
 ID fan power consumption increases.
240 Alternative Energy Sources, Materials and Technologies

Low heat transfer

Low heat transfer is one of the problems faced by the rotary air preheater. The air preheater
have the heating elements of surface area 19 m2. The heat transfer is directly proportional to this
surface area. But the heat transfer area is reduced due to the erosion and corrosion of the heating
elements. The heat transfer is also reduced because of the clogging of dust particles over the heating
elements at the cold ends. Hence the heating elements are kept clean by proper soot blowing with
steam. Poor heat conductivity results in high flue gas outlet temperature and low air outlet tempera-
ture which results in reduction of boiler efficiency [4].

Remedies

 Invert the hot end baskets during overhaul period if the element thickness reduces by
30%.
 Interchange the hot end baskets with the intermediate baskets when the element
height starts reducing.
 Double undulated baskets can be used in cold ends also to increase the heat transfer.

Major heat losses in boiler

The below mentioned percentage of losses has been calculated from the reading taken from
a 210 MW boiler by using the appropriate formulae and the present efficiency has been determined.

LOSSES PERCENTAGE (%)

Heat loss due to dry flue gas (Qdry) 5.14
Heat loss due to moisture in fuel (Qmoist) 4.2
Heat loss due to presence of hydrogen in fuel (QH) 3.5
Heat loss due to unburnt carbon in ash pit (Qcarbon) 5.18
Heat loss due to incomplete combustion (Qinc) 0.19
Total heat losses Qdry + Qmoisture + QH + Qunburnt + Qinc = 18%
Total utilised heat (Quti) 100 – 18 = 82%

The dry and wet losses are the major losses which is directly proportional to the flue gas out-
let temperature [5]. So by reducing the flue gas temperature after air preheater the boiler efficiency
can be increased. The Air preheater outlet temperature is governed by the flue gas inlet temperature
to air preheater, air inlet temperature to air preheater, thermal performance of air preheater and air
preheater seal leakage.

Performance of air preheater

The thermal efficiency of APH is measured by

 Air preheater gas side efficiency
 Air preheater air side efficiency
 The X ratio

If, Tgi = APH gas inlet temperature.

Tgo = APH gas outlet temperature.
Tai = APH air inlet temperature.
Tao = APH air outlet temperature.
Tgo (nl) = APH gas outlet temperature at no seal leakage.
 Applied Mechanics and Materials Vol. 787 241

Gas side efficiency = (1)

Where, Tgo (nl) = (2)

Where, Al = % of weight of air leakage through seals.

= 0.9 x seal leakage % by volume.

= (3)

Cpa / Cpg = 0.95

Air side efficiency = (4)

X ratio = (5)

However for all practical purpose only one ratio ie, APH gas side efficiency is enough to de-
termine the performance of APH.

Results and discussion

The efficiency gradually increases as the heat transfer in the air preheater between the flue
gas and the incoming air increases. From fig. 3 it is evident that as the flue gas outer temperature
decreases the boiler efficiency increases.

Fig. 3 Performance of the boiler

It is also proved that for every 220C (approx.) reduction in the flue gas temperature the boil-
er efficiency increases by 1%.
242 Alternative Energy Sources, Materials and Technologies

Conclusion

In this paper the performance of the air preheater has been studied on the basis of the com-
bustion air passing through it. The correct optimization of the combustion air can increase the boiler
efficiency by 2-3%. It also ensures less fuel consumption. By reducing the air preheater leakage the
auxiliary power consumption is also reduced. Thus the fuel is saved which leads to a considerable
amount of profit.

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