Aph PRESENTATION
Aph PRESENTATION
AND ECONOMIZER
Under the guidance of(Internal)
N.B.PRAKASH TIRUVEEDULA
ASSISTANT PROFESSOR
VIGNAN UNIVERSITY
Submitted by
J.SHANMUKA VENKATA GOPICHAND (101FA08133)
L.SURYA TEJA (101FA08141)
CONTENTS
1.
2.
Economizer
3.
Boiler basics
4.
Heat Exchangers
5.
6.
7.
8.
Boiler Efficiency
9.
10. Conclusion
There are two types of air pre-heaters for use in steam generators in thermal power
stations: One is a tubular type built into the boiler flue gas ducting, and the other is a
regenerative air pre-heater.
Ambient air is forced by a fan through ducting at one end of the pre-heater tubes and at
other end the heated air from inside of the tubes emerges into another set of ducting,
which carries it to the boiler furnace for combustion
There are two types of regenerative air pre-heaters: the rotating-plate regenerative air preheaters (RAPH) and the stationary-plate regenerative air pre-heaters.
Rotating-plate regenerative air pre-heater
Economizer
Economizers are mechanical devices intended to reduce energy
consumption, or to perform another useful function such as preheating a
fluid.
Economizer performs a key function in providing high overall boiler
thermal efficiency by recovering low level energy from the flue gas before
it is exhausted to the atmosphere.
Economizer recovers the energy by heating the boiler feed water.
It scavenge the waste heat from thermal exhaust flue gases by passing the
exhaust effluent through heat transfer surfaces to transfer some of the
waste heat to a process media.
It Efficiency is in direct relationship to equipment design and stack gas
velocities.
Velocity increases through the stack as firing rate increases, which results
in a decrease in contact time with the economizer heating surfaces
BOILER BASICS
The hot water or steam under pressure is then usable for transferring the heat for the steam
requirements of process industries or for power generation.
During the combustion process, oxygen reacts with carbon, hydrogen and other elements
in the fuel to produce a flame and hot combustion gases.
As these gases are drawn through the boiler, they cool as heat is transferred to water
The main components in a boiler system are boiler feed water heaters, deaerator, feed
pump, economizer, super heater, Attemperators, condenser and condensate pump.
Heat Exchangers
Heat Exchangers are classified according to their function and geometry:
Function:
Recuperative: two fluids separated by a solid wall
Evaporative: enthalpy of evaporation of one fluid is used to heat or cool the other fluid.
Heat Exchangers
The heat transfer rate for most heat exchangers can be calculated using the LMTD-method
(Log Mean Temperature Difference), if the inlet (T1) and outlet (T2) temperatures are
known:
Q U A T
T2 T1
F
ln T2 / T1
Advantages:
very small
Ideal for transferring heat to / from fluids with very low conductivity or where the heat
transfer must be done in very small spaces
Disadvantages:
high manufacturing costs
very heavy
Extremely high pressure losses.
DESIGN OF ECONOMIZER
ASSUMPTION:
The properties are remains constant under steady state conditions and neglect
surrounding losses. Kinetic and potential energies are neglected.
DESIGN ANALYSIS:
Heat Transfer,
Q = m x c x t
Where m = mass of fluid in kg
= 5 kg/sec
Specific heat of water is 4.18 kj/kg oc
Temperature difference, t = (70oc - 40oc) = 30oc
Q = 5 x 4.18 x 30oc
Q = 627 kW
Heat loosing fluid
Qc = m x c x t
= 16 x 1.005 x (200 160)
= 643.2 kw.
In Counter flow
LMTD = ((Th1 Tc2) - (Th2 Tc1)) / ln ((Th1 Tc2 ) - ( Th2 Tc1 ))
= ((200-70) (160-40)) / ln ((200-70)/ (160-40))
= (130-120) / ln (130/120)
= 10 / ln (1.083)
= 10 / 0.0797
LMTD = 125.47oc
Actually this economizer is a cross flow economizer so, the LMTD equation becomes,
(LMTD)cross = F X (LMTD)counter
Here F = correction factor
It is calculated by using graphical method by using dimension parameters P, Z from graph,
P= (Tc2-Tc1)/(Th1-Tc2)
P= (70-40)/ (200-70)
P= 0.2307
Z= (Th1-Th2)/(Tc2-Tc1)
Z= (200-160)/ (70-40)
Z= 1.33
From this values we get F = 0.98 (from graphically, pgno:31)
So we have multiplied the counter flow LMTD with correction factor F, then we
get LMTD of cross flow
(LMTD) cross = F X (LMTD) counter
= 0.98 x 125.47
= 122.96oc
From Average velocity in the tube and discharge we Calculate total flow area
m= Au
Here m = mass of water
A = Tube flow area
U = velocity of flow = 0.2 m/sec
A = 5 / (1000 x 0.2)
A = 0.025 m2
0.025 =n x /4 x d2
0.025 = n x 3.14 x (0.025)2 / 4
n= 50
Q = m x c x t
Where m = mass flow rate
C = specific heat of air in kJ/kg oc
C = 1.005
t = temperature difference in oc
Here m = 5 kg/sec
Specific heat of water is 4.18 kJ/kg oc
Temperature difference, t = (110 oc - 50 oc) = 60 oc
Q = 5 x 1.005 x 60 oc
Q = 301.5 kw
Heat loosing of fluid Q = m x c x t
= 5 x 1.005 x (270-200)
= 351.75 kw
P= (Tc2-Tc1)/(Th1-Tc2)
P= (110-50)/(270-110)
P= 60/160
P=0.375
Z = (Th1-Th2)/(Tc2-Tc1)
Z = (270-200)/(110-50)
Z = 70/60
Z = 1.16
From this values we get F = 0.94 (from graphically)
So we have multiplied the counter flow LMTD with correction factor F, then we get
LMTD of cross flow
(LMTD)cross = F X (LMTD)counter
= 0.94 x 156.46
= 147.07 oc
Q = UA Tm x F
Where U = overall heat transfer coefficient
A = Area of Air Pre heater
F = correction factor
U = 50 w / m2 oc (As per standard tables)
From Average velocity in the tube and discharge we Calculate total flow area
0.83 m2 = n X /4 X d2
n = 658 tubes
Length of tube for two passes
ndL = 43.015m2
L = 43.015 / (658 x 3.14 x 0.04)
L = 0.52m
BOILER EFFICIENCY
Now we calculate the boiler efficiency of thermax boiler.
Capacity of boiler = 6 tons/hour
Exisisting values
Water temperature (tw) = 35 oc
Mass of steam
(ms) = 6000kg/hr
Mass of fuel
hw = 151.5 kj/kg
Enthalpy of steam at 190 oc
hs =hf +x hfg
= 73.3%
= 14236500/15859831.05 X 100
= 0.89 X 100
Boiler efficiency with air preheater
= 89%
= T2-T1
= 95 OC -85 OC
= 10OC
hw = hf
hw = 806.7
= 6000/1250 (2586.45 206.7)
= 4.8 x 2379.75
= 11422.8 kj
fuel consumption
( kg/hr )
Name
Boiler efficiency
(%)
1250
73.3
with economizer
1250
77
with airpreheater
1083
89
100
90
1300
1250
1250
1250
80
1200
70
60
1150
1100
50
1083
40
30
1050
20
1000
10
0
950
1
CONCLUSION
In this course of project it came to learn about the Design of Air pre-heater and
Economizer in boiler.
By using the Air pre-heater and Economizer boiler Efficiency can be increased.
Gas flow distribution or heat transfer into the economizer section is improved through use
of guide vanes at inlet of economizer duct.
Analysis of economizer module was carried out to predict the economizer feed water
outlet temperature.
The economizer size optimized by reducing the number of tubes of module by enhancing
the heat transfer across the module.
By installing the Air pre-heater and Economizer the total husk consumption rate is
reduced and the efficiency of the boiler is also increased to 73% to 89%