DESIGN CHALLENGES IN LOW FLUE GAS TEMPERATURE HEAT EXCHANGER

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1 DESIGN CHALLENGES IN LOW FLUE GAS TEMPERATURE HEAT EXCHANGER

2 INTRODUCTION Inventor of fuel economisers Founded in Wakefield, UK, 1833 Patented fuel economiser in 1845 More than 180 years heritage Edward Green ( )

3 DRAX POWER STATION, UK 6 X 660 MW ( ) BABCOCK BOILER

4 NANAO POWER STATION 1 X 700 MW SUPPLIED 1997 IHI BOILER, JAPAN

5 LONGANNET POWER STATION, SCOTLAND, 3 X 600 MW 1973 BABCOCK BOILER

6 DATANG INTERNATIONAL POWER GENERATION COMPANY 4 X 600 MW HARBIN BOILER

7 YAO MENG POWER PLANT 4 X 300 MW SHANGHAI BOILER

8 WEIHE POWER STATION 2 X 300 MW DONGFONG BOILER

9 DATTLEN POWER STATION GERMANY, 1 X 1100 MW HITACHI BOILER

10 GREENS STEEL H DESIGN G AS F LO W Research & Development Fins placed in areas of highest heat transfer Fin weld on sides of tube where maximum heat transfer takes place Fin material not placed where dust can accumulate above and below the tube. Fin sizes optimised for efficient use of material.

11 GREENS STEEL H PRODUCTION STEEL H PRODUCTION Fins are held in the correct position by Jaws. Current and forge pressure is applied to weld fins to tube. Tube is precisely indexed forward for next fin weld. Weld Current Weld Current Forge Pressure Forge Pressure

12 PURPOSE BUILT MACHINES

13 OBJECTIVES OF GHE To reduce the exhaust gas temperature from 160 ~ 170 Deg C to about 110 ~ 120 Deg C. While a Desulphurisation / Denitrification equipment are considered, the GHE shall assist to reduce the inlet gas temperature thereby reducing the water consumption. Similarly to reduce the inlet gas temperature for the next generation ESP s.

14 OPTIONS AVILABLE Option 1: GHE installed after the ID Fan

15 OPTIONS AVILABLE Option 2: GHE installed before ESP

16 OPTIONS AVILABLE Option 3: GHE used to control the flue gas temperature entering stack.

17 APPLICATION The GHE used for recovering waste heat and the useful recovered heat can be used for following 1. To produce chilled water in vapour absorption machine to be used in air conditioning 2. To produce flash steam for Desalination 3. Increase feed water temperature at economiser inlet 4. In parallel to LP heater

18 1. PRODUCE CHILLED WATER IN VAM Project: NTPC Ramagundam (1 x 500 MW) Project Details: Waste heat recovery system is designed to recover 500 kw of thermal heat from flue gases to produce 100 tons of refrigeration.

19 FLOW DIAGRAM STACK Flue Gas 110 C 150 C ID FAN Flue Gas Hot Water Chilled Water 95 C FAN HEAT EXCHANGER Hot Water Chilled Water 85 C 7 C ESP, CCR

20 FLUE GAS TEMPERATURE HEAT EXCHANGER INLET C 152 HEAT EXCHANGER OUTLET C 110 FLUE GAS FLOW RATE KG/H 40,250 NM 3 /HR 30,746 APPROXIMATE RADIATION LOSS % 2.0 FLUE GAS COMPOSITION V / V CARBON DIOXIDE % 12.2 WATER VAPOUR % 8 TO 11 (9.5) NITROGEN % 71.2 OXYGEN % 7.0 SOX MG/NM NOX MG/NM SPM MG/NM FLUE GAS VELOCITY HEAT EXCHANGER, AVG M/S 8.52 GAS DRAFT LOSS (OVER HEATING SURFACE ONLY) MM WG 35 WATER FLOW RATE TONS/HR 42.5 HOT WATER PRESSURE LOSS (FRICTION ONLY) KG/CM WATER TEMPERATURE HEAT EXCHANGER INLET C 85

21 SALIENT FEATURES Air Conditioning using Waste heat of flue gas instead of using Electricity or Auxiliary steam. Reduction in Auxiliary power of 0.4 MU/yr for Ramagundam STPS. Green House Gas (CFC & HCFC) free thermally driven 100 TR VAM based AC system. Reduction in CO 2 emission is 320 T/yr for Ramagundam Super Thermal Power Station Potential of scale up to meet entire Air-Conditioning requirement using waste heat from flue gas at power plants

22 STEEL H VS PLAIN TUBE Sr. No. Parameters NTPC Ramagundam STEEL H PLAIN 1 Tubes wide Tubes High Space required LxWxH 3 X 1.5 X X 1.4 X Total Tube Used (m) Heat Transfer Area m Weight (Tons) Air Blasters, Nos Draft loss mmwc 65 90

23 STEEL H VS PLAIN TUBE Sr. No. Parameters NTPC Talchar STEEL H PLAIN 1 Tubes wide Tubes High Space required LxWxH 4.75 X 2.75 X X 2.6 X Total Tube Used (m) Heat Transfer Area m Weight (Tons) Air Blasters, Nos Draft loss mmwc

24 2. PRODUCE FLASH STEAM FOR DESALINATION Project: NTPC Simhadri. Project Details: Waste heat recovery system is designed to recover 795 kw of thermal heat from flue gases to produce 5 TPH of net distillate at less than 5 ppm from ppm cooling tower blow down water (using 1 TPH, 0.34 bar (a) saturated steam) using Multi-effect Distillation System.

25 Main Flue Gas Duct Flue Gas Heat Exchanger Flash Chamber Multieffect Distillatio n System

26 Flue gas to C Flue gas back to main duct at C ID fan Cooling tower blow down water ppm ppm Main Flue gas duct of power plant Flue gas heat exchanger Flash chamb er Multi effect desalination Brine reject Flue gas from power C < 0.5 % of total flue C Boiler make up water at < 0.05 ppm EDI Distillate at < 5 ppm

27 FLUE GAS TEMPERATURE HEAT EXCHANGER INLET C 125 HEAT EXCHANGER OUTLET C 100 FLUE GAS FLOW RATE KG/H 113,000 NM 3 /HR 86,259 APPROXIMATE RADIATION LOSS % 2.0 FLUE GAS COMPOSITION V / V CARBON DIOXIDE % WATER VAPOUR % 9.5 NITROGEN % 71.2 OXYGEN % 7.0 SOX MG/NM NOX MG/NM SPM MG/NM FLUE GAS VELOCITY HEAT EXCHANGER, AVG M/S 9.7 GAS DRAFT LOSS (OVER HEATING SURFACE ONLY) MM WG 40 WATER FLOW RATE TONS/HR 39 HOT WATER PRESSURE LOSS (FRICTION ONLY) KG/CM 2 1 WATER TEMPERATURE HEAT EXCHANGER INLET C 72

28 SALIENT FEATURES Retrieval of unused thermal energy from flue gas No membrane replacement in the RO desalination plant High product water 11 quality of < 2 ppm from Multi-effect Distillation Possible to use power plant cooling tower blow down as source water for desalination No chemical handling Possibility of 100 % availability Reduction in DM plant operating cost Electrical energy consumption of 1.5 kwh /m3 for desalination plant

29 STEEL H VS PLAIN TUBE Sr. No. Parameters NTPC SIMHADRI STEEL H PLAIN 1 Tubes wide Tubes High Space required LxWxH 3.5 X 2.5 X X 2.1 X Total Tube Used Heat Transfer Area m Weight (Tons) Ton Air Blasters, Nos Draft loss mmwc 65 85

30 3. FEED WATER HEATING Project: Reduction in backend temperature by recovering heat before ESP at Hindalco Renukoot. (70 MW COEGN PLANT). Project Details: It is economiser retrofit project for improving heat recovery in existing plant. Heat duty of economiser increased from 2MW to 4.7MW. Feed water temperature in economiser increased from 117 C to 135 C. Flue gas temperature at economiser outlet decreased from 174 C to 140 C.

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33 4. IN PARALLEL TO LP HEATER The GHE is used to heat the condensate return and act in parallel to LP Heaters, thereby reducing the steam consumption. The steam thus saved is used to generate additional incremental power.

34 FREQUENTLY ASKED QUESTIONS 1. What is the lowest temperature possible at the outlet with carbon steel? The outlet gas temperature is determined by sulphur content in coal, acid dew point etc. Generally the target outlet temperature is DegC. The operation temperature of heating tubes shall be taken care with respect to acid dew point. In some cases heating tubes shall use Corten Steel either fully or partly.

35 2. Is the system installed in main duct or slip stream? What is the largest size in service for this application? Usually the system installed in main duct. Depending upon the layout it can be installed on a bypass also. At present the largest, LT Econmiser is in operation on a 600 MW unit, in China in main duct.

36 3. What is the effect on ID fan loading due to GHE s placed in the flue gas path? If LT Economiser is installed before ID fan, the flue gas impact on ID fan is: Flue gas temperature lower Flue gas volume less Draft loss of flue gas larger The new operation point shall be checked on ID fan performance curve. If LT Economiser is installed after ID fan, flue gas volume will not change and draft loss will become larger. Use of ID fan s existing head margin to kill the additional draft loss caused by LT Economiser is recommended.

37 4. For the improvements done in GHE to increase the heat duty, how much is increase in ID fan loading / system resistance in the flue gas path? The increase of ID fan loading will vary on case to case basis. It is determined by GHE parameters and ID fan parameters. The below table provides a reference Item Description Unit 600 MW 450 MW 300 MW GHE Thermal Duty KW Increase in power for ID KW Decrease in power for FGD KW

38 5. What is Heat Transfer Area / Pressure Drop (in GHE / associated duct), space requirement, overall size of installations? Heat transfer area is determined by project requirement. If the project wants to generate large quantity water and recover more flue gas waste heat, a large heating area is needed. Space and draft loss impact each other. If there is a large space left to install GHE, the gas velocity through economiser can be low, and the draft loss can be low. On the other hand, if the space is very little, the unit is designed very compact, and draft loss will be high. If the space is a constraint, the allowable draft loss will be very low and use of elliptical tube is recommended.

39 GREENS STEEL H CASE STUDY CASE SUMMARY IHI in Japan had an existing coal fired boiler that was under performing. IHI failed to meet customer guarantees. It was decided that if it was possible to improve the economiser performance the overall boiler efficiency would be increased The problem was there was no additional space to add extra heating surface in the chamber so Greens supplied a Steel H Retrofit Economiser Case Study 1

40 GREENS STEEL H CASE STUDY Case Study 1 Section of Plain Tube Economiser Section of Steel H Economiser

41 GREENS STEEL H CASE STUDY DETAILS PLAIN TUBE STEEL H Chamber Size wide x 5555 long x 1600 high No. of Tubes Rows 202 rows (22110mm) 202 rows (22205mm) High 16 rows (1483mm) 11.3 rows (1100mm) Gas Temp In o C Gas Temp Out o C Water Temp In o C 278 Case Study 1 Water Temp Out o C Duty KW

42 GREENS STEEL H CASE STUDY CONCLUSION The Steel H Unit provided a 45% increase in duty and at the same time an effective heating surface for use in boilers with high dust laden fuels. RESULT Case Study 1 IHI placed the order for a Steel H unit with Greens

43 GREENS STEEL H CASE STUDY Economiser Case Study 2 PEAT FUEL BFB BOILER WITH GREENS STEEL H ECONOMISER

44 GREENS STEEL H CASE STUDY CASE SUMMARY ESB Ireland wanted to know how a plain steel economiser would compare commercially and technically to a Steel H Economiser. The following is an extract from the presentation made by Greens. Case Study 2

45 GREENS STEEL H CASE STUDY REQUIRED PERFORMANCE DETAILS 274MW Peat Fired BFB Boiler. Maximum gas velocity 15 m/s. Economiser thermal duty 30.5MW Chamber Size 6100mm wide x 10700mm long. 643 tonnes/hr gas in at 422 C out 283 C. 336 tonnes/hr water in at 258 C and bar. Case Study 2

46 GREENS STEEL H CASE STUDY ARRANGEMENT P l a i n T u b e S t e e l H STEEL H v PLAIN TUBE Tube OD, mm Tube Effective Length, mm Tube pitch, h x v, mm Rows wide , x , x Case Study 2 Rows High Total economiser height, m

47 GREENS STEEL H CASE STUDY ARRANGEMENT P l a i n T u b e S t e e l H STEEL H v PLAIN TUBE Fin Pitch, mm Total tube used, m Total Heating Surface, m 2 Number of Banks N/A 66,525 8, ,508 12,042 2 Case Study 2 Weight Tonnes

48 GREENS STEEL H CASE STUDY CAPITAL COSTS ESTIMATE STEEL H v PLAIN TUBE Economiser Cost (Assembled Banks) Tube cleaning System Cost P l a i n T u b e S t e e l H Rs 6,97,00,000 (241%) Rs 28,50, off Rs 2,89,00,000 (100%) Rs 13,50, off Case Study 2

49 GREENS STEEL H CASE STUDY OPERATION P l a i n T u b e S t e e l H STEEL H v PLAIN TUBE Flue Gas Velocity, max m/s Pressure loss, gas side mm WG Feed water velocity avg, m/s Case Study 2 Pressure loss, water side, bar

50 GREENS STEEL H CASE STUDY FANS OPERATIONAL COSTS STEEL H v PLAIN TUBE Cost of operation assuming 15 years at 8600 hours and Rs 3.0 kwh Theoretical power required, kw (friction loss + static head) Associated fan absorbed power, assuming 80% efficiency, kw Cost of Operation P l a i n T u b e S t e e l H Rs 23,33,00, Rs 9,66,00,000 Case Study 2

51 GREENS STEEL H CASE STUDY PUMPS OPERATIONAL COSTS STEEL H v PLAIN TUBE Cost of operation assuming 15 years at 8600 hours and Rs 3.0 kwh Theoretical power required, kw (friction loss + static head) Associated feed pump absorbed power, assuming 70% efficiency, kw Cost of Operation P l a i n T u b e S t e e l H Rs 2,62,00, Rs 85,52,000 Case Study 2

52 GREENS STEEL H CASE STUDY TOTAL OPERATIONAL COSTS FANS PUMPS STEEL H v PLAIN TUBE Cost of operation assuming 15 years at 8600 hours and Rs 3.0 kwh TUBE CLEANING (STEAM) TOTAL OPERATIONAL COSTS P l a i n T u b e S t e e l H 23,33,00,000 9,66,00,000 2,62,00,000 85,52,000?? 25,95,00,000 10,51,52,000 Case Study 2 TOTAL OPERATIONAL SAVING WITH STEEL H 15,43,48,000 ANNUAL OPERATIONAL SAVING WITH STEEL H 1,02,89,000

53 CASE STUDY 3 1,000MW Coal Fired Boiler. 286 Coils at 110mm Horizontal pitch to match wall tubes. Chamber 4950mm wide with coils supported from wall. Maximum gas velocity 15 m/s. 1,960 T/h gas at 533 C in / 370 C out. 2,715 T/h water in at 296 C and 300 bar.

54 CASE STUDY 3 Plain Tube Spiral Fin Steel H Horizontal pitch (mm) Vertical pitch (mm) Tube o/d (mm) Rows wide Effective length (m) 4,810 4,050 4,050 Fin pitch (mm) Bare

55 CASE STUDY 3 Plain Tube Spiral Fin Steel H Velocity (m/s) Rows high Total tube used (m) 94,275 42,247 42,399 Heating Surface (m²) 15,046 18,323 24,580 Total Height (m) Number of banks Weight (tonnes) 1, Press Loss (mm WG) Economiser Cost (%) Supportable at ends Yes No Yes

56 In line tube arrangements offer lowest impact angles and minimum erosion. From the centre line of the tube the erosion rate increases to a maximum at about 30º. Then decreases rapidly as angle approaches 0º. Staggered In-line Wear Rate mg kg

57 GREENS DESIGN EXPERTISE Tube protected while fins can collect heat. Minimum loss of heating surface. Stainless Steel notched and formed to suit the tube. Held in place by wrap around the tube. Erosion Protection

58 Boiler electrical output 350MW Fuel: Coal Commissioned May1997 Inspection carried out in April Photograph taken looking down Through tube in direction of gas flow.

59 6 Boilers each 660MWe. Owned by National Power Plc, UK Fired by coal with 17.5% ash. First Unit on line ECONOMISER Underside of Economiser during Installation.

60 Unit #3 Boiler commissioned in 1974 Inspected 31st May No cleaning before inspection. All gas passages clear of fouling. No ash accumulations. Recorded on the 25th July Unit #1 158,206 hours. Unit #2 164,888 hours. Unit #3 161,877 hours. Unit #4 109,535 hours. Unit #5 103,863 hours. Unit #6 99,301 hours.

61 GREENS APPLICATIONS FOR STEEL H Coal Lignite Heavy Oil Orimulsion Garbage or Refuse (EFW) Bio Fuels (Rice husks/ Bagasse/Wood Straw) Waste Heat Recovery (Cement, Coke) Pulverised Fuels Bubbling Fluidised Bed Circulating Fluidised Bed Incineration 500MW Boiler after firing With Orimulsion. Fuel & Combustion

62 GREENS ECONOMISERS Recovery of Waste Heat from boiler & process flue gas streams in the Power Generation, Refining, Chemical, Process and general industries. Individually designed to client's requirements Wide Variety of Fuels/Combustion Power Station Economisers Greens Economisers operate with large utility super critical power boilers, ranging from 100 MW 1100 MW. Industrial Economisers Greens Industrial Economisers are designed to operate with both shell package type and water tube boilers. The economic range starts at 5 Tonne/Hour.

63 Contact us: Thank You

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