US20110005706A1 - Method for Online Cleaning of Air Preheaters - Google Patents

Method for Online Cleaning of Air Preheaters Download PDF

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Publication number
US20110005706A1
US20110005706A1 US12/499,314 US49931409A US2011005706A1 US 20110005706 A1 US20110005706 A1 US 20110005706A1 US 49931409 A US49931409 A US 49931409A US 2011005706 A1 US2011005706 A1 US 2011005706A1
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United States
Prior art keywords
rotor
passageways
soot
soot blower
depth
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US12/499,314
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English (en)
Inventor
Scott Thomas
Charles A. Lockert
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Breen Energy Solutions LLC
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Breen Energy Solutions LLC
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Filing date
Publication date
Application filed by Breen Energy Solutions LLC filed Critical Breen Energy Solutions LLC
Priority to US12/499,314 priority Critical patent/US20110005706A1/en
Assigned to BREEN ENERGY SOLUTIONS reassignment BREEN ENERGY SOLUTIONS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THOMAS, SCOTT, LOCKERT, CHARLES A.
Priority to CN2010101802478A priority patent/CN101947527A/zh
Priority to JP2010107894A priority patent/JP2011017524A/ja
Priority to EP10007034.1A priority patent/EP2287550A3/en
Publication of US20110005706A1 publication Critical patent/US20110005706A1/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28G—CLEANING OF INTERNAL OR EXTERNAL SURFACES OF HEAT-EXCHANGE OR HEAT-TRANSFER CONDUITS, e.g. WATER TUBES OR BOILERS
    • F28G1/00—Non-rotary, e.g. reciprocated, appliances
    • F28G1/16—Non-rotary, e.g. reciprocated, appliances using jets of fluid for removing debris
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D19/00—Regenerative heat-exchange apparatus in which the intermediate heat-transfer medium or body is moved successively into contact with each heat-exchange medium
    • F28D19/04—Regenerative heat-exchange apparatus in which the intermediate heat-transfer medium or body is moved successively into contact with each heat-exchange medium using rigid bodies, e.g. mounted on a movable carrier
    • F28D19/041—Regenerative heat-exchange apparatus in which the intermediate heat-transfer medium or body is moved successively into contact with each heat-exchange medium using rigid bodies, e.g. mounted on a movable carrier with axial flow through the intermediate heat-transfer medium
    • F28D19/042—Rotors; Assemblies of heat absorbing masses
    • F28D19/044—Rotors; Assemblies of heat absorbing masses shaped in sector form, e.g. with baskets
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28G—CLEANING OF INTERNAL OR EXTERNAL SURFACES OF HEAT-EXCHANGE OR HEAT-TRANSFER CONDUITS, e.g. WATER TUBES OR BOILERS
    • F28G15/00—Details
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28G—CLEANING OF INTERNAL OR EXTERNAL SURFACES OF HEAT-EXCHANGE OR HEAT-TRANSFER CONDUITS, e.g. WATER TUBES OR BOILERS
    • F28G9/00—Cleaning by flushing or washing, e.g. with chemical solvents
    • F28G9/005—Cleaning by flushing or washing, e.g. with chemical solvents of regenerative heat exchanger

Definitions

  • the present invention is directed toward a method for cleaning rotating regenerative air heaters used in coal-fired electricity generating plants.
  • One such preheating technique employs a Ljungstrom air preheater.
  • This air preheater has two side-by-side ducts with flue gas flowing through one duct while an inflow of combustion air is passed through the other duct, the two gas flows being in opposite directions.
  • a rotor is positioned to rotate through both ducts about an axis between the two ducts, transferring heat from the flue gas to the combustion air.
  • Air preheaters are normally operated at sufficiently high temperatures to inhibit condensation inside the heat exchanger of pollutants such as sulfuric acid vapor present in the flue gas.
  • the outlet flue gas temperature is maintained at least above 300 degrees F (149 degrees C), and as high as 350 degrees F (177 degrees C). At these temperatures, aerosol condensation of gaseous sulfuric acid and the associated corrosive effects on the preheater are minimized.
  • Sootblowers for cleaning air heaters are generally of the “retractable” style or the “swing-arm” style. Advantages and disadvantages are found in both styles.
  • Swing arm style soot blowers for cleaning rotary regenerative air preheaters employ a swing-arm mounted for rotation through a set angle or arc with one or more nozzles at the end that blow the soot blowing medium (steam, air or water) onto the rotor as the rotor turns and as the swing-arm rotates through the arc.
  • the soot blower is normally mounted on the cold end of the rotor which is the outlet end for the flue gas.
  • soot blowers typically employ a drive mechanism which includes a worm gear and a worm wheel or chain drive which rotates a lever throw arm.
  • a connecting link attaches the lever throw arm to a lever attached to the soot blower arm mounting plate.
  • This linkage arrangement causes the lever and the soot blower mounting plate to reciprocate back and forth through an arc.
  • This type of mechanism is disclosed in U.S. Pat. No. 6,065,528 to Fierle et al.
  • the swing-arm soot blower constantly changes speed or angular velocity as it sweeps across the rotor. At the beginning and end of its sweep, the velocity is zero with the maximum velocity being at the center of the sweep.
  • Retractable style sootblowers have found more common application in recent years due to their similarity to sootblowers used in other portions of the furnace and due to an improved ability to control their position in the cleaning process.
  • Retractable sootblowers consist of two concentric tubes, one fixed in position and attached to a media source (air, steam, water, etc.) and the other capable of controlled movement into and out of the boiler ducts laterally along the same axis as the fixed tube.
  • a packing material is placed between the inside surface of the outer tube and the outside surface of the inner tube at a the end of the movable tube closest to the media supply line.
  • the end of the inner tube not connected to the cleaning media is open.
  • the end of the outer tube furthest from the cleaning media line is enclosed by a rounded cap containing one or more outlet holes (or nozzles).
  • Cleaning media is introduced into the stationary tube from the media source line through a device called a popet valve.
  • the valve When the valve is opened, the cleaning media is introduced under pressure into the inside of the fixed tube allowing it to travel out the open outer end and into the volume of the outer tube.
  • the packing material prohibits the media from exiting the assembly at the joining point and forces all of the media to travel the length of the outer tube to exit through the cleaning nozzle at the far end of the movable tube.
  • ammonia slippage is essentially a function of the required degree of removal of nitrogen oxide, of the activity of the catalyst, and of the quality of mixing of the injected ammonia with the flue gas. It is also important for the flow through the reactor to be uniform by means of an even flue gas velocity at all locations of the reactor cross section and for it to be possible for all the catalytic converter material to be reached without obstacle.
  • ammonia slippage may occur distributed unevenly across the cross-section of the reactor.
  • ammonia slippage amounts to only a few ppm.
  • levels which are a multiple of this average may occur. This ammonia as well as sulfuric acid vapor will be contained in the flue gas entering the air preheater.
  • the temperature of the flue gas entering the air preheater is typically in the range of 600 to 750 degrees F (315 to 371 degrees C).
  • the sulfur oxides react with the ammonia from the ammonia slippage in accordance with the following equation: NH 3 +H 2 O +SO 3 ⁇ NH 4 HSO 4 , i.e., to form ammonium bisulfate, or according to the equation: 2NH 3 +SO 3 +H 2 O ⁇ (NH 4 ) 2 SO 4 , i.e., to form ammonium sulfate.
  • the gas cools to the range of 230 to 350 degrees F (110 to 177 degrees C).
  • degrees F 110 to 177 degrees C.
  • ammonium bisulfate in addition to sulfuric acid, condenses as a sticky liquid on the air preheater baskets.
  • ammonium bisulfate is so sticky, it captures ash particles and rapidly plugs the gas passages of the device. These deposits may also cause corrosion. Hitherto, this problem has been counteracted by limiting the ammonia slippage to less than 5 ppm, and in some installations even to less than 2 ppm. This entails a correspondingly high outlay for the required catalytic reactor volume. Nevertheless, it is impossible to rule out the possibility of a higher level of ammonia slippage than the mean occurring at some locations over the reactor cross section. Therefore, in some cases a relatively high—even excessively high—ammonia concentration may occur, so that the air preheater is damaged in this area by the above-mentioned processes.
  • Soot blowers as mentioned above are seldom effective in removing ammonium bisulfate deposits.
  • the deposits typically occur in the middle sections of the rotor where soot blower energy has dissipated before the deposit can be reached.
  • the presence of deposits is evidenced by an increased pressure drop across the air preheater on both the air and the gas sides. When this occurs, the power generating unit must be shut down and the air preheater washed with high-pressure water.
  • the present invention is directed toward a method of cleaning those sticky deposits, including ammonium bisulfate, sulfuric acid and other materials, from a rotary air preheater without shutting down the steam generating system. Further, this method can be used to mitigate the accumulation of deposits to the point of pluggage by changing the operating strategy of conventional soot blowers.
  • This method is particularly effective when used with the type of rotary air preheater shown in FIG. 1 .
  • This type of preheater has a heat exchange rotor containing adjacent passageways through which air and flue gas are directed and which is rotated about an axis.
  • a soot blower is capable of being positioned adjacent any selected depth from the outer circumference of the rotor such that a soot blowing medium can be blown from the soot blower into passageways at the selected depth as the rotor is rotated.
  • the rotor In a conventional preheater the rotor is rotated at a constant angular velocity.
  • the angular velocity of the rotor is changed during soot blowing according to the depth of the soot blower nozzle from the outer circumference of the rotor. Specifically the angular velocity is adjusted so that all of the passageways pass over the soot blower at the same or substantially the same tangential velocity.
  • FIG. 1 is a perspective view showing the general arrangement of one type of air preheater with which the present invention may be used.
  • FIG. 2 is diagram of the air preheater and soot blower arrangement of FIG. 1 showing the motors and controller required to practice the present invention.
  • FIG. 3 is a graph showing the pressure drop ( ⁇ P) across the air preheater on the air side and gas side before, during and after cleaning using high pressure water media.
  • FIG. 4 is a perspective view showing the general arrangement of a second type of air preheater with which the present invention may be used.
  • FIG. 1 is a perspective view of a typical air preheater in which flue gas travels in a vertical, up or down direction and is intended to illustrate one type of air preheater in which the present invention is used.
  • the present invention may be applied to horizontal, vertical (cold end on the top) and vertical inverted (cold end on the bottom) air preheaters.
  • FIG. 1 depicts a vertical air preheater with the cold end on the bottom.
  • the air preheater comprises a rotor housing 12 in which is mounted the heat exchange rotor 14 .
  • the rotor is mounted for rotation on the shaft 16 which extends between the upper center section 18 and the lower center section 20 .
  • the rotor is divided into sectors or passageways 22 by the diaphragm plates 24 and heat exchange baskets 26 are stacked into these sectors 22 .
  • the transition duct assemblies Located at the top and bottom of the air preheater and attached to the rotor housing 12 and to the top and bottom center sections 18 and 20 , are the transition duct assemblies identified as 28 , 30 , 32 and 34 .
  • These transition duct assemblies attach the air preheater to the ducting for the air supply to and the flue gas from a steam generator or other combustion equipment.
  • the flue gas may enter the air preheater through transition duct 28 , transfer the heat to the revolving rotor 14 , and exit through transition duct 30 .
  • the combustion air enters through transition duct 32 , picks up the heat from the rotor 14 and exits through transition duct 34 .
  • These transition ducts are constructed to make the transition between the generally circular air preheater and the rectangular power plant ducts.
  • soot blowers there are two soot blowers, one located on the top (or hot end) of the air heater and the other located at the bottom (or cold end) as shown on FIG. 1 . If only one soot blower is used the soot blower is normally located at the cold end (the lower end of FIG. 1 ) because most of the deposits occur at the cold end (exit of the flue gas).
  • the air preheater rotates in the range of 3 ⁇ 4 to 4.0 revolutions per minute (RPM).
  • RPM revolutions per minute
  • the current invention allows complete cleaning regardless of the nature of the deposits.
  • the soot blower is fully inserted to the middle of the rotor with the air preheater rotating at its normal speed. Then the soot blower is retracted in a stepwise fashion. Each step can be any convenient measure, but the greatest success has been achieved with steps of 15 to 60 millimeters.
  • the air preheater rotor RPM is adjusted such that the tangential velocity of the portion of the rotor which passes over the end of the soot blower is constant.
  • the sootblower steps (or indexes) to another location, stops, rotor speed is adjusted to match the new insertion depth and a complete rotor cycle is executed.
  • Complete cleaning at any step may be evidenced by the high pressure spray from the bottom penetrating all the way to the top of the air heater when high pressure water is used as the cleaning media.
  • the size of each step should be chosen according to visual observation or other means.
  • a variable speed drive motor 40 controls rotor RPM and is programmed through the use of a controller 48 to automatically set the rotor RPM in proportion to the soot blower insertion distance.
  • the controls would also specify a minimum RPM (typically 0.2 to 0.5 RPM) to prevent stalling the motor that drives the RPM.
  • the minimum RPM can be different for each air heater, depending on whether it is rotating vertically or horizontally, the style and effectiveness of the support bearings and on the tightness in the sealing mechanisms.
  • the controller may also control the motors 43 , 44 that advance and retract the soot blowers and may control the blower motor 46 .
  • soot blowers top and bottom
  • bottom soot blower is needed when applying this method.
  • Using only the bottom soot blower saves considerable cleaning time and also causes less wear and tear on the hot end basket material. In this manner the number of daily cleans has been shown to be reduced from 4 times per day to 1 or 2 times per day.
  • the benefits of the method are shown in the following example.
  • the air preheater at a North Carolina electric generating station had fouled with ammonium bisulfate deposits to a point where the steam media blowers could not maintain acceptable pressure drop ( ⁇ P) across the rotor.
  • the boiler had to be removed from service every few months to water-wash the air preheaters.
  • the hot end (top section) of these air preheaters is 29-inches thick, while the cold end (bottom section) is 41-inches thick. There are 10-inches of spacing above and below these sections where the soot blowers operate.
  • the power station has two air preheaters of the same size and construction that operate under substantially the same conditions.
  • One preheater was cleaned using the present method while the other preheater was not cleaned.
  • the rotor in the air preheater that was cleaned was modified to permit changes in the rotational speed of the rotor as directed by a controller.
  • a soot blower was positioned opposite the innermost ring of passageways or sectors in the rotor and was activated to blow steam through the passageways as they moved over the soot blower. At this time, each rotor was turning at normal operating speed. The soot blower was then moved in step-wise fashion toward the outer ring of sectors or passageways.
  • the speed of the rotor was slowed such that the angular velocity of the sectors was the same as the angular velocity of the sectors in the innermost depth when the process began.
  • the rotor speed was increased back to the normal operating speed at which the process began. Throughout the process the power station continued to operate normally.
  • the speed of the rotor was 1.5 RPM when the process began and 0.33 RPM when the last ring was cleaned. The cleaning process took between 3 and 4 hours.
  • FIG. 3 shows the pressure drop ( ⁇ P) across the air preheater on the air and gas sides before, during and after cleaning using high pressure water media. Steady operation with partially fouled air heaters is shown on the left side of this figure on Feb. 22, 2008. The air preheater was cleaned on line using this method twice during the period beginning on February 22 and ending on Feb. 24, 2008. During cleaning the boiler output was reduced which reduced the air flow through the preheaters.
  • the present method does not require cleaning of every sector. For some installations it may be satisfactory to clean some but not all sectors in one pass of the soot blower. Then in another pass or at another time other sectors or passageways can be cleaned. Indeed, there may be some preheaters in which certain passageways are rarely or never cleaned.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
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US12/499,314 2009-07-08 2009-07-08 Method for Online Cleaning of Air Preheaters Abandoned US20110005706A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US12/499,314 US20110005706A1 (en) 2009-07-08 2009-07-08 Method for Online Cleaning of Air Preheaters
CN2010101802478A CN101947527A (zh) 2009-07-08 2010-05-10 不停机清洁空气预热器的方法
JP2010107894A JP2011017524A (ja) 2009-07-08 2010-05-10 空気予熱器を作動状態で清掃する方法
EP10007034.1A EP2287550A3 (en) 2009-07-08 2010-07-07 Method for online cleaning of air preheaters

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US12/499,314 US20110005706A1 (en) 2009-07-08 2009-07-08 Method for Online Cleaning of Air Preheaters

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CN104634149A (zh) * 2015-02-04 2015-05-20 马军 带自动清洗功能的从废热空气中回收热量的换热器
US20150198392A1 (en) * 2014-01-13 2015-07-16 Alstom Technology Ltd Heat exchnager effluent collector
EP3076119A4 (en) * 2013-11-25 2017-09-06 Hong, Wonbang Complex cleaning system for heat exchanger
EP3249342A1 (de) * 2016-05-27 2017-11-29 Balcke-Dürr GmbH Luftvorwärmeinrichtung, insbesondere für eine müllverbrennungsanlage, müllverbrennungsanlage, verfahren zum reinigen einer luftvorwärmeinrichtung sowie verfahren zum betrieb einer müllverbrennungsanlage
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US20220349664A1 (en) * 2019-07-26 2022-11-03 Geesco Co., Ltd. Heat exchanger cleaning system and heat exchanger cleaning method

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