Observation and

classification of the fouling

mechanism in rotary
air-heaters
Presenter: Vanessa Mathebula
Academic Mentor: Prof Walter Schmitz
Industrial Mentor: Dr. Chris van Alphen and Mike Lander
Date: 05 May 2014
Eskom Power Plant Engineering Institute
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Acknowledgement
This research was conducted
through the Eskom Power Plant
Engineering Institute (EPPEI)
Eskom Specialisation Centre for
Combustion Engineering at
The University of the Witwatersrand
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Overview
Introduction
Problem Statement
Objectives
Investigational Method
Analyses Procedures and Results
Conclusion
(Shah and Sekuli, 2003)
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Introduction
Air-heaters are heat
exchangers used in
fossil-fuelled power
stations to heat up boiler
air.
Improves the boiler
efficiency and the plant
efficiency.
Recuperative and
Regenerative
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Introduction
Ljungstrm and Rothemhle air-
heaters
Rotors of the Ljungstrm and
Rothemhle twin-flow air-heaters
are similar
Corrugated closed channel steel
plates (elements) packed closely
together in each basket
On load cleaning of passages
between the elements is conducted
using steam sootblowing equipment
Steam supply nozzles on top and
bottom of rotor, on gas side
Off load cleaning conducted using
high pressure water washing
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EPRI, 1998
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Introduction
Fouling occurs as a result of a
build-up of ash particles and other
deposits in the passages of the air-
heater elements
Hot end fouling/plugging:
Caused by boiler conditions such as
incombustibles and coarse debris.
This is sometimes called plugging.
Cold end fouling
Closely related to the condensation of
sulphuric acid at temperatures below
the dew point (Raask, 1985).
AD: acid deposition
T
AD
: acid dewpoint temperature
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Redrawn from Raask, 1985
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Problem Statement
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Fouling and blockage of air-heaters is
experienced
This results in an increase in the pressure
drop across the air heater.
More power is required from the induced
draft fan.
Severely fouled air-heater element packs
have a negative impact on the boiler
efficiency, due to reduced heat transfer
Difficult to clean elements with hardened
deposits
In extreme cases complete replacement
of air-heater elements is required, which
costs millions for each unit.
Matimba
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Objectives
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Identify the mechanism and extend of cold end fouling in the air-
heaters.
A qualitative observation of the fouling distribution across the air-
heater rotor.
An inlet design verification of the velocity profile of the flue gas and air
in the air-heater inlet duct in order to determine its effect on the
temperature distribution in the air-heater rotor and that of the gases
flowing in it.
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Investigational Method
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Qualitative
observation of fouling
distribution at cold end
Determine the mineralogical
composition of the samples
QEMSCAN analyser
(2m lateral resolution)
RAMAN Spectrometer
(1m lateral resolution)
Compare results and location
where samples were taken to
the Qualitative observation
Take ash deposit
samples
Access to the air-heater
matrix
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Investigational Method
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Collect coal analysis
results of Power Station
coal
Determine the flue gas
composition
Determine the dew point
temperatures of H
2
SO
4
and H
2
SO
3
Conduct a sensitivity study of
the dew point temperatures to
changes in coal component
ratios
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Investigational Method
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RAH simulation inputs for Eskoms
Rothemhle twin-flow air-heater
Velocity profile of the air and flue gas
flow into the air-heater, from
Aerotherms (2012) CFD results
Air-heater matrix
dimensions
Run simulation for mal-distribution and
uniform velocity distribution case
Compare primary and
secondary section plate
temperature distribution
results
Compare mal-distribution
results to the uniform
distribution results
Use dew point temperature
results to determine where
condensation of H
2
SO
4
and
H
2
SO
3
would occur
Compare with the
Qualitative observation
Station operating data
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Analysis procedures,
results and discussion
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Qualitative observation and air-heater deposits
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1
3
2
4
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QEMSCAN
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AlSi-sulphate, kaolinite, cenospheres and Al(Si)-sulphate were the
four most dominating minerals/phases
(Van Alphen, 2013)
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Raman
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Filters
Mirrors
Monochromator
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Formation of H
2
SO
4
and H
2
SO
3
1% to 5% of the SO
2
in the flue gas will be converted to SO
3
(Ganapathy, 1989).
1. SO
2
+ O
2
SO
3
(in the flame)
2. SO
2
+ Catalyst (Vanadium pentoxide and iron oxide) SO
3
+ catalyst product
(low temperature zone between 602 C to 752 C)
SO
3
+ H
2
O H
2
SO
4
(below 350 C)
Condensation of the water vapour in the flue gas takes place at temperatures below
the water dew point.
H
2
O + SO
2
H
2
SO
3
Raask (1985) stated that the concentrated solution of H
2
SO
4
would combine with
alkaline ash and a reaction would occur with the air-heater element surface.
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What does that mean?
The fly ash may have adhered to the H
2
SO
4
that condensed, out of the
flue gas, onto the air-heater plates.
Then reacted with some fly ash components or fuel oil char to form the
fouling phases/minerals.
The mixture may have dried up when exposed to higher temperatures.
Quartz and cenospheres would have added to the hardness of the fly
ash deposits.
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Acid dew point calculations and sensitivity for
Duvha coal
From Ganapathy (1989) and Niessen (2002)
Sulphurous acid (H
2
SO
3
):
1000/

3.9526 0.1863 ln

0.000867 ln

0.000913 ln

ln

Sulphuric acid (H
2
SO
4
):
1000/

2.276 0.0294 ln

0.0858 ln

0.0062 ln

ln

Ganapathy (1989) stated that the calculated dew point temperature for
sulphurous acid was lower by 6K and that of sulphuric acid was lower by
9K than published data.
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Acid dew point calculations and sensitivity for
Duvha coal
Sensitivity
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Component Change in mass %
Change in dew point
H
2
SO
4
[C]
Change in dew point
H
2
SO
3
[C]
Sulphur 0.2 2 0.01
Hydrogen 0.41 0.5 1.33
Total Moisture 0.8 0.15 0.34
Water Vapour 0.8 1.5 2.00
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Even versus mal-distribution (plate temps from
RAH)
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Even versus mal-distribution (plate temps from
RAH)
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0
20
40
60
80
100
120
140
160
180
200
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
T
e
m
p
e
r
a
t
u
r
e

(

C
)
Rotation Angle (Degrees)
Annular Division 1 Third Layer and Cold End Plate Temperatures
Uniform third layer inlet
Non-uniform third layer inlet
Uniform third layer outlet (cold end inlet)
Non-uniform third layer outlet (cold end
inlet)
Uniform cold end outlet
Non-uniform cold end outlet
300mm - 16.7%
600mm - 33.3%
600mm - 33.3%
300mm - 16.7%
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RAH simulation for Duvha
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0
20
40
60
80
100
120
140
160
180
200
220
240
260
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
T
e
m
p
e
r
a
t
u
r
e

(

C
)
Rotation angle (Degrees)
Average Primary and Secondary Plate Temperatures
Secondary third layer inlet
primary third layer inlet
Secondary third layer outlet (cold end
inlet)
Primary third layer outlet (cold end
inlet)
Secondary cold end outlet
Primary cold end outlet
143.15 C
It was determined that approximately 35.8% of the rotor volume percentage
would be exposed to temperatures below the dew point of H
2
SO
4
Un-even
300mm - 16.7%
600mm - 33.3%
600mm - 33.3%
300mm - 16.7%
Conclusion
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Conclusion
The qualitative observation at the cold end of a twin-flow Rothemhle
air-heater showed that the primary section was more blocked than the
secondary section.
The QEMSCAN and RAMAN results of the air-heater deposits showed
that AlSi-sulphate, kaolinite, cenospheres and Al(Si)-sulphate were
the four most dominating minerals/phases.
Using RAH simulation model, the plate temperatures of the primary
section were observed to be lower than those of the secondary
section.
It was determined that approximately 35.8% and 25.3% of the rotor
volume percentage would be exposed to temperatures below the dew
point of H
2
SO
4
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Conclusion
Therefore, soot blowing would not be effective for hardened deposition
able to dislodge the solid from the air-heater plates.
RAH is a very useful tool
And CFD as well
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Thank you