GLOBAL STRENGTH

LOCAL FOCUS
LJUNGSTRM
AIR PREHEATERS

Alstom is the global leader in the design,

manufacturing, installation and maintenance
of Ljungstrm Air Preheaters. We are proud
to be the owner of Ljungstrm air preheater
technology with its pedigree dating back
to the 1920s when the first efficient air preheater
was invented in Sweden by Frederick Ljungstrm.
Today, Alstom owns Ljungstrm patents
and trademarks across the world and the
group also combines the resources of industry
leading names SRM, Air Preheater Company,
Kraftanlagen, Gadellius, Stein, PBS and APEL.
Alstom Ljungstrm Air Preheaters
are recognized by boiler companies, utilities
and manufacturers around the world as the best
products of their type which is why they are more
widely used than any other type of heat exchanger.

Unrivalled expertise
in air preheaters
Modular design. Maximum flexibility

The modular design concept behind Alstom Ljungstrm Air

Preheaters is a simple one. Create a family of air preheaters
based on the same general platform and incorporating the latest
best in-class technologies but which, individually, are tailored to
fit a wide variety of different power plants.
Our extensive portfolio of products includes preheaters
for sub-critical, super-critical, ultra-supercritical and CFB
boilers. All, though, are installed in the same way, with an
optimised erection sequence that uses simple structures
and the minimum number of assemblies.

Up to the largest sizes

We recognise that thermal power plants are becoming

increasingly large. The design flexibility built into our preheaters
and, in particular, the wide range of sizes we offer means that
we have already been able to meet the requirements of some
of the largest plants currently being constructed.

Higher efficiency. Lower costs

Our air preheaters can recover up to 15% of boiler heat input,

contributing up to 20% of the overall boiler efficiency while
representing only 2% of total investment in a typical plant.
The impressive performance of our air preheaters is, in part,
the result of our unmatched experience in global boiler projects,
so we appreciate that high thermal efficiency, leakage reduction
and low pressure drop are all essential to their operation.
Consequently, with our preheaters, we offer adaptable sealing
systems giving a wide range of options to reduce leakage
including load following leakage control.

Quality

Our commitment to quality is at the heart of our business.

Our customers know they are receiving the very best
products available.

03

Advanced modular
Make our air

Proven design with customisable options

Ljungstrm Air Preheaters have a reputation for rugged reliability and efficient operation that stretches back to the middle
of the 20th century. Our current family of products are modular in concept so flexibility is built into their design. This means
we can offer a wide range of standardised options when it comes to their construction and installation on site.

Customer benefits
FLEXIBLE ROTOR DESIGN OPTIONS
Centre or peripheral support arrangements
Sizes to meet all preheat requirements
for industrial and utility-sized boilers
Bi-sector, tri-sector and quad-sector arrangements

EFFICIENT SEALING SYSTEMS

Comprehensive options to reduce leakage
Load following leakage control systems
Delivering unique benefits during hot and cold commissioning

ADVANCED TRANSFER SURFACES AND BASKETS

Highest efficiency for lowest pressure drop
Range of profiles that provide easier cleaning
and maintenance during operation
Extended life due to lower soot blowing pressures

REDUCED ERECTION COSTS

Optimised erection sequence with minimum number

of assemblies
Alternative welded and pinned rotor options available
REDUCED MAINTENANCE COSTS
Robust drive configurations
Low maintenance auxiliary systems
Substantial, long-lasting and durable equipment

A 20-30C recovery rate in the Ljungstrm Air Preheater accounts for

1-1.5% reduction in the fuel requirements of the boiler. When installed on two
750 MW coal-fired boilers, the energy saved by the Ljungstrm Air Preheater
is the equivalent of 42 hopper car loads of coal per day
04

engineering

preheaters first choice worldwide

Air preheaters for every application
No other air preheater supplier can match our vast experience of designing equipment for such a wide range of installations
around the world. With our range of versatile modular design platforms and configurations, we are able to meet the many
different requirements our customers have.

Duct and support configurations

The correct selection of duct arrangements is critical to modern

boiler layouts. We recognise this and produce our equipment
in configurations to meet all requirements. Our equipment
can be supplied in bi-sector, tri-sector and quad-sector
arrangements for either a traditional peripheral support
arrangement or for centre column support.

Modular site assembly

Our comprehensive understanding of the requirements of site

construction activities directly influences the modular design
of our air preheaters which incorporates optimised, flexible
assembly. As a result, depending on model size and type and the
available lift capacity on site, we can tailor production to include
efficient partial ground assembly of the units we supply.

05

The rotor

Any configuration,

Design flexibility means greater customer choice

This is particularly true with the heart of our Ljungstrm Air Preheaters the rotor. The Alstom range boasts:

The largest number of rotor sizes of any supplier

Two alternative types of construction
Several different configurations of basket loading
Arrangements from one to four layers of heat transfer baskets
Welded rotor designs use a welded connection between the rotor shaft
and the structural plate work of the rotor
Site assembly requires considerable welding of critical joints
Connection method is the industry standard, due to its low cost
Rotors of this arrangement are built and then loaded with the element baskets

Our unique pinned module designs incorporate a patented arrangement

of pre-built rotor modules connecting to a special rotor shaft
The designs increase the life of the rotor by eliminating the thermal stresses

that occur in welded rotor designs at the point where the main plates are welded
to the rotor shaft
Rotor modules can be pre-loaded with element baskets prior to connection
to the shaft, meaning less time loading baskets at a later stage
Site erection can be completed in less time and critical shaft to rotor welds
are avoided

06

assembly

anywhere in the world

Our experience and knowledge of different rotor designs has helped to establish us
as the leading innovator in rotating air preheater technology

OPTION

BENEFIT / ADVANTAGE

Basic welded rotor

Lowest equipment cost

Modular rotor

Optimised erection with minimised welding and reduced handling

Double sealed rotor

Reduced air to gas direct leakage

Grating style rotor

Changeable baskets without disturbing adjacent layers

ALSTOM PIONEERED the use of special fixtures in our factories

which allow us to build our modular rotor components to the highest
levels of quality and repeatability

07

At the forefront

Delivering long life,

Advanced heating surfaces

We take pride in our long and diversified experience in the design and manufacture of high quality heating elements and are at
the cutting edge of new surface development. Our engineers continue to develop new advanced surface technologies in a range
of materials, thicknesses and depths to meet our global customer requirements. We are able to furnish heating elements that are
optimised for the best heat recovery and lowest pressure drop while remaining compatible with the fuel being fired.

High performance and durability

Correct surface configuration, material, and thickness, are integral to the thermal and
pressure drop performance of any regenerative heat exchanger. Surfaces developed and
optimised by Alstom engineers assure the highest performance and durability available.
Our comprehensive range also allows us to provide aftermarket replacements for older
surface types and, by installing our latest surfaces which are more efficient and remain
cleaner when in operation, deliver efficient upgrade solutions.

Materials and quality

We offer a range of surface and container materials to accommodate all customer

requirements. Our global experience with mild steel, low alloy steel and premium
enameled heating surfaces is unrivalled in our industry. Advanced quality control checks
and processes ensure that the heating element products manufactured at any
of our global facilities perform to our exceptional performance and life standards.

08

of air preheater technology

efficiency and low maintenance

The enameled heat transfer surfaces supplied by Alstom incorporate the latest
wet-coated application processes and technology, to provide products with industry
leading enamel structure, thermal shock durability, cracking resistance and life

Advanced auxiliary equipment and systems

Our air preheaters incorporate systems and equipment that are proven in the field and accepted by customers as the best in their
class. We are continuously improving our auxiliary equipment and system options to provide the latest technology and configurations
while maintaining the robust reliability in operation that is the hallmark of the Ljungstrm Air Preheater.

Efficient sealing systems

As air preheaters get larger the use of sealing systems is increasingly important to
ensure low leakage operation. We offer a range of sealing system options delivering the
lowest air-to-gas leakage while still maintaining the flexibility to operate across a range
of loads. Low maintenance systems are available to provide either full self-adjustment
of the sealing plates or multi-position adjustment across a specified range of load
points.

Bearings and drive systems

The bearing and drive systems incorporated into our air preheaters are the most reliable
and durable designs in our industry and contribute to our air preheaters reputation for
being problem free (with an impressive 99% availability).

09

We are where our

Offices and manufacturing

Europe

North America
Concordia (USA)

Mannheim (Germany)
Wellsville (USA)

Brno (Czech Republic)

India
Delhi (India)

East Asia

Osaka (Japan)

Kobe (Japan)
Shanghai (China)

Shahabad (India)

Latin America
Vinhedo (Brazil)

Aftermarket services

Our involvement with you does not end with the successful installation of one of our air preheaters. Were committed to our
customers and offer additional added-value services. To provide life extension and plant upgrades, we support all existing
installations with our genuine replacement parts in addition to component or system upgrades. Our aftermarket solutions provide
operators of both Alstom and other OEM equipment with valuable benefits in the areas of thermal efficiency, leakage reduction,
fuel compatibility and SCR retrofit upgrades.

Supply of genuine replacement parts with warranty support

Equipment inspections, condition assessments and life evaluations
Components upgrades for Alstom as well as other air preheater designs
Engineering studies for plant upgrades
10

customers need us

facilities across the world

We combine rigorous research and development with a comprehensive global

after-sales service to ensure our equipment operates efficiently and cost-effectively
in the long-term

Field service

Across the globe we maintain

a highly experienced staff of technical
service specialists and engineers
who are available 365 days a year to
help ensure the efficient and reliable
operation of your Ljungstrm Air
Preheaters. They can assist with outage
planning, inspection, and diagnostic
services and provide technical
assistance for routine and emergency
maintenance planning and repair.

Laboratory testing

In our laboratories, we use a range of

specialised equipment and procedures
to ensure the quality and durability of
our preheating products. We maintain
metallurgical testing facilities to
maintain our excellence in areas such
as heating element deposit & corrosion
analysis and failure root cause
analysis. Our dedicated soot blowing
test rig enables us to test surfaces for
cleanability as well as operation under
adverse conditions and our state
of the art switching regenerator
provides the platform for us to conduct
long-term tests of heat transfer
surfaces subjected to a spectrum
of thermal, environmental and
mechanical conditions.

Research and development

Research and development is key to

our technological leadership and our
programmes are always adapting to
meet the current and future needs of
the industry. Our competencies include
heat transfer surface computational
fluid dynamics (CFD) modeling,
prototyping, production and physical
testing using multiple sized wind
tunnels. We conduct advanced research
in air preheater fouling and cold end
corrosion and we are constantly
improving our understanding of air
preheater rotor thermal and fatigue
analysis using the latest techniques
in finite element analysis (FEA). We
are proud to claim that none of our
competitors can match our investment
and capabilities in these fields.

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Global leadership
Some of our

Percentage of installations of Alstom designed air preheaters (including licensee installations)

Europe

66%

USA

98%

China

India

MEA

70%
Global Alstom air preheater design
installations (including licensees)

75%

Japan

99%

90%

LAM

75%

With 90 years of air preheater experience, we have supplied thousands of air preheaters
for power generation and industrial applications globally.
We combine our local presence with global knowledge and resources in order to deliver
the technology and services which meet the demanding expectations of our customers
around the world.

12

through global experience

key APH reference sites
New equipment installations

SAUDI ARABIA

Saudi Electric Company

Shoaiba 1-13
13 x 400 MW oil fired boilers
26 x size 28 bi-sector APH
Startup : 2002-2013

GERMANY

MALAYSIA

MOROCCO

MEXICO

EnBW Kraftwerke AG
RDK8
1 x 912 MW coal fired boiler
1 x size 36.5 quad-sector APH
Startup : 2013

TNB Janamanjung
Manjung 4
1 x 1000 MW coal fired boilers
2 x size 34.5 tri-sector APH
Startup : 2015

Retrofit projects

JAPAN

Chugoku Electric Power Co. Inc

Shin Onoda 1&2
2 x 500 MW coal fired boilers
4 x size 30.5 tri-sector air preheaters
Complicated and time-consuming
maintenance on the existing Rothemuhle
style air preheaters justified their replacement
with new Ljungstrm Air Preheaters
selected to meet the specified performance
with lower leakage levels and fit in the space
occupied by the existing units.

Jorf Lasfar Energy Company

Jorf Lasfar 3&4
2 x 260 MW coal fired boilers
2 x size 31.5 tri-sector air preheaters
Fuel switches were creating an issue with
pluggage, so a new heat transfer surface
configuration using advanced loose-packed
heating elements was installed, reducing the
fouling rate while maintaining the efficiency
of the air preheaters.

Comisin Federal De Electricidad

Tuxpan 3-6
4 x 350 MW oil fired boilers
8 x size 29.5 bi-sector air preheaters
Replacement of the complete rotor
and shaft to upgrade the heaters to double
sealing and provide improved thermal
efficiency. Advanced heat transfer profiles
were used with enamelled heating element
in the cold end.

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How Alstom is helping

you meet the challenges
of energy sustainability.

T
LI

G
IN
C
U
RED T OF
CO S CIT Y
RI
ELECT

PE

TITI

AFF

V E A S S E T SY
CIT

ORDAB

L E EL E CT RI

REDUCING
COST OF ELECTRICITY

LOWERING
ENVIRONMENTAL FOOTPRINT

INCREASING
FLEXIBILITY & RELIABILITY

It takes competitive assets to keep

electricity affordable. We enable power
companies to compete successfully in
the marketplace and provide affordable
electricity to consumers. We help you
reduce the cost of electricity through:

Clean generation is one way of

demonstrating environmental
responsibility. Another is lowering
resource usage, visual impact and noise
pollution. In both cases, we can help
you meet or exceed regulations and
environmental standards. That is why
Alstom innovates in the following areas:

Intermittent power generationis a

growing challenge of energy security, as
is maintaining an aging installed base
and adapting it to changing market
conditions. We help you tackle both
issues so that you can enjoy dependable
operations with:

Efficiency improvements
CAPEX reduction/scaling up
Capacity Factor increase (renewable)
Lead time reduction
Competitive O&M
Competitive financing

Renewable portfolio
Natural resource optimisation
Pollutants control
(SOx, NOx, PM, mercury)
CO2 emission reduction & CCS
Land use, visual impact and noise
Water intensity reduction &
recyclability

Maintainability and outage

time reduction
Operational and fuel flexibility
Lifetime extension and power uplift
Designs and service for improved
availability and reliability
Climate packages
Energy storage

Alstom
Alstom is a global leader in the world of power generation,
power transmission and rail infrastructure and sets the benchmark
for innovative and environmentally friendly technologies.

Power generation

Alstom builds the fastest train and the highest capacity automated
metro in the world, provides turnkey integrated power plant
solutions and associated services for a wide variety of energy
sources, including hydro, nuclear, gas, coal, wind, solar thermal,
geothermal and ocean energies. Alstom offers a wide range of
solutions for power transmission, with a focus on smart grids.

Power generation
Alstom Power offers solutions which allow their customers to
generate reliable, competitive and eco-friendly power.

Electrical grid

Alstom has the industrys most comprehensive portfolio of thermal

technologies coal, gas, oil and nuclear and holds leading positions
in turnkey power plants, power generation services and air quality
control systems. It is also a pioneer in carbon capture technologies.
Alstom offers the most comprehensive range of renewable power
generation solutions today: hydro power, wind power, geothermal,
biomass and solar. With ocean energies, we are developing solutions
for tomorrow. Alstom is one of the world leaders in hydro power,
the largest source of renewable energy on the planet.

Rail transport

Printed on environmentally friendly paper. A PDF version of this brochure is available at: www.alstom.com

TPWR/BRCH/GSLFLAP/EN/9.2013/CHE/1659 ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Photo credits: ALSTOM.

Alstom Power
Alstom Brazil
Av. Independencia, 4385
13280-000, Vinhedo
Sao Paulo
Brazil
Phone: +55 19 3826 6767
Alstom China
8F, One Indigo
20 Jiuxianqiao Road
Chaoyang District
Beijing 1000016
China
Phone: +86 10 5630 4000
Alstom Czech Republic
Olomoucka 7/9
656 66 Brno
Czech Republic
Phone: +420 54510 2913
Alstom Germany
Haus Watt
Boveristrasse 22
68309 Mannheim
Germany
Phone: +49 621 329 2100
Alstom India
Tech Boulevard, Tower C
2nd Floor, Plot No. 6
Sector 127, Noida 201 301
Uttar Pradesh
India
Phone: +91 120 434 8056
Alstom Japan
2-3-4 Minatojima-nakamachi
Kobe 650-0046
Japan
Phone: +81 78 303 5060
Alstom United States
3020 Truax Road, Wellsville
NY 14895
USA
Phone: +1 585 593 2700
www.alstom.com