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EFFECTS OF SO3 and ABS on AIR HEATER PERFORMANCE
John Guffre
Paragon Airheater Technologies
WWW.PARAGONAIRHEATER.COM
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Benefits of an Air Heater
• Accounts For ~10% - 15% Of a Unit’s Thermal Efficiency
• Reduces Fuel Cost By $10,000,000 Per Year on a 500 MW Unit
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• ESTABLISHED STANDARD :
–A 10°F Increase In Gas Outlet Temperature Decreases Boiler Efficiency By 0.25%
–10°F Increases Fuel Cost By $ 500,000+/Yr
Gas Outlet Temperature
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GOAL:
Operate At Lowest Practical Gas Outlet Temperature
Gas Outlet Temperature
OBSTACLES:
Condensables
Effects of Gas Temperature on Equipment
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Over-Fire Air
(15 - 20%)
Secondary Air
(55%-65%)
Primary
Airflow
(15%-20%)
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Poor Coal Fineness
often yields poor
distribution
Good Fineness Creates a
homogenous & balanced
mixture
Coal Fineness
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Catalyst Fouling
1. Low Primary Air Temp or Flow
2. Open Mill Classifiers
3. Increase Coal Particle Size
4. Fireball Moves Upward
5. Increased FEGT
6. Popcorn Ash is Formed
7. Catalyst Fouls
8. NH3 Slip Increases
9. AH Fouls
10.Go to Step 1 - Repeat
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To Improve Plant Efficiency
The Air Heater Impacts Combustion and APC Equipment
I.D. FANS
BURNER
S
COMBUSTIO
N
EMISSIO
NS
The SCR Impacts the Air Heater
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Inter-Relationships
• Combustion Performance
• APH performance
• Environmental Control Equipment
• Auxiliary Power Consumption
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Electrostatic Precipitator(ESP) Challenges
Air Heater Leakage: • Increased Gas Volume
• Reduced SCA
• Temperature and Flow Stratification
• Can Reduce Collection Efficiency
Over 1%
Air Heater Efficiency
Deterioration: •May Result from ABS Plugging or
Sorbent
•Increased Gas Temperature
•Increased Fly Ash Resistivity
•Increased Gas Volume
•Decreased SCA
•Decreased Collection Efficiency
Air Heater Problems Shrink the
Relative Size of an ESP
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0
10
20
30
40
50
80 85 90 95 100 105 110 115 120
Emis
sio
ns
mg
/Nm
3
Gas Flow %
Reducing Leakage Reduces ESP Emissions
A 10% Leakage Reduction = • 10% Decrease in Flue Gas Volume • 10% Increase in SCA • Lower Gas Velocity Through ESP • Decreased Particulate Emissions
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Function of an Air Heater
• Extracts Waste Heat From Exhaust Gases
• Recycles That Heat to the Incoming Air
COOL AIR 100oF WARMED AIR 620oF
HOT GAS 700oF COOLED GAS 290oF
260oF
320oF
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GAS TEMPERATURE PROFILE
3500F
3300F 2650F
2950F
~3150F
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SO2 + O + ☺ SO3 + ☺
SO3 + O SO2 + O2
SO3 EQUILIBRIUM
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SO3 REMOVAL TEMPERATURES
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SO3 EXIT CONCENTRATION
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SO3 Vs. Sulfuric Acid Dew Point Temp.
Ref. A&WMA, 2008 Mega Symposium,
“The Effect of SO3 Sorbents on Electrostatic Precipitator Performance”, Paper
# 75
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ROTATIONAL SPEED
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Condensation Deposits
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COLD END CORROSION
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ACID RESISTANT COATINGS
PICK YOUR CORROSIVE
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Downstream Corrosion
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EFFECT OF MOISTURE ON SO3 REMOVAL
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AH SO3 REMOVAL-TEST VS MODEL
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SO Variation with Load and SO
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SO3 Affects ESP Efficiency (Resistivity)
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SO3 Exiting the Air Heater
SO3 at AH Gas Inlet
Metal Temperature
Gas Temperature
Ash Quantity
Ash Alkalinity
PM 2.5
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SO3 - Central To Air Heater Limits
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SCR (Selective Catalytic Reduction)
Ammonia Slip Results in
ABS Deposits in the Air Heater ABS
ABS Deposits Degrade Air Heater
Efficiency and Affect Downstream
Air Pollution Control Equipment
NH3
SO3
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ABS Formation Temperatures
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ABS Buildup at Precipitator Inlet
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ABS Deposition Temperature
oF
ABS
300oF TO 390oF
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“Clean” Air Heater Cold End
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ABS Prevention
Measure ABS Formation
Temperature
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ABS Formation Temperatures (Probe)
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Breen Condensables System
•Predict the Formation of ABS vs. AS
•Predict the Location where ABS will
Deposit
•Adjust the Ammonia Feed
•Change Air Heater Metal Temperature
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Change Air Heater Metal Temperature
Bring ABS Deposits Closer to the Cold End
• Air Heater Bypass Duct
• Change Air Heater Rotational Speed
• Utilize Steam Coils
Must be Mindful of Downstream Limitations – ESP Volume
– ESP Resistivity
– FF Bag Temperature
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Breen Condensables System
•Formation Temp: The temperature at which material will first form
•The Equilibrium Dew Point
•Evaporation Temp: The temperature at which material
will self-evaporate
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AbSensor – AbS/SO3 System
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Condensation Deposits
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Soot Blowers - Typical
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Dynamic Speed Control (DySC)
• Sootblower logic is modified to allow the nozzle to be positioned as desired, and then left stationary
• The Rotor Speed Coordinated With Nozzle Position To Provide Suitable Residence Time.
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Penetration Depth is greater here: Than it is here: Due to significant differences in angular velocity
Penetration vs. Angular Velocity
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Soot Blower Penetration vs. Tangential Velocity
Slow Speed, Full
Penetration
Medium Speed, Partial Penetration
High Speed, Reduced
Penetration
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Angular Velocity/Sootblowing
Perimeter Angular Velocity Increases up to 10x
Inner = 15 ft/min
Outer = 75-150 ft/min
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Dual Media Blower
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Dual Media Blower
On Or Off Line HP Water Wash With Dysc Angular Velocity Control
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• Br2 and/or HBr (Hydrogen Bromide)
• b.p. Br2 = 137F HBr = - 88F • Oxidizes Mercury
• Oxidizes Iron at 300 F+
• HBr + H2O = Hydrobromic Acid (b.p. 280 F)
• Hydrobromic acid is stronger than HCl
Bromine for Hg Oxidation
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RAPID CORROSION OF AIR HEATER ELEMENT
BROMINE PAC PROBLEM?
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HYDROBROMIC ACID (HBr) DEWPOINT
EERC
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Br2 GAS PHASE OXIDATION
EERC
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PROTECTIVE OXIDE LAYER
EERC
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BR2 GAS PHASE OXIDATION
EERC
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RAPID CORROSION OF AIR HEATER ELEMENT
BROMINE PAC PROBLEM?
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EFFECTS OF SO3 and ABS on AIR HEATER PERFORMANCE
John Guffre
Paragon Airheater Technologies
WWW.PARAGONAIRHEATER.COM