PRE-ENG INEERED IN DUSTRIAL PACKAGE HEATERSilkerenergy.com/wp-content/uploads/Pre-engineered_heater_PDF.pdf · Package Air Heater sizing with flue gas mass flow (only for reference)

www.howden.com

AIR PREHEATERS CONFIGURED FOR TODAY’S OPERATING CONDITIONS.

PRE-ENGINEERED INDUSTRIAL PACKAGE HEATERS

1

COMPACT, VERSATILE AND IMPRESSIVELY EFFICIENT

FOR THE FIRST TIME, ROTARY REGENERATIVE HEATERS AT THELOWER END OF THE SIZE RANGE ARE BEING ENGINEERED TO MEETTHE ECONOMIC AND ENVIRONMENTAL CIRCUMSTANCES OF THEFORESEEABLE FUTURE, RATHER THAN THE VASTLY DIFFERENTCONDITIONS THAT PREVAILED THREE OR MORE DECADES AGO.

GASAIR

GAS

HOWDEN REGENERATIVE AIR HEATERS

HOWDEN REGENERATIVE AIR HEATERS USE A SLOWLY ROTATINGWHEEL LOADED WITH SHEET METAL PASSING FROM GAS TO AIRCONTINUALLY TRANSFERRING THE ENERGY FROM THE HOT GASTO COLD AIR OR GAS.

By removing heat from the flue gases leaving the furnace, which in turn reduces the heat lost up to thechimney the heat exchanger preheats the air which goes directly to the burners. This significantly increasesthe overall thermal efficiency of the boiler.

Regenerative Airheater offer distinct advantages over tubular Airheaters. These include:

• More compact design

• Lower pressure drop

• Lower weight

• Fouling does not affect heat transfer

• Improved cleanability

• Greater performance flexibility

• Removes cold corner problems

AIR

Advances in element design and enamelling havedramatically raised thermal efficiency and cleanability,improved seals have brought enhanced systemintegrity, and parameter-based computerised designhas vastly reduced engineering lead times, with aresulting drop in capital costs. These are major stepsthat make Howden regenerative heaters the mostcost effective choice for new plant. They offer evengreater benefits where existing preheaters areapproaching the end of their useful life, maintenanceand operating costs are starting to escalate, andreplacement becomes the preferred option.

Howden has over 150 years of experience in air andgas handling equipment, and a worldwide reputationfor engineering of the highest quality. We have beenassociated with rotary regenerative air heaters since1923, when we set up a joint venture company withFredrik Ljungström to develop the technology. Overthe subsequent 85 years, we have been involved in research and development designed to improveefficiency and performance. For many decades, ourequipment has been utilised in critical applications of all kinds throughout the world.

PRODUCT SIZE RANGE

Size 15 Size 16 Size 17 Size 18 Size 19 Size 20 Size 21

Packaged Air Heater Size

Package Air Heater sizing with flue gas mass flow (only for reference) Package Air Heater sizing with recovered energy (only for reference)

Packaged Air Heater Size

Gas Temperature drop 150˚CGas Temperature drop 200˚CGas Temperature drop 250˚C

Notes: Flow and MW recovered arebased on normal operating conditions.

250

200

150

100

50

0

15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5

Tons per hour 18

1614121086420

15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5

MW

32

EXCEPTIONAL EXPERIENCE THAT BRINGS PRACTICAL BENEFITS


Building on tried and tested technology while taking advantage of the economies brought by state-of-the-art computerised design, we havedeveloped a modular approach that bringssubstantial and measurable system improvementsinto industrial package heater units customisedprecisely to customer needs.

The Howden pre-engineered package heater offers significantly reduced leakage, better thermalperformance, greatly improved cleanability, ease ofmaintenance and exceptional long-term reliability. Our research in recent years has been driven by theglobal need to reduce fuel consumption and minimiseenvironmental impact, and these industrial preheatersincorporate developments that have already proventheir value in highly critical applications.

For replacement heaters in existing plants, we canprovide new equipment that matches the previousunit while bringing vastly improved efficiency andthermal performance. We can fit the package toexisting foundations, ductwork, power supplies and other site arrangements, introducing valuablegains in performance and reliability with the minimum of on-site work.

THE DESIGN ADVANTAGE

By integrating our unique experience with leading-edge 3D design software, we have madesignificant reductions in engineering time and cost.We have developed a full set of parameters for eachcomponent of the air preheater package, and cannow use that data to create a machine to a precisespecification, add the desired ancillary equipment,make adjustments to optimise the overall performanceand match the heater to its final installation.

Throughout the design process, each individual partand the whole assembly can be freely rotated andminutely examined on screen in 3D representations.Once it has been comprehensively checked, finalised

and approved, finished production drawings can be produced very quickly. Experience shows that we have cut lead time to around one-sixth of theprevious average, and we hold exceptionally largereserve stocks of steel to avoid delays at this stage.Once an order has been placed, the heater can be in production within weeks.

To carry the time advantage through to shipping,installation and commissioning, whenever feasiblethe heaters are fully assembled in the factory anddelivered as a single unit ready to be slotted intoplace. Larger units, of around size 17.5 and over, are supplied partially assembled in a way that offers the most practical and economical balancebetween transport logistics and site installation.

OUR WORLDWIDE EXPERIENCE, SUPPORTED BY LEADING EDGE R&D AND WINDTUNNEL FACILITIES, GIVES US A UNIQUE OPPORTUNITY TO TAKE AN INTEGRATEDAPPROACH TO ALL ASPECTS OF AIR PREHEATER TECHNOLOGY.

CUSTOMISED CONFIGURATION

We supply industrial package heaters in sizes up to21.5 in both vertical and horizontal configurations,and virtually every parameter can be modified orchanged to suit the application and duties of theheater and the preferences of the customer. Heatersup to size 17.5 are housed in a square casing with no need for transition ducts, and size 18 and aboveare in octagonal casings with transition ducts. These factors are, however, fully customisable at the customer’s request.

REDUCED LEAKAGE & REDUCED FUEL COSTS

One of the most significant advancements we haveintroduced is the use of effective seals in this sizerange. An effective sealing system substantiallydecreases FD fan power consumption and increasesperformance of equipment downstream from the airpreheater. These are highly sensitive issues now andlikely to grow even more important in the future. We install as standard double axial seals and eithersingle or double radial seals configuration as required.Our principle task is to match the heater we supply to the exact performance and cost parameters set by the customer.

WE HAVE DEVELOPED A FULL SET OF PARAMETERS FOR EACH COMPONENT OF THE AIR PREHEATERPACKAGE, AND CAN NOW USE THAT DATA TO CREATE A MACHINE TO A PRECISE SPECIFICATION, ADD THE DESIRED ANCILLARY EQUIPMENT, MAKE ADJUSTMENTS TO OPTIMISE THE OVERALL PERFORMANCEAND MATCH THE HEATER TO ITS FINAL INSTALLATION.

54 PRE-ENGINEERED INDUSTRIAL PACKAGE HEATERS

THE PACKAGES WE SUPPLY ARE DESIGNED TO INCLUDE ALL OF THE REQUIREDCOMPONENTS AND SYSTEMS READY FOR COUPLING INTO THE PLANT ON SITE.

MORE THAN THE SUM OF THE PARTS

1. HEATING ELEMENTS

We have unrivalled experience in heater element design, and canprovide profiles, materials and finishesto match any application. Our state-of-the-art HC ElementsTM range providesexcellent thermal performance withexceptional cleanability by using arevolutionary transverse herringbonesheet that reduces skew flow, eliminatescold corner and low velocity areaproblems, and helps to prevent foulingand plugging. Its aerodynamicallyclosed design also assists sootblowingby maintaining full jet pressure across the whole depth of the element basketwhile introducing internal turbulence to promote effective cleaning.

Like other Howden elements, the HC ElementsTM design is available in anenamelled version that raises thermalperformance and cleanability to evenhigher levels. We can provide fullspecifications about the various profiles to allow operators to select the elements that will optimise theeconomic and thermal performance of their plant.

The Howden Surepack Elements®

basket uses computer-controlledpresses to introduce precisely the right degree of pressure prior towelding, providing optimum rigidityand guarding against damage to theelement profile or enamel coating.

2. AXIAL & RADIAL SEALS

The seals we have incorporated arebased on our enormous experience in large-scale heat exchangers. We use single leaf proximity seals designedfor optimum effectiveness at normaloperating temperatures, and we installas standard double axial seals andeither single or double radial sealsconfiguration as required.

To ensure that the leakage figures aremaintained at the lowest level over thefull working life of the heater, all of theseals are designed as consumables andare fully and easily replaceable on site.

3. BEARING HOUSING &TRUNNION COOLING SYSTEM

The bearing from the hot side isrefrigerated as standard with a watercooling jacket and in case of high gasinlet temperature a rotatory joint isused to refrigerate the trunnion.

4. DRIVE UNIT

We can supply either central orperipheral drives as standard. Unlessthere are strong reasons to chooseperipheral (rack and pinion) drives, we strongly recommend the use ofcentral motors. They offer greatereconomy, easier installation andreplacement and, by removing theneed for a rack, they allow axial seals to run the full length of the rotor andthus contribute to leakage reduction.

Backup drives are a standard option,and both electric and air motors can be supplied. Frequently, the preferredcombination is an electric main driveand an air motor for backup.

5. ALARMS & MONITORING

In addition to oil temperature androtation monitoring as standard, we can fit fire detection sensors and firefighting lances if required.

These options and configurations have been selected to offer thegreatest flexibility to the customerwhile maximising the benefits of ourparameterised design process. In thisway, we can ensure that the heater is engineered as an integrated wholewith every aspect of its performanceoptimised for its unique specificationand duties.

6. SIDE WITHDRAWAL DOOR

For easy cold layer baskets removal a side removal access door is installed.This prevents the need for removingthe hot end baskets to get access to the cold-end baskets.

7. TRANSITION DUCTS

We supply package heaters ready to fit into the existing or plannedductwork of their destination. Wherethe heater is supplied in an octagonalcasing, this normally involves the fitting of transition ducting to createsquare profile. However, we cansupply transition ducts if required.

8. BEARINGS

We use only the highest qualitybearings sourced from manufacturerssuch as SKF, and have introduced anew bearing system that allows axialmovement in the shaft to accommodatethermal expansion in the rotor.

9. WASHING PIPE

We supply a washing pipe for off-linewashing during overhaul. Additionally,we can supply semi-retractable orretractable sootblowers for cleaningpurposes. The cleaning/washingdevices can be adjusted or adapted tosuit the configuration, fuel and dutiesof the heater.

HEATING ELEMENTS

RADIAL SEALS

ALARMS & MONITORING

DRIVE UNIT

BEARING HOUSING &TRUNNION COOLINGSYSTEM BEARINGS8

TRANSITION DUCTS7

SIDE WITHDRAWAL DOOR6

WASHING PIPE9

HEATING ELEMENTS1

RADIAL SEALS2

ALARMS &MONITORING5

5

DRIVE UNIT4

BEARING HOUSING &TRUNNION COOLINGSYSTEM

3

BEARINGS8

TRANSITION DUCTS7

SIDE WITHDRAWALDOOR6

WASHING PIPE9

HORIZONTAL AIRHEATER VERTICAL AIRHEATER

1

2

4

3

76

Despite the fact that it is designed to fit, like a directplacement, into the existing foundations, ductworkand power supply of your existing heater – itscomponents is state-of-the-art technology customisedto meet your demanding requirements.

In addition to the reduction in maintenance worriesand costs, there are significant savings arising fromgreatly enhanced fuel efficiency. The combination ofvastly reduced leakage, better thermal performancefrom improved element designs and packing, andmuch better cleanabilty to maintain the efficiency and reduce fouling, adds up to a significant reduction

in running costs and, a factor that is becoming even more important, improved environmentalresponsibility.

The opportunity to introduce these improvements in a planned and phased way, during scheduleddowntime for maintenance for example, should be carefully considered. The speed and ease ofreplacement means that the installation process can be fitted into narrow time frames, and thepayback in reduced running and maintenance costs, and peace of mind, is considerable.

A NEW HOWDEN PACKAGE HEATER IS NOT SIMPLY A REPLACEMENT IN-KIND.


THE COST OF REPAIRING AND MAINTAINING PACKAGE HEATERS THAT ARE MORE THAN TWENTY YEARS OLDSHOULD BE CAREFULLY BALANCED AGAINST THE POTENTIALBENEFITS OF REPLACEMENT.

POSITIVE FORWARD PLANNING:TIME TO UPGRADE

Apart from the ever-increasing need to maximise thebenefits we draw from our limited supplies of fossilfuels and to reduce environmental emissions, thereare compelling economic reasons to make the changeas part of the strategic forward planning of the plant.

The cost of repairing and maintaining packageheaters that are more than twenty years old shouldbe carefully balanced against the potential benefits of replacement.

Primarily, there is the need to balance the capitalinvestment, a figure greatly reduced by ourparameterised design and production processes,

against both the maintenance budget, whichnaturally increases as the heater becomes older, and the increasing possibility of an unplanned outage due to fouling, plugging or other failure. The costs associated with maintaining an ageingheater to operate at the operation level necessary for optimum boiler performance combined with theincreased risk of unplanned outages can be morethan those of replacement with an updated andefficient Howden industrial package heater. Theargument for a serious examination of the costs and savings are powerful even from this standpoint.

8

Our air preheaters are supported by a fullcommitment to after sales service and spares. We retain all production drawings and specificationsfrom every heater we supply to ensure that the partswe provide match what is needed for your heater.

REGENERATIVE HEATER TECHNOLOGY

DOES NOT STAND STILL. OUR POLICY

IS ALWAYS TO DESIGN FOR FUTURE

UPGRADEABILITY, AND WE ARE HAPPY

TO ADVISE ON WAYS OF INCORPORATING

THE LATEST DEVELOPMENTS INTO THE

EQUIPMENT WE SUPPLY.


www.howden.com

LOOKING TOWARDS THE FUTUREHOWDEN INDUSTRIAL PACKAGE HEATERS ARE DESIGNED TO GIVE TROUBLE FREE, ROUND-THE-CLOCK OPERATION WITH MINIMAL PLANNED MAINTENANCE.

HOWDEN ENGINEERS ARE READILYAVAILABLE THROUGHOUT THEWORLD FOR CONSULTATION,SERVICE AND SUPPORT.

For further information including, if you choose,a fully costed case study of the benefits that a new Howden industrial package heater could bring to you plant and a demonstration of ourdesign software, please contact:

Howden SpainLo Vilagrán, s/nCtra. F-40 Km 1 a Los CamachosApdo. 11730360 La UniónMurcia, Spain

Tel: +34 968 32 00 64Fax: +34 968 50 60 77Email: [email protected]

Howden, founded in 1854, is the world’s leading supplier of fans,compressors and rotary regenerative heat exchangers for a large range of industrial applications.Whether pre-engineered or custom built for a specific application, our products are known throughout the world for their high levels of performance, reliability and innovation.

The combination of our product knowledge with our extensive applicationsexperience, gained by our engineers on sites throughout the world, allowsus to provide our customers with support from the initial project inceptionright through to the end of the plant life.

www.howden.com


Our new industrial package heaters allow the benefits of Howden’s experience and engineering skill to be made available to energy-intensive applications as diverse as petrochemicals, metal refining, chemicals, steel production, small power generators and heating plant.

©Howden Group Limited. All rights reserved. 2011Howden and the flying H logo are registered trade marks belonging to Howden Group Limited.

Howden SpainLo Vilagrán, s/nCtra. F-40 Km 1 a Los CamachosApdo. 11730360 La UniónMurcia, Spain

Tel: +34 968 32 00 64Fax: +34 968 50 60 77Email: [email protected]

Petrochemical Metal Refining Chemicals Steel production Small power generatorsand heating plant

PRE-ENG INEERED IN DUSTRIAL PACKAGE HEATERSilkerenergy.com/wp-content/uploads/Pre-engineered_heater_PDF.pdf · Package Air Heater sizing with flue gas mass flow (only for reference)

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