Table of Contents
What is Air Preheaters (APH)
Air Preheaters (APH) are the Shell and tube type Heat Exchangers used for preheating the air which is fed to the boiler or furnaces/kilns for combustion of fuels. The Air Pre heater’s primary objective is to extract the waste heat from the flue gases leaving the boiler.
Thermodyne Engineering Systems manufacture Air Preheaters which are given as a standard side accessory along with the main equipment – Boiler, in a Packaged Type Boiler, Combi Boilers.
What is the function of the air preheater?
The main function of an air preheater is to increase the thermal efficiency of a boiler by preheating the combustion air using waste heat from the flue gases. This process improves combustion rates, combustion efficiency, and overall boiler efficiency.
Air Pre heater in Boiler
Air preheaters are devices used in boilers to heat the combustion air before it enters the boiler. This process improves the thermal efficiency of the boiler system by reducing the amount of fuel required to achieve the desired temperature.
Benefits of using an air preheater:
- Increases boiler efficiency
- Reduces fuel consumption
- Lowers emissions
Applications of air preheaters:
- Power plants
- Industrial boilers
- Commercial boilers
What is the function of the air preheater in boiler ?
An air preheater is a crucial component in boiler systems, primarily responsible for enhancing the boiler’s efficiency. It achieves this by preheating the combustion air before it enters the boiler furnace, leading to several benefits:
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Reduced fuel consumption: Preheating the combustion air significantly reduces the amount of fuel needed to reach the desired boiler temperature. This translates into lower fuel costs and a more environmentally friendly operation.
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Improved combustion efficiency: By supplying preheated air, the combustion process becomes more efficient, leading to a more complete fuel burn. This results in higher heat release and better overall boiler performance.
Why is hot air sent to the furnace?
For generating fire in a boiler furnace 3 main ingredients are needed: Fuel, Air & Ignition. Air is used in a Boiler for the combustion of fuel. Based on the stoichiometry calculation, the right quantity of air along with excess air is fed into the boiler furnace for the combustion of fuel.
Generally, fuel fed to the boiler is at normal room temperature, and for the combustion of fuel to take place; the temperature of the fuel is increased from its room temperature to ignition temperature. So to increase the efficiency of the combustion process as well as a boiler, hot air is fed to the furnace for the combustion of fuel.
Type of Air Preheaters (APH)
We manufacture different types of air preheaters:-
- Shell and tube type single pass air pre-heaters
- Shell and tube-type dual-pass air pre-heaters
- Finned tube air pre-heaters
Working of Air Preheaters(APH)
Air Preheaters have a shell and tube type construction where exhaust heat from the flue gases is transferred to the air when they come in indirect contact with each other.
Air Preheaters consist of a shell where tubes are arranged in a square or triangular pitch and are welded to a tube plate. Depending upon the type of operation and ease of cleaning, flue gases & air can be allowed to travel either shell side or tube side interchangeably.
Also Read: What is Combi Boiler?
Thermodyne Boilers finned tube air preheaters are designed to maximize efficiency by increasing the heating surface area without increasing the space requirement.
Thermodyne Engineering Systems manufacture air preheaters that are tailor-made to suit the customer’s requirement.
Our Air Preheaters are designed in both 1 and 2 passes for both flue gases and air to extract maximum heat from the flue gases.
Thermodyne Boilers manufacture air pre-heaters for a wide capacity range and can satisfy the various fuel requirements of a customer such as:
- Wood
- Coal
- Husk
- Bagasse
- Petcoke
- Light Oil and Heavy Oil
Air Preheater Pros:
- 2 pass design to extract maximum waste heat from flue gases leaving the boiler.
- It is used to extract waste heat from the flue gases leaving the boiler exhaust thereby increasing the efficiency of a boiler by 2-3 %.
- It is used to preheat the fuel which further increases the boiler efficiency.
- Payback time is less.
Air Preheater Cons
- Adding equipment or accessory in the path of flue gases increases flue gas pressure drop down the line, so the size of the Induced Draft Fan increases.
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Industrial Boiler Spare Parts
An APH is a heat exchanger that is used to preheat the air that is used to burn fuel in a boiler. This preheating increases the efficiency of the boiler by reducing the amount of fuel that is needed to heat the air.
There are two main types of APHs: recuperative and regenerative. Recuperative APHs use a single heat exchanger to transfer heat from the flue gases to the air. Regenerative APHs use a series of heat exchangers that are alternately exposed to the flue gases and the air.
There are several advantages to using an APH, including:
Increased cost
Increased maintenance requirements
Potential for increased corrosion
Power plants
Industrial boilers
Heating systems
Marine vessels
An APH works by transferring heat from the flue gases to the air that is used to burn fuel. The flue gases are heated by the combustion process, and they flow through the heat exchanger. The air then flows through the heat exchanger, and it absorbs heat from the flue gases. The preheated air then flows into the combustion chamber, where it is used to burn fuel.
APHs require regular maintenance to ensure that they operate properly. This maintenance includes:
Cleaning the heat exchangers
Replacing the seals
Lubricating the bearings
APHs can last for many years with proper maintenance. However, they may need to be replaced if they become damaged or corroded.
APHs can pose a safety hazard if they are not properly maintained. Some of the safety concerns associated with APHs include:
Fire
Explosion
Corrosion
Toxic fumes
Manufacturers’ websites
Technical manuals
Trade publications
Professional organizations
An air preheater is a device that heats the air before it enters a boiler. This helps to improve the efficiency of the boiler by reducing the amount of fuel that is needed to heat the water.
There are two main types of air preheaters: recuperative and regenerative. Recuperative air preheaters use a heat exchanger to transfer heat from the flue gases to the air. Regenerative air preheaters use a rotating wheel that is coated with a heat-absorbing material. As the wheel rotates, it alternately exposes the hot flue gases and the cold air to the heat-absorbing material.
Air preheaters work by transferring heat from the flue gases to the air. This is done through a heat exchanger or a rotating wheel. The heated air then enters the boiler, which helps to improve the efficiency of the boiler.
There are several benefits to using an air preheater, including:
Increased boiler efficiency.
Reduced fuel consumption.
Reduced emissions.
Longer boiler lifespan.
The most common problems with air preheaters include:
Fouling.
Leaks.
Damage to the heat exchanger or rotating wheel.
The lifespan of an air preheater will vary depending on the type of air preheater and the maintenance schedule. However, most air preheaters will last for many years.