Air Frhlich

Flue Gas Heat Exchangers

In Finland: Taniplan Ky Kyltie 18 B 20 00320 Helsinki Tel. 09-4583 120 Fax 09-4583 119 Email info@taniplan.fi

Internet http://www.taniplan.fi

Air Frhlich Flue Gas Heat Exchangers

Application Areas with Flue Gases
* Oil and coal-fired power plants and co-generation plants * Industrial combustion plants * Refuse and special waste incineration plants

Heat displacement with a raw gas cooler and clean gas heater

Direct heat exchange by StagavoR

1. Reheating of Clean Gases behind Scrubbers

Clean gases discharged from wet absorbers (scrubbers) are water vapour saturated and still contain droplets and residual particulate matter. These gases must be dried by reheating before admission into subsequent components or into the discharge stack. For this purpose, AIR FRHLlCH supplies static heat exchangers as a proven and economical solution.
Steam reheating by means of steam/gas preheater

Clean gas drying by admixture of hot air from StagavoR

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Air Frhlich Flue Gas Heat Exchangers

2 Utilization of the Heat of Clean Gases from Denox-Reactors
lf the SCR facility is mounted behind the scrubber, the raw gases must be reheated to the reaction temperature of approx. 300 C. AIR FRHLICH static heat exchangers with high thermal efficiency dispense in large measure with the need to use external energy sources. The main heating is effected via the multistage steel tube heat exchanger or the counterflow plate-type heat exchanger. To prevent corrosion in the cold inlet zone, the raw gases must be preheated by means of an acid-resistant heat exchanger. This may be realized through: a) A steam/gas preheater (also suitable for cold start-up) b) ReheatIng behind the scrubber by means of a StagavoR c) Use of an acid-resistant first stage of the heat exchanger operating with the pre-cooled clean gases behind the Denox facility

Raw gas heating in front of Denox-reactor using a counterflow platetype heat exchanger; preheating by means of a steam/gas preheater

3 Energy Saving by Utilization of Flue Gas Heat

The energy content of the flue gas can be used at various points in the flue gas line for energy saving purposes or to increase plant efficiency. For this purpose, the heat exchanger must satisfy the necessary requirements in respect of temperature, corrosion resistance and cleaning capacity on the raw gas side. AIR FRHLlCH builds heat exchangers for use: * as air preheaters * as economizers * for heat extraction Combinations Further application areas and combinations or modifications of the three examples of use described here are of course feasible and have already been implemented in a great many plants.

Raw gas heating in front of Denox-reactor using a multi-stage steel tube heat exchanger; preheating by means of a steam/gas preheater or an acid-resistant first stage

Air preheater

Economizer

Heat extraction

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Air Frhlich Flue Gas Heat Exchangers

Stagavo and Static Air Preheaters
Acid-resistant Flue Gas Heat Exchangers by AIR FRHLICH
The heat exchanger with fully synthetic tubes has been developed to meet the need for a heat exchanger with unlimited corrosion resistance in the acid dew point range of flue gases. The temperature ranges of raw gases in coal- and refuse firing systems are such that only fluorinated synthetics, such as PTFE, PFA and PVDF are suitable for this application. The exchanger surfaces consist of tubes which are sealed on both sides in tubeend plates which are also corrosion resistant; the tubes, depending on their length, are fixed with a variable number of spacers.

Special Steel Tube Version, lined with Synthetic Material

Provided that the gases which flow through the tubes do not condense and contain no harmful substances (e.g. air or dry clean gases) a lower cost version with steel tubes, lined with synthetic material, can be chosen. These tubular heat exchangers only offer corrosion resistance in the area of gas circulation around the tubes.

Glass Tube Heat Exchangers - a Low Cost Solution

Glass tubes can also be used to a limited extent as heat exchanger surface for air preheaters in contact with flue gases, provided that no condensing fluorides occur.
Design
Glass tube air preheaters IAir preheaters with lined steel tubes A ir preheaters with fully synthetic tubes B lock-type S tagavosR

StagavoR in Block- and Ring~type Designs

Depending on the flue gas flow rate to be processed, block- or ring-type designs will be chosen. For flue gas volumes of up to about 1 million Nm3/h, a more economical solution for the design of ducts and hoods is generally adopted with the BlockStagavoR. For larger flue gas volumes, a ring-type StagavoR layout will be chosen to save space and handle the flow requirements.

Type Designation N otes

GRS -S, GE S, FGRS, C asing design and GHS , GFS ja GTS tube seals deoending on application area FRS FHS, FE S FFS , FTS, EFS Flue gases around the tubes Flue gases around the tubes B oth gas sides in fluorinated synthetic design B oth gas sides in fluorinated synthetic design for large volumes in power plants

Ring-type S tagavosR FFR, EFR 1)

Gas flows through StagavoR

Heat exchangers with fully synthetic tubes will preferably be built with vertical tube configuration. The raw gases flow downwards through the tubes while the clean gas (generally arriving from the SOx-absorber) is conducted horizontally around the tubes.

S tagavosR is a registered trade name of A IR FRHLICH 1) Ring-type StagavosR are supplied in co-operation with A ppratebau Rothemle

Design for Higher Raw Gas Temperatures

The heat exchanger with fully synthetic tubes can be used at temperatures of up to 250 C. For higher temperatures, AIR FRHLICH builds a special model with a metallic raw gas inlet seal. Provided that minimum temperatures are respected for the raw gas and maximum temperatures for the clean gas, this version is suitable for raw gas inlet temperatures of up to 320 C.

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Air Frhlich Flue Gas Heat Exchangers

Model of ring-type StagavoR for power plant applications1)

StagavoR and Static Air Preheaters StagavoR unit module

Stagavos R with fully synthetic tubes require compensation for length variation caused by temperature differences, the lower tube-end plate therefore is designed as a membrane

Metallic tube sealing for Stagavos R in the temperature range up to 320 C

Block-type StagavoR for reheating clean gases by utilization of raw gas heat

Air preheater in glass tube design: the casing has an acid-resistant lining

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Air Frhlich Flue Gas Heat Exchangers

Steam/Gas Preheaters and Gas/Water Heat Exchangers

AIR FRHLlCH gas/water heat exchangers in plain tubular design, using stainless steel tubes or PFAlined compound tubes, are proven appliances for use as flue gas heaters and flue gas coolers to satisfy exacting standards.

Acid-resistant Designs
The heat exchangers with full corrosion protection on the gas side are made of stainless steel tubes lined with fluorinated synthetics. The tube-end plates are also lined on the gas side with plates of fluorinated synthetics. This design combines pressure resistance of the steel tubes on the water or steam sides with excellent corrosion resistance of the synthetic material on the gas side. The proverbial anti-adhesion properties of fluorinated synthetics limit the susceptibility to fouling and ensure easy cleaning on the gas side. These heat exchangers are built to comply with the relevant regulatory provisions on steam vessels, in particular when they are designed as steam preheaters. official acceptance certificates are supplied.

Stainless Steel and Glass Tube Heat Exchangers

Stainless steel plain tube heat exchangers are used as gas preheaters and coolers for gases with a low corrosive effect. The AIR FRHLICH glass tube heat exchanger is suitable for special appli cations, in particular at relatively low water pressures.

Design
Steam/gas preheater Raw gas cooler Clean gas heater

Type Designation
FDG-D/-P

Notes
Synthetic material lining on gas side For heat displacement systems in power plants and refuse incineration plants Feed water, heat extraction for district heating or process water

FWG-B/-P/-D

Economizer

SWG, FWG, FGWG, GWG

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Air Frhlich Flue Gas Heat Exchangers

Steam/gas preheater for clean gas application

Stainless steel tube economizer for high gas temperatures

Acid-resistant gas cooler for waste incineration plant

Steel tubes lined with fluorinated synthetics, water headers outside of gas flow

Special welding of tubes into tube-end plate

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Air Frhlich Flue Gas Heat Exchangers

The Denox-Gas preheater
Gas/Gas Heat Exchangers by AIR FRHLICH with High Thermal Efficiency
AIR FRHLICH builds low-cost tubular and plate-type heat exchangers in carbon steel for flue gases in the temperature range above the acid dew point. The steel tube production plant of the Arbonia-Forster-Group is directly adjacent to the AIR FRHLICH heat exchanger assembly shop. This brings AIR FRHLICH logistic benefits for the procurement of steel profiles and round tubes.

Tubular Heat Exchanger (SRX) (multiple countercrossflow)

The AIR FRHLICH tubular Denoxgas preheater offers maximum operational dependability: * Possible sulphate deposits around the tubes can be washed off easily * Single tubes in horizontal tube arrangement or modules can be replaced * Fluorinated synthetics can be used to protect the first (cold) stage against SO3condensation on the clean gas side

Plate-Type Heat Exchanger (SPG) (counterflow)

The AIR FRHLICH plate-type heat exchanger is built with rectangular profile tubes. It combines a compact design with high thermal efficiency (low temperature difference). It will generally be preceded by a steam/gas preheater or StavagoR, with corrosion protection to preheat the raw (cold) gases.

Counterflow plate-type heat exchanger

Gas preheater exchange surface (m2)

Thermal efficiency (low temperature difference) - - - - - Plate-type heat exchanger (counterflow) _____ Tubular heat exchanger (counter-crossflow)

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Air Frhlich Flue Gas Heat Exchangers

AIR FRHLICH Denoxgas preheaters are based on steel tubing manufactured by the Arbonia-Forster-Group. Both, round tubes and profile tubes, are manufactured inhouse.

Steel plate Denox-gas preheater designed to ensure high thermal efficiency (low temperature difference)

Tubular heat exchanger (vertical tube configuration)

Structure of the platetype heat exchanger with profile tubes

Steel tube heat exchanger in countercrossflow design

Tubular heat exchanger (horizontal tube configuration)

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Air Frhlich Flue Gas Heat Exchangers

Corrision-resistant Linings

Acid-resistant heat exchangers are not coated but lined with fluorinated synthetics, using a fixing system which has been specially developed by AIR FRHLICH. AIR FRHLICH specialists are able to fit this lining even on complex duct sections in all sizes.

Total protection against corrosive attack on the gascarrying ducts is guaranteed:

* Temperature resistance to 250 C * Leakproof * Repairable * Independent of duct material and surface finish * Long life expectancy (no abrasion)

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Air Frhlich Flue Gas Heat Exchangers

Cleaning Facilities Our Reference Plants
AIR FRHLICH has acquired many years experience in the construction of heat exchangers for flue gases. Depending on the particular application, a cleaning facility must be provided for the heat exchanger on the raw gas side, and in some cases also on the clean gas side. Water is generally used for cleaning. Cleaning Systems: * Revolving spray pipe cleaning * Movable spray pipe cleaning * Manual cleaning by water injection during regular plant shutdown Large numbers of AIR FRHLICH heat exchangers have been in successful worldwide use since 1978 as air preheaters and economizers or for heat extraction. Steam/gas preheaters, StagavosR (static gas preheaters) and heat displacement systems made by AIR FRHLICH give excellent results in reheating applications behind scrubbers. Between 1987 and 1992 alone, some 100 units of this kind were incorporated into waste incineration plants. Many Denox-gas preheaters have been delivered or already ordered since 1992. The experience acquired by AIR FRHLICH guarantees the dependability of its products.

Stagavo with integral movable spray pipe cleaning system

Reheating unit in waste incineration plant

Assembly of a large Denox-gas preheater, built as a 4-stage tubular heat exchanger Revolving spray pipe cleaning system with washing in progress

Block-type StagavoR in a coal-fired industrial power plant

Revolving spray pipe cleaning device Stagavo installed in Japan

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Air Frhlich Flue Gas Heat Exchangers

AIR FRHLICH - The Specialists for Static Heat Exchangers

Our head quarters in Oberaach, Switzerland, are responsible for development, design, fabrication and marketing. Established 1972 as Air Frhlich, AG for energy recovery; since March 1, 2000 name changed to Air Frhlich Engineering AG. Air Frhlich Engineering AG Weidweisen CH-8587 Oberaach

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