Industrial REKULUVO

Datum Erstellung:21.11.2002letzte Änderung: 21.11.2002

erstellt durch: O. Brasseur

Presentation

„REKULUVO COUNTER-FLOW AIR PREHEATER TECHNOLOGIE“

GEA-ECOFLEX GMBH

Dr.-Ing. Olivier Brasseur



Heat Recovery

Power plant Industry

Three main fields:Small power plants < 50 MW (IPP's, Biomass, etc.)Primary APHCFB-Boiler(POWERISE-REKULUVO)

All Processes with Reformer, mainly:Methanol plantAmmonia plantHydrogen plantAlso:Ethylen, sulfuric acid plantCatalytic combustion

REKULUVO field of application



StackPrimaryReformer

450 °C

CombustionAir

390 °C

Features:Flue gas range 50.000 - 500.000 Nm3/hTemperature differential 70 - 20 KPressure difference: Typical 100 mbarMaterial CS, Corten, Stainless steel 304, 316Countries: USA, Trinidad, India, Ägypt, Iran,

Indonesia, Europe, Japan

35 °C

Heat recovery duct

30 °C

150 °C

REKULUVO for Reformer processes



completely welded plates

Counterflow plates

Inlet flow channels (gas 1)

Inlet flow channles (gas 2)

The counter flow design offers the highest thermal recovery among all heat exchanger types. Modular construction, welding know-how and adequate material permits a large range of application for REKULUVO.

Principle of REKULUVO



1.060

Plate profilel

Repartition 1/2 - 1/2For clean fuel

30

Gap = 6 mm

Plate thickness 0,37 to 1,0 mm

Pla

te le

ng

thfr

om

57

8

to 2

.97

8 m

m,

12

0 m

m S

tep

Counter flow plates of REKULUVO

Corrugated surface increase the heat transfer.



Automatice Welding line Plate packs ready for dispatch

The plate placks of the REKULUVO are all manufactured in Ratingen / Germany. All other components can be manufactured almost everywhere else in the world under German supervision.

Manufacture of plate packs in Ratingen



Leaktest in the shopThe plate placks of the REKULUVO are all tested with pressurised air (+50 mbar) prior to installation. The guaranteed tightness amounts to 99.9 % . In fact, the tightness is greater than 99.99 %!

Leak test of Plate packs in Ratingen



Assembly of plate packs in casing

The plate placks are tight welded to the casing. The welding occurs on the top and on the bottom.



The system of standard modules is suitable for volume flows of approx.:

5.000 to 2.000.000 m³/h npt wetwith a space requirement of approx.:

1 bis 400 m²

Casimg side to side build up to REKULUVO of any size

Special expansion joints take care of thermal expansion in 3 Dimension



Assembly with distribution hoods

While both flue gas and air flow vertically through the plates, the distribution hood adapt any duct routing to the REKULUVO

Upper hood

Lower hood

Heat Exchanger body



The plate packs can be replaced in the same manner as during their installation. No special crane, space or tools are necessary for this action. Dismantling of ducts or piping for space reason is not necessary anymore.

Replacement of plate packs



Guide shaping

Blowing pressure min. 6 bar

Guide shaping

Min. blowing pressure 6 bar

If possible, blow through per clearance

Vacuum clean module surface thoroughly!

If possible, blow through per clearance

Manual cleaning concept

It is of advantage to let the main fan run at low speed in order to reduce the dust generalisation.

If there are heavy dirt accumulation, the system can be washed by using water or high pressure water.



C2

C4

With high efficient soot blower system, the counter flow plate is suitable for a dust load under dry condition up to 100 g/Nm3.

Stationary cleaning device



Summary of Features of REKULUVO

Construction Features:

•It is is a plate type Air Preheater for atmospheric pressure range:

• It works per counter flow and is therefore extrem compact as well as high performing

• It is all welded and therefore completely leak free

• It has modular construction and fits to any Layout

• Flow direction is vertical

Technical Features:

•Fuel: Coal , Oil, Biomass, Waste, Natural Gas

•Medium: Gaseous like air or Flue gas

•Volume Flow: min. 5,000 max. 2,000,000 kg/hr

•Temperature: CS up to 490 °C, SS304 up to 550 °C, SS316 up to 650 °C

•Pressure: max. Diff. Pressure 400 mbar

•Heat Recovery efficiency up to 97 %

•Dust load max. 100 g / Nm3

•Material Carbon steel, Corten, Stainless Steel, enamelled CS



METHANOL PLANT CAPACITY CUSTOMER DESIGNCMC Trinidad 1.500 tpd Ferrostaal Davy McKeeM4, Trinidad 1.650 tpd Ferrostaal John Brown / UKMethanex II / Chile 2.500 tpd John Brown/US John Brown / USMethanex III / Chile 2.500 tpd John Brown/US John Brown / USIran Kharg I / Iran 1.250 tpd Lurgi / Sp Lurgi / DGNFC / India 600 tpd GNFC Jacobs EngineeringM5000 5.4000 tpd Ferrostaal Davy Process TechnologySIPC 3.000 tpd Chiyoda Jacobs Engineering

ETHYLEN PLANTBasell #18, Wesseling /D 900 tpd Basell KTIBasell #17, Wesseling /D 900 tpd Basell KTI

AMMONIA PLANTAbu Qir III 1.250 tpd Krupp-Uhde Krupp-UhdePorto Maghera 600 tpd Linde Selas-KirchnerSuez 1.250 tpd Krupp-Uhde Krupp-UhdeKoch Nitrogen 1.650 tpd KNC KelloggPUSRI IB 1.250 tpd PUSRI KelloggCNC / Trinidad 1.750 tpd Ferrostaal KelloggIGCL / Indogulf 1.500 tpd Indogulf Kellogg

REKULUVO References for Chemical Plants / 1



SULFUR PLANT CAPACITY CUSTOMER DESIGNHull Pigment / UK - Haldor Topsoe Haldor Topsoe

Catalytic CombustionCatalyst Plant / Denmark - Haldor Topsoe Haldor TopsoeCondea - Oschatz Fluor DanielEuroftal - Euroftal Balcke-DürrOltchim - Pantochim Balcke-Dürr

CrackerExxon / Baytwon - KTI BechtelExxon / Toscoe Refinery - Petrochem BechtelExxon / Pipe Still - Exxon -Exxon / PCLA - Exxon -

REKULUVO References for Chemical Plants / 2



Material selection: main possible material

Material

Chemical Composition

Application

Restriction

Carbon SteelDC04: 0.8 mm

C: 0,08P: 0,03S: 0,03Mn: 0,4Ti: -

Above Water & Acid dew point

Temp < 490 °C

Corten WtSt-370.8 mm, 1. 0 mm

C: 0,12P: 0,07-0,15S: 0,035Mn: 0,20-0,50Ti:-Si: 0,25-0,75Cu: 0,30-0,55Cr: 0,50-1,25Ni: 0,65V: -

Above acid dew point

Temp < 490 °Cmin. 80 to. required

Stainless SteelAISI 304: 0.6 mm

C: 0-0,07P: -S: -Mn: -Ti:-Si: -Cu: -Cr: 17,0-18,5Ni: 8,5-10,5V: -

Below acid dew point, no Chloride

Temp < 550-580 °C

Stainless SteelAISI 316Ti: 0.6 mm

C: 0-0,08P: -S: -Mn: -Ti: 5 x %C -0,80Si: -Cu: -Cr: 16,5-18,5Ni: 10,5-13,5V: -Mo: 2,0-2,5

Below acid dew point, slight chloride allowed

Temp < 650 °C

Other material: 316 L, 904 L, C-22, enamelled carbon steel



Material selection: Dew point consideration

50

60

70

80

90

100

110

120

130

140

150

0,01 0,1 1 10 100 1000

SO2 Content in ppmv

De

w p

oin

t in

°C

Acid Dew point for typical Natural gas combustion with 68 % N2, 1,6 % O2 and 24 % H2O (blue 64 °C) 14 % H2O (magenta 54°C) at 1 % Conversion rate

Water dew point



Material selection

We want to avoid THIS (Typical Cold end Corrosion at Cross flow HX)

Air inlet temp of 27 °C

Flue gas Outlet of approx. 150 °C

Natural Gas Combustion

Typical Material for Application below or close to the dew point is Stainless steel SS304



Material selection

Corrosion of Corten cold end section Air inlet temp of 29 °C Flue gas outlet of approx. 150 °CNatural Gas Combustion

Replacement with Balcke-Dürr REKULUVO made of Stainless steel 1.4301 (SS304)



Usually, The increase of the O2 content in the flue gas (or another single component) is an indicator for leakage in a heat exchanger. During a shut down, leakages can be detected by:

Visual inspection (90% of the cases)

Smoke bombsThe inlet flange of the low pressure side has to be blanked prior to the test. The smoke passing from one side to the other side shows the leaking area.

Florescent duts testThe inlet flange of the low pressure side has to be blanked prior to the test. A synthetic organic colorant (DayGlo T11) is added to the suction side of the blower (minimum speed). Inspection with black light will clearly shows areas for repair.

Leakage detection on site



In case of need for a repair, two alternatives have to considered:

Small deterioration (local damage, mechanical influence, fire, etc..)In case of deterioration of up to 10 % of the cross surface, the plate can be easily be blinded with a steel cover. Approx. the same duty can be obtained.

Large deterioration (corrosion, age, etc..)In case of deterioration of more than 10 % of the cross surface, it is recomended to proceed to an replacement of the plate packs. This replacement can be partial ot total, depending of the size of the damaged cross surface.

Repair possibilities



FeaturesFully welded platestype heat exchanger

Counter flow heat exchanger

Compact

Modular construction

AdvantagesNo leakage.Tightness guarantee > 99.9%

Maximum heat recovery

Less weight

No upscale problems

BenefitsID and FD-FanPower consumption is lower(as actual gas quantity is lower)

Increase in plant capacityoptimised heat recovery

Suit to existing foundation concrete

Suitable to any flow ranges

Features / Advantages / Benefits of REKULUVO

Vertical flow direction Feasibility to wash both waysMaintenace to initial pressure drop, less power consumption



Thank you for your Attention



3.250 4.530 5.650 4.200

6.6

60

7.8

50

REKUGAVO Tubular heat exchanger

In Comparison the REKUGAVO requires38 % less space and has13 % less overall height46 % less construction volume30 % less heating surface25 % less weight30 % less insulated surface

Operating conditions:Volume flow:50.000 m³/h i.N.fMax. Temperature: 280 °CEfficiency:: 83 %

Comparison between Tube & REKULUVO



Stack

ESP

Boiler

125 °C380 °C Flue gas

350 °C

Features:Flue gas range 200.000 - 300.000 Nm3/hTemperature differential up to 20 KMaterial Carbon steel, enamelled platesCustomers: Boiler maker, OperatorCountries: West-Europe

Air30 °C50 °C

REKULUVO for Power plants < 50 MWel



Stack

ESP

Boiler

125 °C

380 °C

45 °C / 40 mbar

30 °C Air

Flue gas

280 °C

Features:Flue gas range 200.000 - 300.000 Nm3/hTemperature differential 50 - 20 KPressure differential: 100 - 350 mbarMaterial CS, Corten, enamelled plates

30 °CAir

380 °C

50 °C / 150 mbar

350 °C

ESP

REKULUVO as Primary APH



StackBoiler

160 °C290 °C

Primary Air

Flue gas

250 °C

ESP

Features:Flue gas range 200.000 - 300.000 Nm3/hTemperature differential 100 - 20 KPressure difference: 150 - 350 mbarMaterial Carbon steel, Corten

30 °C50 °C / 350 mbar

Secondary Air

30 °C45 °C / 150 mbar245 °C

REKULUVO for atmospherical fluidised Bed Boilers



Stack

ESP

Boiler

380°CFlue gas

350 °C

Features:Flue gas range 500.000 - 1.000.000 Nm3/hTemperature differential 40 - 25 KMaterial Carbon steel, enamelled platesCountries: Germany

Primary Air30 °C50 °C

140 °C240 °C

HP Feed water heater

REKULUVO for Powerise (Power plant > 50 MWel)

Documents

Industrial REKULUVO