Abstract: An air preheater (APH) temperature control system, including at least a first APH or combustion/secondary air bypass duct in metered communication with a combustion air inlet duct and a secondary air duct, adapted in use to bleed a portion of the combustion air as secondary air bypass from the air inlet duct upstream of the APH 100 for reintroduction downstream into the secondary air duct, and a flow control device for metering or controlling volumetric flow of the secondary air bypass and tempering primary air flow in use operative to maintain the flue gas outlet temperature at or above a desired minimum predetermined temperature for the incident flue gas volumetric flow exiting the APH alone or in conjunction with other tempering means maintaining mills outlet temperature within a safety range of T10MIN to T10MAX.

Abstract: A support structure for a rotary regenerative heat exchanger includes an upper section, a lower section, and a plurality of support members. The upper section includes an upper ring having a first exterior surface, an upper hub and at least three upper spokes each extending between and secured at respective ends thereof to the upper ring and the upper hub. Each of the plurality of support members are fixedly secured, directly or indirectly, to the upper ring and the lower section. An annular space is between the upper ring and the lower ring, which is configured to receive compartments of a rotor assembly. The upper hub, the upper spokes and the support members cooperate to provide rigidity to the support structure by cooperating to support and transmit the weight of the upper spokes, the upper ring and the upper hub to the lower section.

Abstract: A seal assembly includes a leaf assembly and a supplemental leaf assembly. The leaf assembly includes a first leaf having a first base section. The first base section defines a first fastening area for securing the first leaf to a diaphragm of the preheater. The first leaf has a first elongate section extending away from the first base section and terminating at a first distal end thereof. The leaf assembly further includes a second leaf that engages a portion of the first leaf. The second leaf has a second base section. The second base section defines a second fastening area for securing the second leaf to the diaphragm. The second leaf has a second elongate section extending away from the second base section and terminating at a second distal end thereof. The supplemental leaf assembly is secured to the first leaf and slidingly engaging the second leaf.

Abstract: A support structure for a rotary regenerative heat exchanger includes an upper section, a lower section, and a plurality of support members. The upper section includes an upper ring having a first exterior surface, an upper hub and at least three upper spokes each extending between and secured at respective ends thereof to the upper ring and the upper hub. Each of the plurality of support members are fixedly secured, directly or indirectly, to the upper ring and the lower section. An annular space is between the upper ring and the lower ring, which is configured to receive compartments of a rotor assembly. The upper hub, the upper spokes and the support members cooperate to provide rigidity to the support structure by cooperating to support and transmit the weight of the upper spokes, the upper ring and the upper hub to the lower section.

Abstract: A heat transfer sheet assembly for a rotary regenerative heat exchanger has first and second heat transfer sheet elements stacked one against the other with a first repeat of a first profile on one sheet element opposing a second repeat of a second profile on the other sheet element. The sheet elements are spaced apart by a plurality of wide-gauged parallel sheet spacing features of the first profile repeat RI of the second profile repeat to form a generally close sided elongate channel for gaseous flow therethrough. The second profile of repeat includes an elongate fifth sheet spacing feature in the form of a lobe contacting undulations of the adjacent first profile of repeat.

Abstract: A rotor for a high temperature rotary pre-heater includes a hub that has an exterior surface thereon. The rotor includes an annular rim positioned around and coaxially with the hub. The annular rim has an interior surface. A plurality of partitions extend between the hub and the annular rim. Each of the partitions is located in a predetermined circumferential position by one or more alignment features. The exterior surface, the interior surface and/or the partitions have one or more of the alignment features thereon.

Abstract: A method for improving effectiveness of a steam generator system includes providing a steam generator system including a steam generator vessel, an air supply system and an air preheater. The air supply system is in communication with the steam generator vessel through the air preheater and the steam generator vessel is in communication with the air preheater. The air supply system provides a first amount of air to the air preheater. At least a portion of the first amount of air is provided to the steam generator vessel. A flue gas mixture is discharged from the steam generator vessel. At least a portion of the flue gas mixture flows into the air preheater. SO3 in the flue gas mixture is mitigated before the flue gas mixture enters the air preheater.

Abstract: Disclosed is a heat transfer assembly for a rotary regenerative preheater. The heat transfer assembly includes a plurality of heat transfer elements stacked in spaced relationship to each other in a manner such that each notch from a plurality of notches of one of the heat transfer element rests on respective flat sections from a plurality of flat sections of the adjacent heat transfer elements to configure a plurality of closed channels, each isolated from the other, wherein each of the channels has a configuration in a manner such that each of corrugation sections from a plurality of corrugation sections of one of the heat transfer elements faces respective undulation sections from a plurality of undulation sections of the adjacent heat transfer elements.

Abstract: A basket for an air preheater includes two metallic frames each having two corner pieces and two connector pieces. For each frame, one of the connector pieces is secured to one end of each of the corner pieces and another of the connector pieces is secured to an opposite end of each of the corner pieces thereby forming a rectangular opening in each frame. The basket includes two heavy gauge metallic sheets that are secured to the corner pieces, thereby spacing the frames equally apart from and parallel to one another thereby forming a channel between two of the sheets.

Abstract: A stack of heat transfer sheets includes one or more first sheet which includes a first undulating surface formed by first lobes that are parallel to each other and oriented at a first angle. The first sheets include a second undulating surface formed by second lobes that are parallel to each other and oriented at a second angle, different from the first angle. The first sheets include a third undulating surface formed by third lobes extending from one or more ends of the first sheet and terminating at an intermediate point between the end and an opposing end thereof. The third lobes are parallel to each other and parallel to the direction of flow through the stack. The stack includes one or more second sheets defining a plurality of sheet spacing features which engage a portion of the first sheet.

Abstract: A trunnion bolt monitoring system for an air preheater trunnion has a plurality of trunnion bolts through which extends a respective blind bore each in gas tight connection at its open end to a pressurized manifold comprising piping and T-fittings. Depressurisation of the manifold indicative of fatigue cracking of any one bolt is detected by electrical monitoring of three pressure sensors.

Abstract: A seal assembly includes a first leaf with a spacer secured proximate a distal end of the first leaf. The spacer extends along the first leaf from an outboard end of the spacer to an inboard end thereof. The seal assembly includes a second leaf that is secured to the spacer so that the distal end is positioned proximate the outboard end of the spacer. The second leaf has an elongate section that extends away from the distal end. The elongate section extends beyond the inboard end of the spacer and terminates along the first bend of the first leaf, so that a portion of the second leaf proximate the terminus of the second leaf is slidingly moveable relative to and in compressive engagement with a portion of the first bend, and a portion of the second elongate section is spaced apart from the first elongate section.

Abstract: A heat transfer sheet assembly for a rotary regenerative heat exchanger has first and second heat transfer sheet elements stacked one against the other with a first repeat of a first profile on one sheet element opposing a second repeat of a second profile on the other sheet element. The sheet elements are spaced apart by a plurality of wide-gauged parallel sheet spacing features of the first profile repeat R1 of the second profile repeat to form a generally close sided elongate channel for gaseous flow therethrough. The second profile of repeat includes an elongate fifth sheet spacing feature in the form of a lobe contacting undulations of the adjacent first profile of repeat.

Abstract: Disclosed is a heat transfer assembly for a rotary regenerative preheater. The heat transfer assembly includes a plurality of heat transfer elements stacked in spaced relationship to each other in a manner such that each notch from a plurality of notches of one of the heat transfer element rests on respective flat sections from a plurality of flat sections of the adjacent heat transfer elements to configure a plurality of closed channels, each isolated from the other, wherein each of the channels has a configuration in a manner such that each of corrugation sections from a plurality of corrugation sections of one of the heat transfer elements faces respective undulation sections from a plurality of undulation sections of the adjacent heat transfer elements.

Abstract: A trunnion bolt monitoring system for an air preheater trunnion has a plurality of trunnion bolts through which extends a respective blind bore each in gas tight connection at its open end to a pressurized manifold comprising piping and T-fittings. Depressurisation of the manifold indicative of fatigue cracking of any one bolt is detected by electrical monitoring of three pressure sensors.

Abstract: A method for improving effectiveness of a steam generator system includes providing air to an air preheater at a mass flow such that the air preheater has a cold end outlet temperature defined by the improved air preheater operating with increased heat recovery (HR) of at least 1% calculated according to the equation: HR=100%×((Tgi?TgoAdvX)/(Tgi?TgoSTD)?1). The method requires either reducing the amount of heat that flows into the air preheater from the flue gas and/or increasing the amount of heat extracted from the flue gas. The method includes mitigating SO3 in the flue gas which is discharged directly from the air preheater to a particulate removal system and then directly into a flue gas desulfurization system.

Abstract: A seal assembly includes a leaf assembly and a supplemental leaf assembly. The leaf assembly includes a first leaf having a first base section. The first base section defines a first fastening area for securing the first leaf to a diaphragm of the preheater. The first leaf has a first elongate section extending away from the first base section and terminating at a first distal end thereof. The leaf assembly further includes a second leaf that engages a portion of the first leaf. The second leaf has a second base section. The second base section defines a second fastening area for securing the second leaf to the diaphragm. The second leaf has a second elongate section extending away from the second base section and terminating at a second distal end thereof.

Abstract: Disclosed is a heat transfer assembly for a rotary regenerative preheater. The heat transfer assembly, includes, a plurality of heat transfer elements stacked in spaced relationship to each other in a manner such that each notch from a plurality of notches of one of the heat transfer element rests on respective flat sections from a plurality of flat sections of the adjacent heat transfer elements to configure a plurality of closed channels, each isolated from the other, wherein each of the channels has a configuration in a manner such that each of corrugation sections from a plurality of corrugation sections of one of the heat transfer elements faces respective undulation sections from a plurality of undulation sections of the adjacent heat transfer elements.

Abstract: A basket for an air preheater includes two metallic frames each having two corner pieces and two connector pieces. For each frame, one of the connector pieces is secured to one end of each of the corner pieces and another of the connector pieces is secured to an opposite end of each of the corner pieces thereby forming a rectangular opening in each frame. The basket includes two heavy gauge metallic sheets that are secured to the corner pieces, thereby spacing the frames equally apart from and parallel to one another thereby forming a channel between two of the sheets.

Abstract: A seal assembly includes a first leaf with a spacer secured proximate a distal end of the first leaf. The spacer extends along the first leaf from an outboard end of the spacer to an inboard end thereof. The seal assembly includes a second leaf that is secured to the spacer so that the distal end is positioned proximate the outboard end of the spacer. The second leaf has an elongate section that extends away from the distal end. The elongate section extends beyond the inboard end of the spacer and terminates along the first bend of the first leaf, so that a portion of the second leaf proximate the terminus of the second leaf is slidingly moveable relative to and in compressive engagement with a portion of the first bend, and a portion of the second elongate section is spaced apart from the first elongate section.