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 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: 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 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 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: 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 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 method for improving effectiveness of a steam generator system includes providing air to an air preheater in excess of that required for combustion of fuel and providing the air at a mass flow such that the air preheater has a cold end metal temperature that is no less than a water dew point temperature in the air preheater and such that the cold end metal temperature is less than a sulfuric acid dew point temperature. 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. Flue gas reheat air is fed from the air preheater to heat the flue gas prior to entering a discharge stack to raise the temperature of the flue gas to mitigate visible plume exiting and to mitigate corrosion in the discharge stack.

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 method for improving effectiveness of a steam generator system includes providing air to an air preheater in excess of that required for combustion of fuel and providing the air at a mass flow such that the air preheater has a cold end metal temperature that is no less than a water dew point temperature in the air preheater and such that the cold end metal temperature is less than a sulfuric acid dew point temperature. 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. Flue gas reheat air is fed from the air preheater to heat the flue gas prior to entering a discharge stack to raise the temperature of the flue gas to mitigate visible plume exiting and to mitigate corrosion in the discharge stack.

Abstract: A heat transfer sheet [60,160,260,360] for a rotary regenerative heat exchanger is shaped to include sheet spacing features [59], which provide spacing between adjacent heat transfer sheets [60,160,260,360], and undulation surfaces [68,70] (corrugations) in the sections between the sheet spacing features [59]. The undulation sections [68,70] are constructed of regularly spaced lobes [64,72] extending at an angle with respect to the spacing features [59]. The undulating sections [68,70] impart turbulence in the air or flue gas flowing between the heat transfer sheets [60, 160, 260, 360] to improve heat transfer. The heat transfer sheets [60,160,260,360] may include undulating surfaces that differ in angle of their lobes [64,72].

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 heat transfer sheet [60,160,260,360] for a rotary regenerative heat exchanger is shaped to include sheet spacing features [59], which provide spacing between adjacent heat transfer sheets [60,160,260,360], and undulation surfaces [68,70] (corrugations) in the sections between the sheet spacing features [59]. The undulation sections [68,70] are constructed of regularly spaced lobes [64,72] extending at an angle with respect to the spacing features [59]. The undulating sections [68,70] impart turbulence in the air or flue gas flowing between the heat transfer sheets [60, 160, 260, 360] to improve heat transfer. The heat transfer sheets [60,160,260,360] may include undulating surfaces that differ in angle of their lobes [64,72].

Abstract: An economical heat recovery system [100] is described for use in a boiler [26] includes an air preheater [150] that receives hot flue gasses [FG1] and inlet air and creates heated air [A2] and incremental air [A2?]. The incremental air [A2?] is provided to a regenerative heat capture and transfer (RHCT) system [300] positioned to receive the incremental air [A2?] from the air preheater [150]. The RHCT includes a heat exchanger [310] that preheats feed water [WF1] for the boiler [26]. Since a heat exchanger [310] receives clean air as opposed to those of the prior are, it may be made more efficient with more heat exchange units in closer proximity, since there is little chance of blockage. Also, there is less maintenance with the present invention.

Abstract: An arrangement is provided in an air preheater for mounting and adjusting the axial seal plates in relation to the rotor using a reduced number of adjustable mountings and replacing the remaining adjustable mountings with adjustable compression stops. These adjustable compression stops engage but require no attachment to the axial seal plates. This reduces the work necessary in the limited space between the air preheater housing and the axial seal plates thereby reducing costs and facilitating installation and replacement.

Abstract: The rotor for a rotary regenerative air preheater is fabricated from a combination of shop assembled rotor sector modules and field assembled components so as to eliminate the double plate diaphragms of conventional modular rotors. The shop assembled modules comprise one or more sectors and the field assembled components fit between the spaced shop assembled modules spaced around the rotor hub. The support gratings between the diaphragm plates support modular heat exchange baskets which are loaded into the rotor radially from the periphery.

Abstract: A regenerative bed incinerator 10 incorporates a dwell chamber 18 disposed between a pair of spaced regenerative heat exchange the beds 14A and 14B, one of which serves as a gas preheating bed and the other of which serves as a gas cooling bed. At periodic intervals, the direction of flow through the incinerator 10 is reversed so that the functions of the beds 14A and 14B is reversed. A hot gas vent duct 80 is provided for selectively bypassing a portion 7 of the hot, incinerated process exhaust gases 5 around the gas cooling bed into the gas exhaust duct 70 for venting to the atmosphere. A bypass damper 88, which is controlled by control means 86 in responsive to exit gas temperature measurements from thermocouple 90, is positioned in the hot gas vent duct 80 to control the amount of hot, incinerated process exhaust gases bypass around the gas cooling bed.

Abstract: A heat exchange apparatus (10) formed of a plurality of heat exchange modules (20) mounted together in side-by-side relationship to form a box-like array. Each heat exchange module (20) houses a multiplicity of heat exchange tubes (44) which provide a flow passage through which a first heat exchange fluid, such as air, is passed in heat exchange relationship with a second heat exchange fluid, such as flue gas, passing through the heat exchange apparatus over the heat exchange tubes.

Abstract: A recuperative tubular heat exchanger comprised of a plurality of tube-bundle heat exchange modules (20) stacked in a spaced array and interconnected by U-shaped, open-end header conduits (30) to form a serpentine flowpath through which a fluid to be heated is passed in heat exchange relationship with a heating fluid passing in cross flow over the tube bundle modules. The interconnected modules together with the header conduits form an integral assembly which is free to slide on support beams (26) so as to float within the housing (12) of the heat exchanger in response to the thermal deformation of the tube bundle modules.