UltraGen Optimising thermal flow to maximise power

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Edwina Hart
5 years ago
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1 UltraGen Optimising thermal flow to maximise power Better cleanability, reduced pressure drop, increased performance

2 Howden has been driving the evolutionary development of rotary heat exchangers for almost 100 years. Now, revolutionary change has arrived... welcome to UltraGen. For decades, we have been introducing steady improvements into the way that heat exchangers work. We developed today s most effective element profiles, structured to promote air flow, thermal exchange and cleanabilty. We produced and refined coatings that resist corrosion and fouling. We designed a highly effective on-line cleaning system. Now, we have introduced three major technological advances that work in harmony to bring the most dramatic leap forward in heat exchanger operation since its invention UltraGen.

UltraGen the next generation of heat exchanger technology Throughout the steady development of heat exchangers,

problems and issues. We have seen, at first hand, how different fuels affect performance.

We can now announce a breakthrough in the drive to eliminate cold end fouling that will significantly raise

3 UltraGen the next generation of heat exchanger technology Throughout the steady development of heat exchangers, Howden has worked in partnership with power plant customers throughout the world, investigating real-life problems and issues. We have seen, at first hand, how different fuels affect performance. We know that the greatest challenge to continual efficiency is heater fouling and plugging, particularly at the cold end. For decades we have been researching and testing materials, element profiles, enamels and cleaning systems. We can now announce a breakthrough in the drive to eliminate cold end fouling that will significantly raise generating station output. UltraGen A triple technology that achieves far more than the sum of the parts. The new HCP Element for cold end application SureCoat Plus (enamelled mild steel) and SureCoat Premium (enamelled LACR steel) The Enerjet cleaning system 1

4 Each component of UltraGen works to maximise the benefits drawn from the others. Each one can be used individually to deliver positive results. However, together they offer a radical leap forward in the fuel efficiency of the generating process. The UltraGen advantage For the first time, cold end elements will provide an optimised profile at each temperature band without losing flow direction or introducing inter-tier losses. Enamelled mild Steel (SureCoat Plus) or enamalled LACR steel (SureCoat Premium) elements offer a previously unattainable combination of strength and cleanability. High performance cleaning, with integrated sootblowing and high-pressure washing, can be carried out during normal heat exchanger operation. HCP Element UltraGen The benefits of improved heat exchanger performance are delivered in parallel with reduced fan energy consumption. Enerjet SureCoat 2

1 2 3 The HCP Element An understanding of the behaviour of various flue gases within the different temperature bands of a heat exchanger is a vital foundation for improving performance.

into and out of the space between layers. Combining two profiles within one element represented an enormous technical challenge.

The HCP design provides precisely the right performance at each part of the cold-end stage without introducing the disruption of the two-element approach.

steel, also known as Corten. Until now, enamelled elements have had to be manufactured using decarburised steel as the base material.

5 The HCP Element profile Combining two profiles into one deep element, with the extent of each section optimised for flow, greatly reduces dispersion. The cleaning force penetrates deeper into the elements, making the cleaning process far more effective The HCP Element An understanding of the behaviour of various flue gases within the different temperature bands of a heat exchanger is a vital foundation for improving performance. We created optimised profiles for each band, but the use of two separate element layers inevitably disrupted flow direction and introduced inter-tier losses as the flow path expands and contracts into and out of the space between layers. Combining two profiles within one element represented an enormous technical challenge. In overcoming that challenge we can now, for the first time, economically manufacture a single, extra deep, dual-profile element. The HCP design provides precisely the right performance at each part of the cold-end stage without introducing the disruption of the two-element approach. SureCoat enamelling Before the practice of enamelling was developed, cold end elements were produced from higher strength materials, normally mild steel (MS) or Low Alloy Corrosion Resistant (LACR) steel, also known as Corten. Until now, enamelled elements have had to be manufactured using decarburised steel as the base material. Following customer demand, we undertook an extensive R&D programme in conjunction with Europe s leading suppliers of enamel frits. We have now developed new enamel frits and processes which are compatible with the use of mild steel (SureCoat Plus) and LACR steel (SureCoat Premium). SureCoat thus combines strength and durability with corrosion resistance. Enerjet cleaning system Removing contaminants from heat exchanger elements is an essential operation. It maintains effective flow through the heater and prevents the pressure drop from placing excessive demands on fans. The Enerjet system, tested and proven in the field, uses high intensity needle jets, from the cold end only, to blast deposits away using only a small volume of water. Custom designed nozzles on fully or semi-retractable lances move across the elements, cleaning the surfaces efficiently while the heat exchanger is in normal operation. Enerjet is highly effective when used with HCP Element profiles and SureCoat enamelling. 3

UltraGen is by far the fastest and most economic pathway to dramatically enhanced heat exchanger

Howden Heater Technology The major advance represented by UltraGen is built on an understanding of

and extending the working life of heat exchangers.

We developed the SurePack computerised basket packing system.

Howden use only the most advanced dry electrostatic coating process.

6 UltraGen is by far the fastest and most economic pathway to dramatically enhanced heat exchanger performance, bringing a significant increase in power generating capability. Howden Heater Technology The major advance represented by UltraGen is built on an understanding of heat exchanger technology that dates back to our work with Fredrik Ljungström, the inventor of the technology. Since that time, Howden research, development and manufacturing has been improving the performance and extending the working life of heat exchangers. Our skill, experience and expertise have provided innovations that are now industry standards. We developed the SurePack computerised basket packing system. We designed the HC Element profile to eliminate skew flow and cold corners. Howden use only the most advanced dry electrostatic coating process. We devised the highly effective VN sealing system to eliminate leakage drift. We have created a dependable computer modelling package for element selection. Every step forward is the result of listening to the people who rely on safe, robust and efficient heat exchanger operation as an essential part of their processes. Applications knowledge is at the root of every advance we make. 4

7 For a fully costed appraisal of the benefits UltraGen could bring to your power plant, please contact your local Howden office.

www.howden.com At the heart of your operations Howden people live to improve our products and services and for over 160 years our world has revolved around our customers.

We have innovation in our hearts and every day we focus on providing you with the best solutions for your vital operations. Howden Spain Ctra. F-40, km.

8 At the heart of your operations Howden people live to improve our products and services and for over 160 years our world has revolved around our customers. This dedication means our air and gas handling equipment adds maximum value to your operations. We have innovation in our hearts and every day we focus on providing you with the best solutions for your vital operations. Howden Spain Ctra. F-40, km. 1 a Los Camachos La Union, Murcia, Spain Tel: Fax: sales.hs@howden.com Howden Group Limited. All rights reserved Howden and the flying H logo are registered trade marks belonging to Howden Group Limited.

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