GLOBAL STRENGTH LOCAL FOCUS
LJUNGSTRÖM ® AIR PREHEATERS
Alstom is the global leader in the design, manufacturing, installation and maintenance of Ljungström® Air Preheaters. We are proud to be the owner of Ljungström® air preheater technology with its pedigree dating back to the 1920s when the first efficient air preheater was invented in Sweden by Frederick Ljungström. Today, Alstom owns Ljungström® patents and trademarks across the world and the group also combines the resources of industry leading names SRM, Air Preheater Company, Kraftanlagen, Gadellius, Stein, PBS and APEL.
Alstom Ljungström® Air Preheaters are recognized by boiler companies, utilities and manufacturers around the world as the best products of their type which is why they are more widely used than any other type of heat exchanger.
Unrivalled expertise in air preheaters Modular design. Maximum flexibility
Higher efficiency. Lower costs
The modular design concept behind Alstom Ljungström® Air Preheaters is a simple one. Create a f amily of air preheaters based on the same general platform and incorporating the latest best in-class technologies but which, individually, are tailored to fit a wide variety of different power plants.
Our air preheaters can recover up to 15% of boiler heat input, contributing up to 20% of the overall boiler efficiency while representing only 2% of total investment in a typical plant.
Our extensive portfolio of products includes preheaters for sub-critical, super-critical, ultra-supercritical and CFB boilers. All, though, are installed in the same way, with an optimised erection sequence that uses simple structures and the minimum number of assemblies.
Up to the largest sizes We recognise that thermal power plants are becoming increasingly large. The design flexibility built into our preheaters and, in particular, the wide range of sizes we offer means that we have already been able to meet the requirements of some of the largest plants currently being constructed.
The impressive performance of our air preheaters is, in part, the result of our unmatched experience in global boiler projects, so we appreciate that high thermal efficiency, leakage reduction and low pressure drop are all essential to their operation. Consequently, with our preheaters, we offer adaptable sealing systems giving a wide range of options to reduce leakage including load following leakage control.
Quality Our commitment to quality is at the heart of our business. Our customers know they are receiving the very best products available.
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Advanced modular Make our air Proven design with customisable options Ljungström® Air Preheaters have a reputation for rugged reliability and efficient operation that stretches back to the middle of the 20th century. Our current family of products are modular in concept so flexibility is built into their design. This means we can offer a wide range of standardised options when it comes to their construction and installation on site.
Customer benefits FLEXIBLE ROTOR DESIGN OPTIONS Centre or peripheral support arrangements Sizes to meet all preheat requirements for industrial and utility-sized boilers Bi-sector, tri-sector and quad-sector arrangements
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EFFICIENT SEALING SYSTEMS Comprehensive options to reduce leakage Load following leakage control systems Delivering unique benefits during hot and cold commissioning
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ADVANCED TRANSFER SURFACES AND BASKETS Highest efficiency for lowest pressure drop Range of profiles that provide easier cleaning and maintenance during operation Extended life due to lower soot blowing pressures
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REDUCED ERECTION COSTS Optimised erection sequence with minimum number of assemblies Alternative welded and pinned rotor options available
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REDUCED MAINTENANCE COSTS Robust drive configurations Low maintenance auxiliary systems Substantial, long-lasting and durable eq uipment
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A 20°-30°C recovery rate in the Ljungström® Air Preheater accounts for 1-1.5% reduction in the fuel requirements of the boiler. When installed on two 750 MW coal-fired boilers, the energy saved by the Ljungström® Air Preheater is the equivalent of 42 hopper car loads of coal per day 04
engineering preheaters first choice worldwide Air preheaters for every application No other air preheater supplier can match our vast experience of designing equipment for such a wide range of installations around the world. With our range of versatile modular design platforms and configurations, we are able to meet the many different requirements our customers have.
Duct and support configurations The correct selection of duct arrangements is critical to modern boiler layouts. We recognise this and produce our equipment in configurations to meet all requirements. Our equipment can be supplied in bi-sector, tri-sector and quad-sector arrangements for either a traditional peripheral support arrangement or for centre column support.
Modular site assembly Our comprehensive understanding of the requirements of site construction activities directly influences the modular design of our air preheaters which incorporates optimised, flexible assembly. As a result, depending on model size and type and the available lift capacity on site, we can tailor production to include efficient partial ground assembly of the units we supply.
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The rotor Any configuration,
Design flexibility means greater customer choice This is particularly true with the heart of our Ljungström® Air Preheaters – the rotor. The Alstom range boasts:
• The largest number of rotor sizes of any supplier • Two alternative types of construction • Several different configurations of basket loading • Arrangements from one to four layers of heat transfer baskets • Welded rotor designs use a welded connection between the rotor shaft and the structural plate work of the rotor • Site assembly requires considerable welding of critical joints • Connection method is the industry standard, due to its low cost • Rotors of this arrangement are built and then loaded with the element baskets
• Our unique pinned module designs incorporate a patented arrangement of pre-built rotor modules connecting to a special rotor shaft • The designs increase the life of the rotor by eliminating the thermal stresses • •
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that occur in welded rotor designs at the point where the main plates are welded to the rotor shaft Rotor modules can be pre-loaded with element baskets prior to connection to the shaft, meaning less time loading baskets at a later stage Site erection can be completed in less time and critical shaft to rotor welds are avoided
assembly anywhere in the world Our experience and knowledge of different rotor designs has helped to establish us as the leading innovator in rotating air preheater technology
OPTION
BENEFIT / ADVANTAGE
Basic welded rotor
Lowest equipment cost
Modular rotor
Optimised erection with minimised welding and reduced handling
Double sealed rotor
Reduced air to gas direct l eakage
Grating style rotor
Changeable baskets without disturbing adjacent layers
ALSTOM PIONE ERED the u se of speci al fixtures in our facto ries which allow us to build o ur modul ar rotor comp onents to the highest levels of quality and repeatability
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At the forefront Delivering long life,
Advanced heating surfaces We take pride in our long and diversified experience in the design and manufacture of high quality heating elements and are at the cutting edge of new surface development. Our engineers continue to develop new advanced surface technologies in a range of materials, thicknesses and depths to meet our global customer requirements. We are able to furnish heating elements that are optimised for the best heat recovery and lowest pressure drop while remaining compatible with the fuel being fired.
High performance and durability Correct surface configuration, material, and thickness, are integral to the thermal and pressure drop performance of any regenerative heat exchanger. Surfaces developed and optimised by Alstom engineers assure the highest performance and durability available. Our comprehensive range also allows us to provide aftermarket replacements for older surface types and, by installing our latest surfaces which are more efficient and remain cleaner when in operation, deliver efficient upgrade solutions.
Materials and quality We offer a range of surface and container materials to accommodate all customer requirements. Our global experience with mild steel, low alloy steel and premium enameled heating surfaces is unrivalled in our industry. Advanced quality control checks and processes ensure that the heating element products manufactured at any of our global facilities perform to our exceptional performance and life standards.
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of air preheater technology efficiency and low maintenance The enameled heat transfer surfaces supplied by Alstom incorporate the latest wet-coated application processes and technology, to provide products with industry leading enamel structure, thermal shock durability, cracking resistance and life
Advanced auxiliary equipment and systems Our air preheaters incorporate systems and equipment that are proven in the field and accepted by customers as the best in their class. We are continuously improving our auxiliary equipment and system options to provide the latest technology and configurations while maintaining the robust reliability in operation that is the hallmark of the Ljungström® Air Preheater.
Efficient sealing systems As air preheaters get larger the use of sealing systems is increasingly important to ensure low leakage operation. We offer a range of sealing system options delivering the lowest air-to-gas leakage while still maintaining the flexibility to operate across a range of loads. Low maintenance systems are available to provide either full self-adjustment of the sealing plates or multi-position adjustment across a specified range of load points.
Bearings and drive systems The bearing and drive systems incorporated into our air preheaters are the most reliable and durable designs in our industry and contribute to our air preheaters’ reputation for being problem free (with an impressive 99% availability).
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We are where our Offices and manufacturing
Europe North America Concordia (USA)
Mannheim (Germany) Brno (Czech Republic) Wellsville (USA)
East Asia Osaka (Japan)
India Delhi (India)
Kobe (Japan) Shanghai (China)
Shahabad (India)
Latin America Vinhedo (Brazil)
Aftermarket services Our involvement with you does not end with the successful installation of one of our air preheaters. We’re committed to our customers and offer additional added-value services. To provide life extension and plant upgrades, we support all existing installations with our genuine replacement parts in addition to component or sys tem upgrades. Our aftermarket solutions provide operators of both Alstom and other OEM equipment with valuable benefits in the areas of thermal efficiency, leakage reduction, fuel compatibility and SCR retrofit upgrades.
• Supply of genuine replacement parts with warranty support • Equipment inspections, condition assessments and life evaluations • Components upgrades for Alstom as well as other air preheater designs • Engineering studies for plant upgrades 10
customers need us facilities across the world We combine rigorous research and development with a comprehensive global after-sales service to ensure our equipment operates efficiently and cost-effectively in the long-term
Field service
Laboratory testing
Research and development
Across the globe we maintain a highly experienced staff of technical service specialists and engineers who are available 365 days a year to help ensure the efficient and reliable operation of your Ljungström® Air Preheaters. They can assist with outage planning, inspection, and diagnostic services and provide technical assistance for routine and emergency maintenance planning and repair.
In our laboratories, we use a range of specialised equipment and procedures to ensure the quality and durability of our preheating products. We maintain metallurgical testing facilities to maintain our excellence in areas such as heating element deposit & corrosion analysis and failure root cause analysis. Our dedicated soot blowing test rig enables us to test surfaces for cleanability as well as operation under adverse conditions and our state of the art switching regenerator provides the platform for us to conduct long-term tests of heat transfer surfaces subjected to a spectrum of thermal, environmental and mechanical conditions.
Research and development is key to our technological leadership and our programmes are always adapting to meet the current and future needs of the industry. Our competencies include heat transfer surface computational fluid dynamics (CFD) modeling, prototyping, production and physical testing using multiple sized wind tunnels. We conduct advanced research in air preheater fouling and cold end corrosion and we are constantly improving our understanding of air preheater rotor thermal and fatigue analysis using the latest techniques in finite element analysis (FEA). We are proud to claim that none of our competitors can match our investment and capabilities in these fields.
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Global leadership Some of our
Percentage of installations of Alstom designed air preheaters (including licensee installations)
Europe
66%
USA
98%
China
India
MEA
75%
Japan
99%
90%
70% Global Alstom air preheater design installations (including l icensees)
LAM
75%
With 90 years of air preheater experience, we have supplied thousands of air preheaters for power generation and industrial applications globally. We combine our local presence with global knowledge and resources in order to d eliver the technology and services which meet the demanding expectations of our customers around the world.
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through global experience key APH reference sites New equipment installations
SAUDI ARABIA
GERMANY
MALAYSIA
Saudi Electric Company Shoaiba 1-13 13 x 400 MW oil fired boilers 26 x size 28 bi-sector APH Startup : 2002-2013
EnBW Kraftwerke AG RDK8 1 x 912 MW coal fired boiler 1 x size 36.5 quad-sector APH Startup : 2013
TNB Janamanjung Manjung 4 1 x 1000 MW coal fired boilers 2 x size 34.5 tri-sector APH Startup : 2015
JAPAN
MOROCCO
MEXICO
Chugoku Electric Power Co. Inc Shin Onoda 1&2 2 x 500 MW coal fired boilers 4 x size 30.5 tri-sector air preheaters
Jorf Lasfar Energy Company Jorf Lasfar 3&4 2 x 260 MW coal fired boilers 2 x size 31.5 tri-sector air preheaters
Comisión Federal De Electricidad Tuxpan 3-6 4 x 350 MW oil fired boilers 8 x size 29.5 bi-sector air preheaters
Complicated and time-consuming maintenance on the existing Rothemuhle style air preheaters justified their replacement with new Ljungström® Air Preheaters selected to meet the specified performance with lower leakage levels and fit in the space occupied by the existing units.
Fuel switches were creating an issue with pluggage, so a new heat transfer surface configuration using advanced loose-packed heating elements was installed, reducing the fouling rate while maintaining the efficiency of the air preheaters.
Replacement of the complete rotor and shaft to upgrade the heaters to double sealing and provide improved thermal efficiency. Advanced heat transfer profiles were used with enamelled heating element in the cold end.
Retrofit projects
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How Alstom is helping you meet the challenges of energy sustainability.
It takes competitive assets to keep electricity affordable. We enable power companies to compete successfully in the marketplace and provide affordable electricity to consumers. We help you reduce the cost of electricity through:
• Efficiency improvements • CAPEX reduction / scaling up • Capacity Factor increase (renewable) • Lead time reduction • Competitive O&M • Competitive financing
Clean generation is one way of demonstrating environmental responsibility. Another is lowering resource usage, visual impact and noise pollution. In both cases, we can help you meet or exceed regulations and environmental standards. That is why Alstom innovates in the following areas:
• Renewable portfolio • Natural resource optimisation • Pollutants control (SO , NO , PM, mercury) • CO emission reduction & CCS • Land use, visual impact and noise • Water intensity reduction & x
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recyclability
Intermittent power generationis a growing challenge of energy security, as is maintaining an aging installed base and adapting it to changing market conditions. We help you tackle both issues so that you can enjoy dependable operations with:
• Maintainability and outage time reduction • Operational and fuel flexibility • Lifetime extension and power uplift • Designs and service for improved availability and reliability • Climate packages • Energy storage
Alstom Alstom is a global leader in the world of power generation, power transmission and rail infrastructure and sets the benchmark for innovative and environmentally friendly technologies.
Power generation
Alstom builds the fastest train and the highest capacity automated metro in the world, provides turnkey integrated power plant solutions and associated services for a wide variety of energy sources, including hydro, nuclear, gas, coal, wind, solar thermal, geothermal and ocean energies. Alstom offers a wide range of solutions for power transmission, with a focus on smart grids.
Power generation Alstom Power offers solutions which allow their customers to generate reliable, competitive and eco-friendly power.
Electrical grid
Alstom has the industry’s most comprehensive portfolio of thermal technologies – coal, gas, oil and nuclear – and holds leading positions in turnkey power plants, power generation services and air quality control systems. It is also a pioneer in carbon capture technologies. Alstom offers the most comprehensive range of renewable power generation solutions today: hydro power, wind power, geothermal, biomass and solar. With ocean energies, we are developing solutions for tomorrow. Alstom is one of the world leaders in hydro power, the largest source of renewable energy on the planet.
Rail transport
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Alstom Power Alstom Brazil Av. Independencia, 4385 13280-000, Vinhedo Sao Paulo Brazil Phone: +55 19 3826 6767 Alstom China 8F, One Indigo 20 Jiuxianqiao Road Chaoyang District Beijing 1000016 China Phone: +86 10 5630 4000 Alstom Czech Republic Olomoucka 7/9 656 66 Brno Czech Republic Phone: +420 54510 2913 Alstom Germany Haus Watt Boveristrasse 22 68309 Mannheim Germany Phone: +49 621 329 2100 Alstom India Tech Boulevard, Tower C 2nd Floor, Plot No. 6 Sector 127, Noida 201 301 Uttar Pradesh India Phone: +91 120 434 8056 Alstom Japan 2-3-4 Minatojima-nakamachi Kobe 650-0046 Japan Phone: +81 78 303 5060 Alstom United States 3020 Truax Road, Wellsville NY 14895 USA Phone: +1 585 593 2700
www.alstom.com
