Tube Bundle Heat Exchanger Air Preheater

1: Tube Bundle Heat Exchanger Air Preheater

 

1. Product Definition
 

An industrial air preheater is a critical tail-heating surface device integrated into CFB boilers. Positioned downstream of the economizer, it recovers waste heat from exhaust flue gases to preheat primary and secondary combustion air, maximizing overall thermal efficiency and reducing fuel consumption.

 

2. Product Manufacturing Process
 

1): Raw Material Preparation: High-grade carbon steel plates and corrosion-resistant alloy tubes are inspected and precision-cut using automated CNC laser equipment.

2): Tube & Plate Forming: Tubes are cold-drawn and bent to exact radii, while casing panels are punched and formed for modular assembly.

3): Welding & Assembly: Robotic welding secures tube bundles to header plates, ensuring leak-proof structural integrity under thermal stress.

4): Testing & Coating: Units undergo hydrostatic pressure testing and anti-corrosion sandblasting, followed by high-temperature industrial coating before export packaging.

 

3. Product Applications
 

1): CFB Boiler Integration: Positioned in the tail flue duct to capture residual heat from exhaust gases before entering the bag filter.

2): Thermal Power Plants: Elevates combustion air temperature to stabilize ignition and enhance combustion efficiency in utility boilers.

3): Industrial Steam Generation: Deployed in heavy manufacturing and co-generation plants utilizing coal, biomass, or multi-fuel combustion.

 

4. Product Advantages
 

1): High Thermal Efficiency: Maximizes waste heat recovery from tail flue gases, significantly lowering plant operating and fuel costs.

2): Robust Leak-Proof Design: Precision robotic welding and rigorous hydrostatic testing guarantee zero leakage between gas and air streams.

3): Corrosion Resistance: Premium alloy materials and protective coatings withstand aggressive sulfur and low-temperature acid dew point corrosion.

4): Optimized Flow Dynamics: Streamlined tube arrangements minimize pressure drop while maintaining high heat transfer coefficients.

5): Seamless Retrofitting: Modular dimensions match standard CFB boiler layouts for fast on-site installation and minimum downtime.

 

 

 

2: Parameters

 

1. Technical Specifications & Product Attributes

 

Attribute Category	Technical Specification Details
Product Name	CFB Boiler Air Preheater (Tubular / Plate Type)
Equipment Function	Flue Gas Heat Recovery & Combustion Air Preheating
Core Components	Tube Bundles, Tube Sheets, Casing, Expansion Joints
Customization	Built-to-Order based on Boiler Capacity & Drawing Specs
Compliance Standards	ASME, ISO9001, GB/T, CE Certified

 

 

2. Main Parameters:

 

Flue Gas Inlet Temp	300°C – 450°C
Air Inlet Temp	20°C – 60°C
Design Pressure	Up to 2.5 MPa (Positive/Negative pressure options)
Heat Transfer Rate	88% – 94% Thermal Effectiveness
Tube Material	Corten Steel, 20#, ND Steel, Stainless Steel

 

 

 

 

 

3: Our Factory Advantages

 

1. Advanced thermal design and optimization engineering ensure our air preheaters deliver maximum heat recovery and superior thermal effectiveness for industrial boilers.
 

2. Premium corrosion-resistant materials and rigorous weld inspections effectively prevent acid dew point corrosion and guarantee long-term operational reliability.
 

3. Precision-engineered modular structures and strict manufacturing tolerances facilitate fast on-site retrofitting, seamless duct integration, and reduced downtime.
 

4. Comprehensive multi-stage quality control, including strict hydrostatic testing and non-destructive examination, ensures 100% leak-proof performance under extreme pressures.
 

5. Fully customizable engineering solutions tailored to exact client drawing specifications and diverse fuel types maximize return on investment.

 

 

4: FAQ

 

Q1: How does the air preheater integrate into the CFB boiler system shown in the diagram?

A: It is located in the tail pass downstream of the economizer and upstream of the baghouse dust collector, recovering heat from the exhaust flue gas to preheat incoming combustion air.
 

Q2: What materials are selected to prevent low-temperature corrosion in this section?

A: We typically use corrosion-resistant materials such as Corten steel (weathering steel) or ND steel to withstand sulfuric acid condensation at the cold end of the preheater.
 

Q3: Can you manufacture replacement preheater bundles based on our existing plant drawings?

A: Yes. We specialize in custom fabrication matching exact dimensional and performance parameters from client engineering drawings or physical templates.
 

Q4: What is the standard production lead time for an air preheater unit?

A: Standard manufacturing takes approximately 5 to 9 weeks, depending on raw material availability, tube specifications, and order volume.
 

Q5: What quality testing is performed before delivery?

A: All units undergo strict quality control, including dimensional checks, raw material spectrometry, 100% weld seam inspection (NDE), and hydrostatic pressure testing before shipment.

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