Parametric Study of Flow Uniformity for Mitigating Ammonium Bisulfate Fouling in Air Preheaters Based on CFD Simulations

Ammonium bisulfate (ABS) fouling in air preheaters has become a critical challenge restricting the safe and efficient operation of coal-fired units. Optimizing the flow field of the outlet of the upstream SCR system is a potentially effective path to mitigate ABS fouling. In this work, CFD simulations were conducted on the SCR De-NOx system and its succeeding flue ducts connected to the air preheater. The simulation results of the original design show that a significant velocity deviation exists at the inlet of the air preheater (with the CV1 up to 53.2%), with a portion of the flue gas adhering to the walls, which could induce ABS fouling in the low-temperature region. By adding flow guide plates into the flue duct, the flow uniformity before the air preheater was expected to be effectively improved. Notably, considering the deposition characteristics of ABS and the operating characteristics of the rotary air preheater, this study proposed a novel evaluation indicator, radial variance coefficient (CV2), which focuses on the velocity uniformity based on the annular sector unit, to indicate the risk of ABS deposition. The influence on velocity uniformity of different flow guide plate layouts was analyzed. Based on the multiple evaluation metrics including pressure drop and flow uniformity, the optimal layout scheme was then selected. After optimization, the radial variance coefficient decreased from 30.7% to 11.7%, with the pressure drop slightly increased from 50 Pa to 80 Pa. This study could help to reduce unit failure frequency and support efficient operation of coal-fired power plants.