Air Preheater in Thermal Power Plant: Boosting Efficiency and Reducing Costs

Why use an air preheater in a thermal power plant? Air preheaters are critical components that enhance the overall efficiency of power generation by recovering waste heat from flue gases and transferring it to combustion air. This process significantly reduces fuel consumption, lowers emissions, and improves boiler performance.

In thermal power plants, air preheaters play a vital role in optimizing energy efficiency. Studies show that integrating an air preheater can improve boiler efficiency by 5-10%, leading to substantial cost savings. For instance, a 500 MW coal-fired plant using an air preheater can save up to 30,000 tons of coal annually, reducing CO2 emissions by approximately 75,000 tons. The recovered heat increases combustion air temperature, ensuring complete fuel burning and minimizing unburnt carbon losses. Additionally, air preheaters help meet stringent environmental regulations by cutting NOx and SOx emissions.

Modern air preheaters, such as rotary regenerative or tubular types, are designed for durability and low maintenance. Leading manufacturers like Howden, GE, and Babcock & Wilcox provide advanced solutions tailored for high-capacity plants. Real-world data from power plants in India and China confirms that air preheaters contribute to a 2-3% reduction in heat rate, translating to millions in annual savings. By investing in high-quality air preheaters, thermal power plants can achieve long-term operational reliability, regulatory compliance, and enhanced profitability.