Computational prediction of erosion of air heater elements by fly ash particles

Seven different plate element profiles were used to investigate how erosion varies with the element geometry under the operational conditions for Matimba Power Station (as an example). Very low erosion rates (less than 0.5 mg of steel removed per kilogram of ash throughput) and long service lives were predicted for the elements with the flow channels between the plates running parallel to the direction of bulk gas flow. On the other hand, high erosion rates (2-5 mg/kg) and shorter service lives (15-35 years) were predicted for the elements with plates having corrugations that run at an angle to the direction of bulk gas flow.