Tubular Boiler Air Preheater Assembly For Flue Gas Heat Recovery Welded Housing

Tubular Air Preheater Assembly for Flue Gas Heat Recovery with Carbon Steel Tube Bundle and Welded Housing

The Tubular Air Preheater Assembly is a critical flue gas heat recovery component fabricated by Boyu Heavy Industry using our core tube bundle fabrication and steel structure welding capabilities, designed for preheating combustion air in industrial and utility boilers. As a specialized boiler component manufacturer with 200,000-ton annual tube fabrication capacity, Boyu produces tubular air preheaters leveraging our CNC tube cutting, automatic welding, tube expanding and pressure testing capabilities. This assembly serves the primary function of transferring heat from boiler flue gas to combustion air, raising air temperature from ambient to 150-300C, thereby improving boiler thermal efficiency by 5-8 percentage points and reducing fuel consumption. As industries continually seek to optimize energy efficiency and reduce operational costs, the tubular air preheater has become an indispensable component in modern boiler systems.

The Tubular Air Preheater Assembly is specifically constructed as a tube-and-tube-sheet heat exchanger, with flue gas flowing inside the tubes and combustion air flowing across the tube bank externally in a cross-flow arrangement. Boyu fabricates the tube bundle from certified seamless or welded carbon steel tubes (Q235/SA-179 or 20G/SA-210), with tube diameters typically 32-51mm and wall thickness 2-4mm. The tube sheets are fabricated from carbon steel plate with precision-drilled tube holes, and tubes are secured by tube expanding and seal welding to ensure leak-free operation between the gas and air sides. The steel housing is fabricated from structural steel plate with reinforced stiffeners, designed to withstand flue gas pressure and thermal expansion stresses.

Manufactured at Boyu's integrated fabrication facility, every Tubular Air Preheater Assembly undergoes CNC tube cutting, precision tube sheet drilling, tube expanding, seal welding, housing fabrication and comprehensive leak testing. The assembly is designed for compatibility with specific boiler flue gas and air duct dimensions, with standard flange or weld connections ensuring direct installation. Boyu's 3000-ton monthly production capacity enables competitive lead times, with typical delivery of 30-45 days for complete assemblies. Complete material certificates, weld procedure records and leak test reports accompany every shipment. The modular design allows for individual tube bundle section replacement during maintenance without removing the entire housing.

One significant advantage of Boyu-fabricated Tubular Air Preheaters is the integration of tube bundle fabrication and steel housing construction in one facility. Our experience in heat exchanger and primary cooler fabrication translates directly to air preheater production, with proven tube expanding techniques and seal welding methods that ensure long-term leak-free performance between gas and air sides. Additionally, the cross-flow tubular design provides reliable heat transfer with minimal maintenance requirements, as the straight tube configuration facilitates easy cleaning and inspection. Compared with regenerative air preheaters, tubular designs offer zero air-to-gas leakage, making them preferable for applications where leakage must be minimized.

The Tubular Air Preheater Assembly is adaptable to various boiler types, capacities and fuel types, making it suitable for power generation, coking, petrochemical, steelmaking, biomass energy and waste-to-energy industries. Its versatility enables application in both horizontal and vertical flow configurations across boiler sizes from small industrial units (10t/h) to large utility units (1000t/h and above). Furthermore, the assembly can be customized for specific flue gas conditions, including different tube pitches, tube lengths, housing dimensions and material configurations, ensuring optimal heat transfer performance and pressure drop for each application.

In addition to functional benefits, the Tubular Air Preheater Assembly is designed with durability and maintenance convenience in mind. The use of certified boiler tube materials ensures reliable heat transfer performance, with corrosion-resistant options available for aggressive flue gas environments. The modular tube bundle design allows for targeted replacement of damaged sections during scheduled maintenance. Boyu provides technical support for thermal design calculation, tube layout optimization, corrosion analysis and material selection, helping clients achieve optimal heat recovery with minimum pressure drop and maximum service life.

To summarize, the Boyu Tubular Air Preheater Assembly represents a high-quality flue gas heat recovery solution leveraging our core tube bundle fabrication expertise. By delivering precision-fabricated, leak-tested assemblies with verified heat transfer performance, it improves boiler thermal efficiency, reduces fuel consumption and lowers greenhouse gas emissions. Our integrated manufacturing capability, systematic material selection and expert technical support make this product an ideal choice for boiler operators and EPC contractors seeking reliable air preheater solutions. Investing in Boyu-fabricated tubular air preheaters is a strategic decision that supports long-term energy efficiency, cost savings and environmental compliance.

Features

·        Boyu integrated fabrication: CNC tube cutting + expanding + seal welding + housing welding

·        Carbon steel tubes: Q235(SA-179) / 20G(SA-210), OD 32-51mm, WT 2-4mm

·        Cross-flow design: flue gas inside tubes, air across tube bank externally

·        Zero air-to-gas leakage (vs regenerative type), straight tubes easy to clean

·        100% leak testing after tube expanding and seal welding

·        Improves boiler efficiency by 5-8%, preheats air to 150-300C

·        Modular tube bundle for individual section replacement

·        Precision-drilled tube sheets with hole position tolerance +/-0.5mm

·        Adaptable to 10t/h to 1000t/h+ boilers, horizontal or vertical flow

·        Expert support for thermal design, tube layout and corrosion analysis

Technical Parameters

Applications

The Boyu Tubular Air Preheater Assembly is a critical flue gas heat recovery component fabricated using our core tube bundle fabrication capabilities. Manufactured in Shandong, China, this assembly is available in customizable configurations to match diverse boiler requirements. Certified with ISO9001, ASME, Grade A and SGS, the product guarantees high quality and reliable heat recovery performance.

This Tubular Air Preheater is widely used in power station boilers, industrial steam boilers, coking waste heat boilers, biomass boilers, waste-to-energy boilers and metallurgical exhaust gas boilers where combustion air preheating is required to improve boiler efficiency. Its cross-flow tubular design ensures zero leakage and reliable heat transfer across a wide range of boiler capacities and fuel types.