Pressure drop dynamic in a convective axis regenerative boiler using heavy crude oil

Crude oil is a source of energy, but its use in thermoelectric power plants generates deposits in the heaters and reheaters of the convective axis, decreasing thermal efficiency and increasing fuel consumption. The study aimed to analyze the pressure drop dynamics in the heaters and reheaters of the convective axis of a regenerative steam generator using heavy crude oil. The research was conducted at Unit 6 of 10 de Octubre Thermoelectric Power Plant in Cuba, where the pressure drop dynamics of a 125 MW steam generator were analyzed using real-time monitoring and predictive models based on operational data. Theoretical and actual values were compared within power ranges of 60-125 MW, with measurements taken using inline sensors and equations to determine path losses. The results showed an exponential increase in pressure drop, particularly at 90–95 MW and 120–125 MW, due to the accumulation of deposits, affecting gas circulation and operational stability. The models obtained presented determination coefficients higher than 0.9, validating their predictive accuracy. The accumulation of deposits on heat transfer surfaces increases pressure drop, reduces power, and raises fuel consumption. Continuous monitoring and predictive models optimize cleaning intervals.