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The main goal of this study is to achieve the extended operating life of the rotary regenerative air pre-heater (Ljungström) of Bandar Abbas power plant by modifying operational parameters by decreasing the corrosion. To achieve this goal, a three-dimensional CFD simulation of the Ljungström is carried out, utilizing the thermal non-equilibrium porous media model. Temperatures are validated against measured data from the power plant with a maximum relative error of 5.54% on the Celsius scale, and mass flow rates are validated with a maximum relative error of −5.25%. The effect of the Ljungström key parameters including the rotational speed, cold layer material, inlet air/flue gas temperature, and mass flow rate, are analyzed in presence of leakages and neglecting it, using porous media approach. The leakage effect is investigated considering radial and axial/peripheral clearances. Finally, a simulation is performed by applying feasible improved parameters extracted from the above analyses considering the effect of all parameters together in presence of leakages, which shows a 6.14% improvement in the Ljungström effectiveness, reducing the total leakage to about one-third of the actual model and eliminating any corrosion.

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