Heat Transfer Analysis of Forced Circulated HRSG

Prepared by Swapnil Vanjara Guided by Dr. P. Prabhakaran Professor, msu Mechanical Depart ment

Thermal Design Ideas for Systematic Development of Heat Recovery Steam Generators

R S

What?:
The heat recovery steam generator (HRSG) is a heat exchanger designed to recover the exhaust waste heat from power generation plant prime movers, such as gas turbines or large reciprocating engines, thus improving overall energy efficiencies.

Why?: HRSGs help bring overall plant efficiency to 85%90%, and

the economic and environmental benefits are well recognized. In a recent Chinese triple-pressure HRSG application, an exhaust gas flow of 702 kg/s was cooled from an inlet temperature of 596C to 119C at the HRSG outlet before exhausting to stack. Total heat removed was 371 MWth.

Role of SG in Rankine Cycle

Perform Using Natural resources of energy .

Steam Generation Theory

HRSG Plant Layout

A Physical View

Classification
Use basis cogenration/combined cycle Circulation basis naturally/forced or vertical tube/horizontal tube

Circulation Basis
Naturally circulated

forced circulated

Vertical tubes can handle much higher heat fluxes than horizontal tubes, up to 40% to 50% more1. Known

Use Basis

cogeneration efficiency Upto 90 %

Combined cycle 60 65%

Mechanism of Heat Transfer : Generalized Newtons Law of Cooling

Rate of heat transfer from hot gas to cold steam is proportional to: Surface area of heat transfer Mean Temperature difference between Hot Gas and Cold Steam.

Thot gas,in Tcold steam,out

Q NEWTON Asur Tmean

Thot gas,out

Tcold steam,in

Pinch and Approach Points

Note: This is the Design mode ..We cannot preselect pinch and approach points in offdesign mode!

Pinch Point:- Difference between the gas temperature leaving the evaporator and temperature of saturated steam Approach Point:- Difference between the temperature of saturated steam and the temperature of the water the evaporator

Facts about Pinch and Approach Points

Pinch and Approach points are selected in unfired mode at Design gas flow, exhaust gas temperature. These are called design pinch and approach points

Once selected, they fall in place in other cases of gas flow/inlet gas temperature/steam conditions, whether unfired or fired.
Pinch/approach points increase with inlet gas temperature They cannot be arbitrarily selected

Facts about Pinch and Approach Points

They cannot be arbitrarily selected -temperature cross can occur -low pinch point may not be physically feasible unless extended surfaces are used -affected by inlet gas temperature -economizer steaming is a concern ;suggest minimum approach at coldest ambient HRSG conditions -steam temperature can be achieved in fired conditions if it is achieved in unfired conditions

HRSG surfaces are determined once design pinch/approach points are selected

Why HRSG exit gas temperatures cannot be assumed

Exit gas temperature cannot be assumed as in conventional fired steam generators as temperature cross can occur.Looking at the superheater and evaporator,we have: WgxCpgx(tg1-tg3)=Ws(h5-h7) (1) Looking at the entire HRSG,

WgxCpgx(tg1-tg4)=Ws(h5-h8)

(2) [blow down and heat loss neglected]

Dividing (1) by (3) and neglecting effect of variations in Cpg with temperature,we have: (tg1-tg3)/ (tg1-tg4)= (h5-h7)/ (h5-h8)=K For steam generation to occur and for a thermodynamically feasible temperature profile,two conditions must be met: If pinch and approach points are arbitrarily selected,one of these may not be met. (3) stm temp,F sat sat sat temp,F 338 366 K .904 .8704 exit gas,F 300 313

Psig 100 150

250
400 400 600

sat
sat 600 sat

406
448 450 490

.8337
.7895 .8063 .7400

332
353 367 373

tg3>ts and tg4>tw1.

Pinch=20F,approach=15 F,gas inlet=900 F,feed water=230 F

600

750

492

.7728

398

RFERANCES
U.P.B. Sci. Bull. Series D, Vol. 71, Iss. 4, 2009 ISSN 1454-2358 ADVANCED HEAT TRANSFER BY V. GANPATHY POWER PLANT ENGINEERING BY ARORA & DOMKUNDWR ASME PTC 4.4-2008 [Revision of ANSI/ASME PTC 4.4-1981 (R2003)]

Simplified HRSG Performance

Using the concept that firing in a HRSG is 100 % efficient,we can evaluate the performance in fired case for estimation purposes.

Example:160,000 lb/h of exhaust at 950 F enters a HRSG to generate 600 psig steam at 750 F from 230 F water.Determine unfired steam production and also burner duty,firing temperature and exit gas temperature when generating 35,000 lb/h of steam at 600 psig,750 F. Solution:Using 25 F pinch and 20 F approach,compute energy absorbed by SH+evap=160,000x0.27x(950-517)x0.98=18.33 MM Btu/h=Ws(1378.9-455.4) or Ws=19,850 lb/h. Energy absorbed by HRSG=19,850x(1378.9-199.7)=23.4 MM Btu/h=160,000x0.98x0.268x(950-tg4) or tg4=393 F.
Fired case: Energy absorbed by steam=35000x(1378.9-199.7)=41.27 MM Btu/h. Additional fuel energy required=(41.27-23.4)=17.87 MM Btu/h. Oxygen consumed=17.87x106/(160000x58.4)=1.91 % So there is plenty of oxygen left. Firing temperature=17.87x106=160000x0.3x(T-950) or T=1322 F Exit gas temperature=1322-41.27x106 /(160000x.275x.98)=364 F

Design & Off-design calculations

DESIGN unfired establishes configuration establishes surface areas indirectly only one case zero desuperheater spray pinch and approach points selected zero economizer steaming WHATIF STUDIES steam pressure variations firing temperature restrictions effect of fuels performance testing effect of gas turbine load variations in ambient temperature

OFF-DESIGN
unfired/fired/fan mode/combination several cases possible computes desuperheater spray

pinch and approach points computed

economizer steaming possible

A simple example of simulation

The energy transferred to the evaporator is given by: Q=WgCp(T1-T2)=UST=US (T1-T2)/ln[(T1-ts)/(T2-ts)] ; simplifying, ln[(T1-ts)/(T2-ts)]=US/WgCp . In a fire tube boiler,U Wg0.8. For a water tube

boiler,U Wg0.6 ,neglecting the effects of temperature.

Then, Wg0.2ln[(T1-ts)/(T2-ts)]=K1 for a fire tube boiler and Wg0.4ln[(T1-ts)/(T2-ts)]=K2 for a water tube boiler

Example: A water tube boiler is designed to generate

steam at 250 psig with 100,000 lb/h of flue gas at 1000 F.Exit gas temperature is 500 F.What is the exit gas temperature when 90,000 lb/h of flue gas enters the boiler at 970 F and steam pressure is 200 psig?

Solution: First compute K2 using design conditions...

1000000.4ln[(1000-406)/(500-406)]=184.4=K2
In the off-design case,900000.4ln[(970-388)/(T2388)]=184.4 or T2=473 F.Duty and steam generation may be computed from this. [406 and 388 F are saturation temperatures corresponding to 250 and 200 psig respectively.]

Example of a HRSG simulation

Example:140,000 lb/h of turbine exhaust gases at 980 F enter a HRSG generating sat steam at 200 psig.Determine the steam generation and temperature profiles if feed water temperature is 230 Fand blow down=5%. Solution: Let us choose a pinch point of 20F and approach of 15 F.Sat temperature=388F. Gas temperature leaving evaporator=408 F and water temperature entering it is 373 F.Evaporator duty=140000x.99x.27x(980-408)=21.4 Mm Btu/h. [ 1% heat loss and average specific heat of 0.27 Btu/lbF is assumed] Enthalpy absorbed in evaporator=1199.3-345+.05x(362.2-345)=855.2 Btu/lb

[1199.3,345 and 362.2 are enthalpies of sat steam,water entering evaporator and saturated water respectively]. Hence steam generation=21.4x106/855.2=25,000 lb/h
Economizer duty=25000x1.05x(345-198.5)=3.84 Mm Btu/h .gas temperature drop=3840000/(140000x.253x.99)=109 F.Hence exit gas temperature=408-109=299 F

Off-design Performance
Simulate the HRSG performance with a 165,000 lb/h of gas flow at 880 F.Steam pressure =150 psig. Using the model for evaporators discussed elsewhere,ln[(980-388)/(408388)]=Kx140000-0.4 or K=387.6 Under new conditions: ln[(880-366)/(Tg366)]=387x165000-0.4 =3.1724 or Tg=388 F.Evaporator duty=165000x.99x.27x(880388)=21.7 MM Btu/h In order to determine the steam flow,the feed water temperature to evaporator must be known.Try 360 F.Then steam flow=21.7x106/[1195.7-332)+.05x(338.5332)]=25,110 lb/h. Economizer duty(assumed) Qa=25110x1.05x(332-198.5)=3.52MM Btu/h.Compute (US)d=Q/T for economizer based on design conditions. Q=3.84x106 T =[(408-373)-(299-230)]/ln[(69/35)]=50 F.(US)d=3840000/50=76800. Correct this for off-design case. (US)p=(US)dx(165000/140000).65=85200.The effect of variations in gas temperature is minor and not considered. The energy transferred =(US)p xT. Based on 360F water exit temperature,the economizer duty=3.52MM Btu/h and gas temperature drop=3520000/(165000x.99x.253)=85 F or exit gas =388-85=303 F.T=[(303-230)-(388-350)]/ln[(73/28)]=47 F or transferred duty=85200x47=4.00 Mm Btu/h.As this does not match the assumed value of 360F and duty ,another iteration is required. It can be shown at 366 F,the balance is obtained.

HRSG Performance Calculations

Performance may be obtained even if HRSG geometry is unknown using simulation concept.

Why are HRSGS inefficient?

Low steam/gas ratios

Low inlet gas temperatures(900 F vs 3300 F)

Temperature profiles depend on steam pressure and temperature

Higher the pressure,lower the steam generation

Higher the steam temperature,lower the steam generation (and higher the exit gas temperature)

Improving HRSG Efficiency

Design with lower pinch and approach points Use of secondary surfaces such as condensate heater,heat exchanger,deaerator Consider multiple pressure HRSG Use supplementary firing

Optimize temperature profiles by rearranging surfaces

Improving HRSG performance

Bottom line is to lower the exit gas temperature!

RESULTS OF A SIMPLE STUDY

Data Gas inlet temp,F Stack gas temp,F Steam to turbine,Klb/h Steam to deaerator Feed water temp,F Electric power,kw base 975 374 80 10250 240 6528 Cond htr Heat exch 975 975 310 80 1730 240 6830 323 80 3400 151 6770 LP evap 975 297 80 0 240 6890

Gas flow=550,000 lb/h pinch=20 F approach=20F,make up=60 F,cond pr=2.5 in hg,steam at 620 psig,650F

HRSG simulation steam parameters,establish HRSG Knowing gas flow,temperature,analysis and

temperature profiles,duty and steam flows.In the design case,solve for:UA=Q/ T.In the off-design case knowing the new gas parameters,use the NTU method to establish performance using Q=(UA)T.Correct for UA using new gas parameters. We do not have to compute U. Hence there is no need to know the tube size,fin details,HRSG mechanical data;anyone can perform such calculations and evaluate HRSG performance in unfired,fired modes,evaluate burner duty,optimize temperature profiles,predict part load performance,review performance different gas turbines...

HRSG Temperature profile

HP stage is followed by LP section. Not a very efficient design

HRSG Temperature profile

Using common Economizer concept,we improve energy recovery

HRSG performance at Low Load

HRSG performance at 40 % load. Note steaming in economizer and also the high exit gas temperature.

HRSG Simulation-unfired case

HRSG simulation-fired case

Effect of ambient temperature on HRSG performance

Multiplication factor on steam flow is 0.1

Evaluating HRSG performance

HRSG performance is evaluated at different gas flow,exhaust temperature conditions to see if the performance is reasonable.

Evaluating HRSG performance

Design basis

TWO OR SINGLE PRESSURE HRSG-case 1

We are trying to see if a 2 pressure HRSG is required. Customer wants about 40,000 kg/h,30 kg/cm2 steam and 3000 kg/h steam at 6 kg/cm2 in fired mode and about 3500 kg/h LP steam in unfired mode,which is taken off the drum and pressure reduced..

Multiple Pressure Level HRSG

Design Problem

Design a forced- circulation waste heat recovery boiler to recover energy from the gas turbine exhaust with the following parameter:Gas turbine capacity = 15 MW Fuel = natural gas Gas quantity =900,000 lb/hr Gas temp. entering the boiler =900dg.F Steam pressure @ evaporator =400psia Super heater steam temp. =600dg.F feed water temp. entering economiser =260dg.F

Radiation losses 2% fouling effect s may be neglected and suggested total gas pressure is 8 in wc.

Solution
Assume pinch point 40dg F and Aapproch point from steam table @ 400 psia Tsat =445dg.F Hence, Gas temp leaving the evaporator will be Tg3= Tsat + Tpinch = 445 + 40 =485dg.F Temperature leaving economiser(tw2) T7 = Tsat - Tapproch = 445 - 40 =400dg.F
tg1 T5 T6 tg3

T7(tw`2

Heat Balance
Heat loss in evaporator and super heater Q(sh+evap)=Wg*Cp*(tg1-tg3)* radiation losses =900000*1.088*(500-245)*0.98 =95x10E6 BTU/hr (Cp=0.26 BTU/lb dg.f)
Steam Generated Ws=Q(sh+evap)/(h5-h7) h5=enthalpy of super heated steam (assuming 10 psia pressure dropin SH=1308BTU/lb h7=water enthalpy entering evaporator=375BTU/lb Ws= 95E6/(1308-375) =101820lb/hr

Heat Balance (con)

Economizer Absorption Q(economizer)=Ws*(h7-h8) h8=Enthalpy of feed water at 260 F=229BTU/lb Q(economizer) =101820(375-229) =14.9x10E6 BTU/hr Super Heater Absorption Qsh=Ws*(h5-hv) hv=enthalpy of saturated steam at 400psia=1205BTU/lb Qsh=101820(1308-1205) =10.5x 10E6 BTU/hr Gas temp. leaving Economizer Tg4= tg3-(Q(eco)/(wg*Cp*%radiation losses)) =485-(14.9x10E6/(900000*0.26*0.98) =420dg.F

Heat Balance (con)

Gas temp. drop = Q(SH)/ (wg*Cp*%radiation loss) =10.5x10E6/(900000*0.26*0.98) =45dg./F Gas temp. entering Evaporator =Tg1-Gas temp drop = 855 gd.F

Results
Section Superheater Evaporator Economiser Q (BTUx10E6/hr) 10.5 84.5 14.9