Heat Transfer & Steam Generation in A Furnace

P M V Subbarao
Professor
Mechanical Engineering Department

Generation of Entropy to Generate Most Eligible

Steam …..
 The Basics of Flow Steam generation

Supercritical Steam Generation

Subcritical Flow Boiling

Pump Exit
 Natural Circulation Boiler

Dry Steam to Super heaters

Pump Exit

Hot Water
 Forced Circulation Boiler

Dry Steam to Super heaters

Pump Exit

Hot Water

Recirculation Pump
 Forced Circulation Boiler

Dry Steam to Super heaters

Hot Water

Pump
 Once Through Steam Generator

Once-through tangential fired

Max. continuous rating: 520 kg/s
Max.Steam temperature outlet: 540°C
Live steam pressure outlet: > 18.3 MPa
Super Critical Nuclear Reactor
Religious to Secular Attitude of Water
Radiation Provoked Convective Heat Transfer

Heat flux, q” (W/m2)is reaching tube surface

flam radiation.

Newton’s law of Cooling:

The rate of cooling of a Hot Tube Wall 

Temperature excess of wall  Contact Surface
area of fluid and wall.
The proportionality variable is known as
Convective Heat Transfer Coefficient.
 T 
k fluid  
 r  wall
h
Twall  T 
 Physics of Convective Heat Transfer

 T 
k fluid  
 r  wall
h
Twall  T 
• Estimation of heat transfer coefficient is
basically computation of temperature profile in
a fluid.
• A general theoretical and experimental study
to understand how the stagnant layer is to be
developed in every application.
• The global geometry of the solid wall and
flow conditions will decide the structure of
stagnant layer.
 Heat Absorption Capacity of Fluid

The rate of heat absorption per unit surface area of a

fluid, defined as Newton’s law of convection as:

T
q  hTwall  T   k
''

r y 0

D
Conduction resistance k fluid
Nu  Nu 
Convection resistance 1
h
Local Nusselt Number
 Subcritical Once Through Flow Boiling :
Uniform Heat Flux

Fluid Temperature
x=1

Tube Wall
Temperature

x=0
Boiling Map & Effect of Non Uniform
Heat Flux
Real Sub-critical Boiling Process in A
Vertical Tube
 Defensive Method of Flow Boiling
Geometries
Steam

Partial Steam Steam

Complete or Once-
Generation through Generation

Heat Input
Heat Input
Water

Water
Water
Tube Wall Temperature : Sub-critical Flow
Boiling

Twall ( z )  Tsaturation  T fw

''
q
Newton’s Law of Cooling: T fw 
h
Religious to Secular Attitude
Tube Wall Temperature : Super-critical Flow
Boiling

Twall ( z )  T fluid ( z )  T fw

Newton’s Invention: ''

q
T fw 
h
Why are we doing this Entropy Generation???

A Means to meet Extra-somatism

Role of Steam Generator in Rankine Cycle
Rankine Cycle using Nuclear Fuel As A Source of
Thermal Energy
Rankine Cycle using Geothermal Energy As A
Source of Thermal Energy
Ranking Cycle using Solar Thermal Energy
Ranking Cycle for Biomass Thermal
Power Plant
Selection of Steam Generation Pressure in
A Rankine Cycle
 Constant Pressure Steam Generation
Entropy vs Temperature
8
7 @15MPa
6
5
4
3
2
1
0
0 100 200 300 400 500 600 700 800
Specific Volume vs Temperature

@15MPa

@35MPa
Steam Generation : Expenditure vs Wastage

Vapour
h mfuel

Liquid

s
Look for More Opportunities to Reduce
Wastage

S  m  s
Follow the Steam Path : Early Stage

S  m  s
Follow the Steam Path : Middle Stage

S  m  s
Follow the Steam Path : End Stage

S  m  s
Follow the Steam Path : The End

S  m  s
Save Wastage thru Recycling !?!?

S  m  s
Regeneration Cycle with Mixer
(Open Feed Water Heater)
 Synthesis of Rankine Cycle with OFWH

S6  m total  s6  S5  m total  s5

T 6
4 p 2 =p6 6’
S3  S2  y  m total  smix S6'  S5  y  m total  s5
3
2
ym  total  s5
S1  1  y  m total  s1  S2
1 7
1  y  m total

S
 Analysis of mixing in OFWH

Constant pressure mixing process

y
h6
Consider unit mass
flow rate of steam thru
the turbine

h2 1-y
h3

Conservation of energy:

y  h6  1  y  h2  h3 y  h6  h2   h3  h2
h3  h2
y
h6  h2
 Analysis of Regeneration through OFWH
h3  h2
y
h6  h2

 h5  h4 
Q in  m

Q Out  m 1  y h7  h1 
   
W net  W bleed  W cond  W pumps
 
 1  y h2  h1 
 W pump12  m  h4  h3 
& W pump3 4  m


  y h5  h6   1  y h5  h7   1  y h2  h1   h4  h3 
W net  m
 Optimal Location of FWH

  

 W n et
  W netbleed W netcon d

Q in Q in

 

 W netbleed
  W netcond

Q in Q in

  bleed  condensing

h3  h2
y
h6  h2
 Performance of OFWH Cycle

0.49 ~ 12MPa
0.485
0.48
0.475
total 0.47
0.465
0.46
0.455
0.45
0 5 10 15 20
pbleed, MPa
 Performance of bleed Steam

0.07 ~ 2 Mpa

0.06

0.05

0.04
bleed
0.03

0.02

0.01

0
0 5 10 15 20
pbleed, MPa
Comparison of Performance of Bleed &
Condensing Steams

0.5
0.45
cond
0.4
0.35
0.3
0.25
0.2
0.15 bleed
0.1
0.05
0
0 5 10 15 20
Pregen, MPa
 Gross Workoutput of bleed Steam

200 ~ 12MPa
180
160 y  h5  h6 
140
wbleed

120
100
80
60
40
20
0
0 5 10 15 20
pregen, MPa