Download - Heat Recovery Steam Generators.pdf
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Industrial Application of Gas Turbines (IAGT)
Introduction to HRSGs
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HRSGHeat Recovery Steam Generator• Also referred to as waste heat
boiler• Cools hot gases – most
commonly the exhaust of a gas turbine
• Generates steam and regains energy
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HRSG• Critical link between the gas turbine and steam turbine in combined
cycle and cogeneration plants
Combined Cycle Plant
Cogeneration Plant
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FUNDAMENTAL PARTS OF HRSGFour Basic HRSG Components• Evaporators (gas to wet
steam heat exchanger)• Economizers (gas to water
heat exchanger)• Superheaters/Reheaters (gas
to dry steam heat exchanger)
• Preheaters (gas to water/glycol/air etc. heat exchanger)
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EVAPORATOR• Vaporize water and produce
steam• Water/steam circulates from
lower drum to steam drum• Steam exits from the steam
drum after passing through steam separating equipment
• Water level must be carefully maintained
LowerDrum
SteamDrum
GasFlow
Steam
Feedwater
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ECONOMIZERS
• Preheats water prior to entry into the steam drum
• Desirable to prevent steam from forming in the economizer
GasFlow
ToEvaporator Feedwater
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SUPERHEATERS/REHEATERS
• Saturated steam from evaporator is sent to superheater to produce dry steam
• Dry steam is required for steam turbines
GasFlow
SHSteam
Dry Steam
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HRSG TYPES
Three (3) Main Types
• NATURAL CIRCULATION HRSGs• FORCED CIRCULATION HRSGs• ONCE THROUGH HRSGs
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NATURAL CIRCULATION HRSG
• Typically horizontal gas flow and vertical tubes
• Tube bundles typically grow thermally down
• For gas turbines less than 50 MW, evaporator is shipped to site in single pieces
• For larger gas turbines the evaporator is shipped in multiple sections
SH Steam Feedwater
EconomizerEvaporator
Superheater
GasFlow
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INTEGRAL STEAM DRUM
• Evaporator shipped to site in single section (up to approx. 400,000 lbs)
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SEPARATE STEAM DRUM
• Evaporator shipped to site in multiple sections• Increased field erection costs
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FORCED CIRCULATION HRSG
• Typically vertical gas flow and horizontal tubes
• Steam/water mixture circulation through evaporator tubes and to/from drum with a pump
• Historically common in Europe due to small footprint
Economizer
Evaporator
Superheater
Feedwater
CirculationPump
Gas Flow
SHSteam
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ONCE THROUGH HRSG
• Typically vertical gas flow and horizontal tubes
• OTSGs eliminate the need for steam drums
• Phase change from water to steam is free to move throughout the bundle
Gas Flow
Economizer
Evaporator
Superheater
Feedwater
SH Steam
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HRSG DESIGN PHILOSOPHY• Exchange heat from the exhaust gas to the fluid at the highest
temperature difference available• Accomplished by making the exhaust gas and the fluid (steam/water)
temperature gradients as nearly parallel to each other as possible
HRSG Temperature Profile - UnfiredSteam Production = 66,850 lb/hr
430517
700
240
495
485
0
100
200
300
400
500
600
700
800
900
0 10 20 30 40Number of Rows
Tem
pera
ture
(F)
Gas Steam/Water
Pinch = 20 F
Approach = 10 F
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SINGLE VS MULTIPLE PRESSRE HRSG• Adding additional pressure levels in the HRSG can increase the
amount of heat that can be recovered from the exhaust gas• As the saturation temperatures are lower at successive pressures, the
stack temperature can be lowered Dual Pressure HRSG Temperature Profile
HP Steam Production = 75000 lb/hLP Steam Production = 100000 lb/h
635660
846
331410
375
495475
375
230
0
100
200
300
400
500
600
700
800
900
1000
0 10 20 30 40 50 60 70Number of Rows
Tem
pera
ture
(F)
Gas HP Steam/WaterLP Steam/Water
HP Pinch = 165 F
HP Approach = 20 F
Common Economizer
390
LP Approach = 35 F
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HRSGs
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HRSGs vs Conventional BoilersDifferences between HRSGs and Conventional boilers
• HRSGs use exhaust from a gas turbine as a heat source and do notneed a dedicated firing system (burner, fan, motor etc.)
• HRSGs typically do not use fans (draft is from gas turbine exhaust)• HRSGs generate steam at multiple pressure levels to improve heat
recovery efficiency• Heat transfer is by convection rather than radiation• HRSGs do not use membrane water walls• HRSGs use finned tubes to maximize heat transfer
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HRSGs vs Conventional Boilers• Differences between HRSGs and Conventional boilers
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Finned Tubing
• Finned tubing is used to increase heat transfer• Two types – solid fins and serrated fins• Heat transfer can be adjusted by changing fin height, fin thickness,
fin density, fin materials• Fins are spiral wound onto tubes using various processes:
– Brazing– Welding
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Finned Tubing
Serrated Finned Tube Solid Finned Tube
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Fabrication of HRSGs• Large HRSGs typically made from pressure part modules referred to
as “harps”• Significant field assembly
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Erection of HRSGs• Shipment of harps, cased or uncased sent to site• Modules stacked up to three (3) wide
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Erection of HRSGs• Steam drum sent to site separately• Exhaust stack sent to site in multiple sections
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Fabrication of HRSGs• Smaller HRSGs such as the OTSG maximize shop fabrication,
minimizing field assembly
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DUCT BURNERS• Add heat to the gas turbine exhaust stream• Exhaust gas typically has enough oxygen to sustain stable
combustion
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DUCT BURNERS• Steam demand increases
without any change in the gas turbine exhaust
• Desired steam flow of final steam temperature cannot be achieved with the available heat from the gas turbine
• Gas turbine is completely down but steam is still needed (Fresh air firing)
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DUCT BURNERS• Burners can be configured to burn a variety of different fuels
from natural gas to oil
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DUCT BURNERS• Fresh air firing is used to produce steam when the gas turbine is
down
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DISTRIBUTION GRIDS
• Used to correct flow maldistribution
• Variable porosity plates and turning vanes commonly used
• Typical gas side pressure drop for a variable porosity plate ranges from 0.5 inches H2O to 3 inches H2O
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FLOW MODELING• Gas flow distribution leaving the gas turbine is non-uniform• Proper performance of the HRSG, duct burner and emission
equipment requires uniform flow and temperature profile
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NOx REMOVAL PROCESS• Ammonia (NH3) is injected into the gas stream upstream of SCR
catalyst• Catalyst layer decomposes NOx (nitrous oxides, principally NO and
NO2) into harmless N2 and H2O
Superheater
Steam Out SCR Catalyst
Economizer
Feedwater
Evaporator
NH3 Injection Grid
Gas Flow
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SCR LOCATION
• SCR must be placed in the appropriate gas temperature zone for maximum efficiency
• Typical medium temperature catalyst maximum continuous temperature is 800 F with excursions to approx. 900 F
60
70
80
90
100
400 500 600 700 800
GAS TEMPERATURE, (°F)
DeNOx
EFFICIENCY,
(%).
Typical DeNOx Efficiency VS. Gas Temperature
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CORROSION IN HRSGsWater dewpoint corrosion• Metal temperatures fall below
the water dewpoint• Can lead to accelerated
corrosion
Acid dewpoint corrosion• Trace quantities of sulphur in
fuel form sulphur trioxide (SO3) and combine with water to form acids
• Leaves deposits on fin tubes
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QUESTIONS ??????