Heat Recovery Steam Generator Design Research Articles

Modelling, Sensitivity and Exergy Analysis of Triple-Pressure Heat Recovery Steam Generator

Combined with the increasing demand for environmental pollution and electrical energy, combined cycle power plant power plants are increasingly important. It is necessary to increase the performance of power plants, reduce carbon emissions and increase energy production. Any change to the heat recovery steam generator design is an important component of the combined cycle power plant, as it directly affects the performance of the combined cycle power plant. This study describes the modeling, sensitivity and exergy analysis of a HRSG in a combined cycle power plant. Three-pressure HRSG was modeled with the Aspen Plus simulation program and sensitivity analysis was performed. At the same time, energy and exergy analyzes were made for each component in the combined cycle power plant.

Dynamic characteristics analysis of a once-through heat recovery steam generator

A U-type once-through heat recovery steam generator (HRSG) is investigated in this paper and emphasis is laid on a mathematical model for its dynamic characteristics analysis. The model is built in the Matlab/Simulink environment based on the thermodynamics principles and conservations of mass, momentum, and energy. Genetic algorithm (GA) is applied as a parameter identification technique to adjust the model parameters. Real-time on-site measurement data of start-up and off-design operation for different conditions are used for model testing and validation. The model can be used to represent the real export parameter changes of heating surfaces for different operating conditions. The results show good predictive capabilities at the respective operating points and the corresponding RMSE (root mean square errors) ranges from 2.9659 to 4.4292, which shows a high accuracy. Simulation results on the outlet temperatures and steam production of single-phase and two-phase heating surfaces are presented. The process of phase transformation is also clearly simulated. The heat preservation coefficient and operational parameters of dynamic characteristics is favorable for the HRSG design optimization and performance prediction.

Development of Russian Once-Through Heat-Recovery Steam Generators for CCPPs of Various Capacities

The foreign experience of using once-through heat-recovery steam generators (HRSG) in CCPPs is presented. Russian developments of once-through HRSGs of various configurations based on modern gas turbines are considered. Design procedures for ensuring the reliability of the heating surfaces of high- and intermediate-pressure evaporators are developed. Technical requirements for the design of vertical and horizontal once-through HRSGs are formulated.

Modelling and practical studying of heat recovery steam generator (HRSG) drum dynamics and approach point effect on control valves

Abstract In this paper, we present a simple procedure to build a model of a heat recovery steam generator (HRSG) evaporator and drum within the environment of MATLAB/Simulink. The HRSG is part of combined cycle power plant that is located at Talkha power station (130 km north of Cairo, capital of Egypt). The model captures the response of water and steam inside HRSG evaporator and drum like drum level, pressure, steam quality and others during different conditions. We discuss some practical concepts in HRSG design, and the importance of HRSG approach point value to drum level stability and control. We also discuss how HRSG approach point can have destroying effect on level control valves of the drum and increase the maintenance cost of the combined cycle power plant.

The optimal design and 4E analysis of double pressure HRSG utilizing steam injection for Damavand power plant

Energy, Exergy, Exergoeconomic and Environmental (4E) analysis of combined cycle power plant utilizing the method of steam injection into the combustion chamber is performed in the current study. Steam is supplied from low pressure (LP) side of the heat recovery steam generator (HRSG). According to genetic algorithm's results, the steam injection elevates the total combined cycle power by 2 MW while lowers the design costs considerably at optimum state. Some parameters restrict the steam injection usage within combined cycles that could be noted as Gas turbine power decline; Gas turbine loss increase due to pressure loss; HRSG's manufacturing costs growth; opposition between high and low pressure flow rate variations; NOX and CO emission costs dependency on optimum conditions. This paper discusses the above limitations for implementation of such technology in combined cycles. At the optimum point, Exergy and thermal efficiencies values increased from 42% and 47.6% to 47.28% and 48.94% respectively. Optimum pinch and approach temperatures for HP and LP sides were computed to be 35, 20, 17 and 37.5, respectively. Also, the optimum value of X parameter is 23.28%; X is defined as the ratio of steam to the inlet air flow rate divided by the other fraction which is the ratio of fuel to input air flow rate while there is no steam injection into the combustion chamber.

Dynamic simulation of a triple-pressure combined-cycle plant: Hot start-up and shutdown

The operation of combined-cycle power plants is increasingly determined by frequent start-ups and shutdowns for grid balancing. This study investigates the capability of a comprehensive process simulation model to predict the transient response of a triple-pressure heat recovery steam generator (HRSG) with reheater to the start-up and shutdown procedures of a heavy-duty gas turbine. The model is based on geometry data, system descriptions and heat transfer calculations established in the original HRSG design. The numerical solution approach and the practical development of a suitable model structure, including the required control circuits, are explained. Detailed simulation results are presented, using initial conditions that correspond to a previous overnight shutdown. Calculations are performed for a complete operating cycle of the plant, where the following main phases are distinguished: start-up procedure, load-following operation, design operation and shutdown procedure. The numerical model is validated with measurement data of the commercial power plant for each pressure stage, yielding good agreement. Deviation from the transient behaviour of the real plant is discussed with regard to modelling assumptions and incomplete information on components outside the HRSG system boundaries.

Investigations for performance enhancement of dual pressure HRSG in gas/steam combined cycle power plants

ABSTRACTA heat recovery steam generator (HRSG) is the vital equipment in a gas/steam combined cycle power plant (CCPP) which plays an important role in enhancing the overall performance of the plant. An HRSG is designed on the basis of the size of the gas and steam turbines used in the power plant. Therefore, the HRSG directly affects the performance of the CCPP and its optimisation based on physical design can improve the plant performance. In the present study, the plant data of the CCPP of NTPC Ltd. at Auraiya (U.P.), India, has been considered for study. A segmented finned model has been chosen as it is the preferred arrangement [Ganapathy, V. 2003. Industrial Boiler and Heat Recovery Steam Generator Design, Application and Calculation. New York: Marcel Dekker Inc.] and thermodynamic investigations have been carried out upon a dual pressure HRSG in a gas/steam CCPP from the perspective of maximum heat recovery and minimum pressure loss. The performance investigations of varying physical parameters of a dual pressure HRSG with segmented fins are useful for CCPP designers and for all those who are engaged in the area of heat recovery.

Thermodynamic performance analysis and algorithm model of multi-pressure heat recovery steam generators (HRSG) based on heat exchangers layout

Changes of heat exchangers layout in heat recovery steam generator (HRSG) will modify the amount of waste heat recovered from flue gas; this brings forward a desire for the optimization of the design of HRSG. In this paper the model of multi-pressure HRSG is built, and an instance of a dual pressure HRSG under three different layouts of Taihu Boiler Co., Ltd. is discussed, with specified values of inlet temperature, mass flow rate, composition of flue gas and water/steam parameters as temperature, pressure etc., steam mass flow rate and heat efficiency of different heat exchangers layout of HRSG are analyzed. This analysis is based on the laws of thermodynamics and incorporated into the energy balance equations for the heat exchangers. In the conclusion, the results of the steam mass flow rate, heat efficiency obtained for three heat exchangers layout of HRSGs are compared. The results show that the optimization of heat exchangers layout of HRSGs has a great significance for waste heat recovery and energy conservation.

Parametric Evaluation of Heat Recovery Steam Generator (HRSG)

AbstractThermal efficiency of a combined cycle power plant depends strongly on a heat recovery steam generator (HRSG), which is the link between the gas turbine‐based topping cycle and steam turbine‐based bottoming cycle. This work is based upon the design of physical parameters of a HRSG. In this article, the physical parameters of a HRSG have been considered to study their implications on HRSG design by comparing the existing plant design with an optimized plant design. Thermodynamic analysis of HRSG for the two designs gives important outcomes which are useful for power plant designers. © 2013 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library (wileyonlinelibrary.com/journal/htj). DOI 10.1002/htj.21106

The Effects of Parameters on HRSG Thermodynamic Performance

Changes of inlet temperature, mass flow rate and composition of flue gas, or of water/steam pressure and temperature in heat recovery steam generator (HRSG), all will modify the amount of waste heat recovered from flue gas; this brings forward a desire for the optimization of the design of HRSG. For single pressure HRSGs with given structures and specified values of inlet temperature, mass flow rate and composition of flue gas, the steam mass flow rate and gas outlet temperature of the HRSG are analyzed as functions of several parameters. This analysis is based on the laws of thermodynamics, incorporated into the energy balance equations for the heat exchangers. Those parameters are superheated steam pressure and temperature, feedwater temperature and pinch point temperature difference. It was shown that the gas outlet temperature could be lowered by selecting appropriate water/steam parameters and pinch point temperature difference. While operating with the suggested parameters, the HRSG can generate more high-quality steam, a fact of great significance for waste heat recovery from wider ranges of sources for better energy conservation.

Applying different optimization approaches to achieve optimal configuration of a dual pressure heat recovery steam generator

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Plant flexibility of a pre-combustion CO2 capture cycle

Abstract The aim of the paper is to investigate plant flexibility for a pre-combustion cycle. That is, answering the question: how flexible is the plant to changes in operating conditions? Steady-state off-design simulations was the key component of the plant flexibility analysis. Specifically, part load behavior and dual-fuel operation of the integrated reforming combined cycle (IRCC) were studied. The idea of the plant was to use hydrogen-rich decarbonized fuel as the primary fuel and natural gas as back-up fuel. If a problem would occur in the reforming, water-gas shift, or CO 2 capture processes there might be a need to switch to a natural gas feed for the gas turbine. This led to design challenges for the heat recovery steam generator (HRSG). The design of the HRSG for the IRCC process was different from an HRSG design in a natural gas combined cycle (NGCC) plant because of the significant amount of steam production from the heat generated in the reforming process. In addition, preheating (within the HRSG) of some of the process streams could add to the complexity in HRSG design. For the concepts studied it was of importance to maintain a high net plant efficiency on both fuels. Therefore the HRSG design had to be a compromise between NGCC and IRCC operation modes. In the analysis performed, part load behavior was good with efficiency reductions from base load operation comparable to that of the reference combined cycle plant. Based on the analysis performed in the present work, it was possible to operate a complex plant like an IRCC at loads down to 60 gas turbine load while capturing 85% of the CO 2 . During start-up and operation at lower loads, CO 2 would not be captured. The investigation was done by using process simulation tools Aspen Plus by AspenTech and GT PRO/GT MASTER by Thermoflow.

Availability analysis of heat recovery steam generators used in thermal power plants

The combined-cycle gas and steam turbine power plant presents three main pieces of equipment: gas turbines, steam turbines and heat recovery steam generator (HRSG). In case of HRSG failure the steam cycle is shut down, reducing the power plant output. Considering that the technology for design, construction and operation of high capacity HRSGs is quite recent its availability should be carefully evaluated in order to foresee the performance of the power plant. This study presents a method for reliability and availability evaluation of HRSGs installed in combined-cycle power plant. The method’s first step consists in the elaboration of the steam generator functional tree and development of failure mode and effects analysis. The next step involves a reliability and availability analysis based on the time to failure and time to repair data recorded during the steam generator operation. The third step, aiming at availability improvement, recommends the fault-tree analysis development to identify components the failure (or combination of failures) of which can cause the HRSG shutdown. Those components maintenance policy can be improved through the use of reliability centered maintenance (RCM) concepts. The method is applied on the analysis of two HRSGs installed in a 500 MW combined-cycle power plant.

HRSG Design for Integrated Reforming Combined Cycle With CO2 Capture

This article illustrates aspects of heat recovery steam generator (HRSG) design when employing process integration in an integrated reforming combined cycle (IRCC) with precombustion CO2 capture. Specifically, the contribution of this paper is to show how heat integration in a precombustion CO2 capture plant impacts the selection of HRSG design. The purpose of such a plant is to generate power with very low CO2 emissions, typically below 100 g CO2/net kWh electricity. This should be compared with a state-of-the-art natural gas combined cycle (NGCC) plant with CO2 emissions around 380 g CO2/net kWh electricity. The design of the HRSG for the IRCC process was far from standard because of the significant amount of steam production from the heat generated by the autothermal reforming process. This externally generated steam was transferred to the HRSG superheaters and used in a steam turbine. For an NGCC plant, a triple-pressure reheat steam cycle would yield the highest net plant efficiency. However, when generating a significant amount of high-pressure steam external to the HRSG, the picture changed. The complexity of selecting an HRSG design increased when also considering that steam can be superheated and low-pressure and intermediate-pressure steam can be generated in the process heat exchangers. For the concepts studied, it was also of importance to maintain a high net plant efficiency when operating on natural gas. Therefore, the selection of HRSG design had to be a compromise between NGCC and IRCC operating modes.

Transient thermal modelling of heat recovery steam generators in combined cycle power plants

Heat recovery steam generator (HRSG) is a major component of a combined cycle power plant (CCPP). This equipment is particularly subject to severe thermal stress especially during cold start-up period. Hence, it is important to predict the operational parameters of HRSGs such as temperature of steam, water, hot gas and tube metal of heating elements as well as pressure change in drums during transient and steady-state operation. These parameters may be used for estimating thermal and mechanical stresses which are important in HRSG design and operation. In this paper, the results of a developed thermal model for predicting the working conditions of HRSG elements during transient and steady-state operations are reported. The model is capable of analysing arbitrary number of pressure levels and any number of elements such as superheater, evaporator, economizer, deaerator, desuperheater, reheater, as well as duct burners. To assess the correct performance of the developed model two kinds of data verification were performed. In the first kind of data verification, the program output was compared with the measured data collected from a cold start-up of an HRSG at Tehran CCPP. The variations of gas, water/steam and metal temperatures at various sections of HRSG, and pressure in drums were among the studied parameters. Mean differences of about 3.8% for temperature and about 9.2% for pressure were observed in this data comparison. In the second kind of data verification, the steady-state numerical output of the model was checked with the output of the well-known commercial software. An average difference of about 1.5% was found between the two latter groups of data. Copyright © 2007 John Wiley & Sons, Ltd.

Influence of the heat recovery steam generator design parameters on the thermoeconomic performances of combined cycle gas turbine power plants

This paper proposes a methodology to identify the most relevant design parameters that impact on the thermal efficiency and the economic results of combined cycle gas turbine power plants. The analysis focuses on the heat recovery steam generator (HRSG) design and more specifically on those operating parameters that have a direct influence on the economic results of the power plant. These results are obtained both at full and part load conditions using a dedicated code capable of simulating a wide number of different plant configurations. Two different thermoeconomic models aimed to select the best design point are proposed and compared: the first one analyzes the generating cost of the energy while the second one analyzes the annual cash flow of the plant. Their objective is to determine whether an increase in the investment in order to improve the thermal efficiency is worth from an economic point of view. Both models and the different HRSG configurations analysed are compared in the results section. Some parametric analysis show how the design parameters might be varied in order to improve the power plant efficiency or the economic results. Copyright © 2004 John Wiley & Sons, Ltd.