Steam Generation Unit Research Articles

Comprehensive Energy and Exergy Analysis of a Pressurized Water Reactor Driven Multi-Stage Flash Desalination Plant

Nuclear energy-based seawater desalination is an environmentally friendly freshwater production approach. This study introduces a novel thermodynamic model integrating a pressurized water reactor’s (PWR) secondary cycle with a multi-stage flash (MSF) desalination facility to enhance freshwater production. The impacts of the design and operating conditions on thermal efficiency, utilization factor, gain output ratio, exergy efficiency, coefficient of ecological performance for cogeneration and exergy destruction factor are investigated. Results reveal that a higher live steam temperature and a reheater mass flow rate ratio is preferable for a better nuclear desalination performance. A larger freshwater production capacity is preferable for a better utilization factor, however increasing the capacity tends to decrease thermal efficiency, coefficient of ecological performance for cogeneration and exergy destruction factor. The selection of steam extraction location is important for very large scale plants, and the outlet of moisture separator is determined to be the best option. Parametric analysis shows that plant’s performance can be significantly improved by adjusting the design conditions. Thermal and exergy efficiencies of an optimized plant configuration are 3.01% and 4.70% higher, respectively as compared to a base plant. It is also found that steam generator and MSF unit cause 3.2% and 82% of the total irreversibility rate of PWR’s secondary cycle and MSF facility, respectively, and have the highest irreversibility rates for these sections of the plant.

Performance Efficiency of Heat Recovery Steam Generator (HRSG) Unit 822-B-202 at TPPI Refinery

The steam generator is vital equipment in oil and gas refinery industry. One of the steam generator equipment in TPPI Refinery other than boiler is Heat Recovery Steam Generator (HRSG). Determine efficiency performance HRSG Unit 822-B202 in this research using compare between energy heat flow for produce steam and energy heat flow from exhaust gas on HRSG stack. The analyze result of efficiency HRSG Unit 822- B-202 when Start-up Commissioning was gotten 96.42%, on September 2021 92.47%, on October 2021 91.46% and November 2021 88.41%. Has occurred decrease of efficiency from start-up Commissioning until November 2021 about 16.95%. Over the past 3 months, efficiency has tended to decrease since commissioning. The calculated decrease in efficiency after commissioning in September was 3.96%. Then from September to October it decreased by 4.97%. However, in November it decreased again by 8.02%. So the accumulated decrease in efficiency of HRSG 822-B-202 during the quarter from Commissioning to November 2021 is 16.95%. So the average decrease in efficiency per month is 5.65%.

Analysis of the regional potential and prospects for converting MSW into hydrogen based on TPPS (using the example of the Ural Federal District)

Analysis of the regional potential and prospects for converting MSW into hydrogen based on TPPS (using the example of the Ural Federal District)

Energy Performance of Steam Generation Unit with Using Non-Renewable Fossil Fuel Like Imported (Indonesian) Coal at Spectrum Dyes and Chemicals Private Limited, Palsana-Surat

Now a day’s competition to became power fuel nation is increase industrialization and develop various process or methods for Energy sector. Due to increases energy demand with suitable use of Energy is important for any developing nation. The current case study work is an account of Energetic performance of steam generation unit like Boiler in the Spectrum Dyes and Chemicals Private Limited. The capacity of the Boiler for the steam generation 10 T/Hr. (2 Unit) and 6 T/hr. (1 Unit) coal fired boiler supplied by Rajdeep Boiler, Sachin. After completing the whole 1st law analysis of the Boiler plant has been presented The analysis carried out by using first law for a particular steam generation unit. There are useful assumption is required to analysis during calculations which is introduced in these performance calculations. Microsoft Excel is used for computer programs are developed for performance calculation energetic analysis of a steam generation plant. The PIE chart is graphical represent to energy flow in the system and the losses in the various components during normal operating condition have been identified. The analysis shows that the 1st law efficiency of Boiler Plant with solid Imported (Indonesian) coal fired boiler is 81.43%.

Effect of steam quality on the oil recovery factor of the Karazhanbas field

Background: The injection of the thermal agent as "steam" reduces the viscosity of the oil and the mobility ratio, which increases the displacement and coverage factor, and ultimately significantly increases the oil recovery factor. This statement was the basis for determining the effect of steam enthalpy on the oil recovery factor, as well as for reliably determining the flow rate of flared gas, as a result of which the existing gas pipeline will be reconstructed, the required amount of fresh water will be calculated, and the distribution of steam pumping in the entire Karazhanbas field.
 Aim: The purpose of the article is to consider the influence of the quality of steam produced at the steam generator units of the Karazhanbas field on the oil recovery factor. The main parameter that determines the quality of steam is dryness, which was calculated using the actual values of the boiler (pressure, temperature, gas flow), flue gas tests on a special device, as well as laboratory tests to determine the heat value of the combusted gas.
 Materials and methods: This work used materials from GHM (geological and hydrodynamic modeling), results of studies of boiler flue gases and heat balance.
 Results: The calculation showed a low quality of the produced steam, which negatively affects the recovery factor.
 Conclusion: Evaluation to determine the optimal value of saturated steam parameters (steam dryness, temperature in terms of development efficiency) showed that the higher the temperature and dryness of steam at the wellhead and bottom hole of the injection well, the higher the oil recovery factor at the Karazhanbas field.

Conceptual Design of Experimental Test Rig for Research on Thermo-Flow Processes During Direct Contact Condensation in the Two-Phase Spray-Ejector Condenser

Abstract The paper presents the conceptual design of a prototype experimental facility for mixing jet-type flow condensers investigations when the steam in exhaust gases is condensed on the water jet in the presence of CO2. The proposed experimental test rig was designed to give abilities to investigate the effectiveness of jet condensers experimentally as part of the CO2 capture phase and especially to investigate Spray-Ejector Condensers (SEC) developed as the combination of ejector and condenser devices. The paper presents the design and key features of the prototype installation components. The basic design was developed based on the simulation results, and for this purpose, model of installation, including characteristics of individual components, was built. The developed model helps to evaluate the main performances of the conceptual test rig and supports the test-rig design process. The main components and the features of the steam generation unit, CO2 supply and mixing with steam, process water preparation, and H2O and CO2 separation subsystem are discussed. The measuring system was designed to test the efficiency of compression and condensation processes of the SEC fed by the CO2/H2O gas mixture. The performances of the two-phase jet condensers can be analyzed by experimental investigation and calculation of heat transferred to the cooling water during direct contact condensation with the presence of CO2. The paper presents the results of heat flowrates and their uncertainties for the selected period of the experimental test, confirming the application of the novel developed test rig.

Machine learning-assisted tri-objective optimization inspired by grey wolf behavior of an enhanced SOFC-based system for power and freshwater production

Machine learning-assisted tri-objective optimization inspired by grey wolf behavior of an enhanced SOFC-based system for power and freshwater production

Performance of hydrogen and power co-generation system based on chemical looping hydrogen generation of coal

Performance of hydrogen and power co-generation system based on chemical looping hydrogen generation of coal

Development of Maintenance Management Strategy Based on Reliability Centered Maintenance for Marginal Oilfield Production Facilities

The present work adopted Reliability Centered Maintenance (RCM) methodology to evaluate marginal oilfield Early Production Facility (EPF) system to properly understand its functional failures and to develop an efficient maintenance strategy for the system. The outcome of the RCM conducted for a typical EPF within the Niger Delta zone of Nigeria provides an indication of equipment whose failure can significantly affect operations at the production facility. These include the steam generation unit and the wellhead choke assembly, using a risk-based failure Criticality Analysis. Failure Mode and Effect Analysis (FMEA) was conducted for the identified critical equipment on a component basis. Each component of the equipment was analyzed to identify the failure modes, causes and the effect of the failure. The outcome of the FMEA analysis aided the development of a robust maintenance management strategy, which is based on an optimized mix of corrective, preventive and condition-based monitoring maintenance for the marginal oilfield EPF.

Design and development of solar hybrid distillation system for essential oil extraction from turmeric

The present study was conducted to design and develop the solar hybrid essential oil extraction system from turmeric at Department of Processing and Food Engineering, PAU, Ludhiana, Punjab. The developed system has six solar parabolic trough concentrator, steam generation unit, steam distillation unit, condensing unit and essential oil separator. A prototype of solar hybrid essential oil extraction system of 10 kg was designed and developed. The volume of steam distillation unit was 0.061m3 and volume of steam generation was 0.057 m3. The essential oil was extracted by using three turmeric grates size that is, 14.50 mm, 15.620 mm and 17.53 mm size. The smallest particle size (14.50 mm) having the highest essential oil yield (45 ml/kg) obtained from turmeric grates (P2, L42). The developed system was supplied additional 2 kW energy to extract oil from the turmeric grates. The results obtained from the study indicated that smallest grates size (14.50 mm) has the highest oil yield as compared to the largest grates size (17.53 mm). The steam generation and steam distillation unit has efficiency of 60 and 55.17%, respectively while the condensing unit having the efficiency of the 47.22%. The solar parabolic trough concentrators ensured energy saving of 21.53% and required 6.20 h extraction time. Developed system can be effectively helps in energy saving, reduced time required for oil extraction which makes the system more economical. Novelty impact statement In the developed solar hybrid essential oil extraction system, the oil extraction was performed by the steam diffusion mechanism, as there is no such technology available for the essential oil extraction through the steam diffusion from turmeric. The developed hybrid system ensures 21.53% saving of electrical energy and 17.33% saving of the overall extraction time for the essential oils from turmeric grates. It can be installed and operated on a rooftop, so no additional space is needed. The developed system act as a tool for the generation of the extra income for the farmers in term of value addition.

Impact of recent district heating developments and low-temperature excess heat integration on design of industrial energy systems: An integrated assessment method

One of today’s biggest challenges is taking effective measures to mitigate negative effects and consequences of human-made climate change such as sector coupling and excess heat valorization. In this work, sector coupling of residential and industrial heat supply are considered in an optimization-based design and operation evaluation for industrial energy supply systems with the aim of minimizing costs and determining the impact of on-going developments and progresses in district heating systems. The developed method is applied to a use case with a superstructure for the industrial energy system including a biomass-fired steam generation unit, two heat pumps and various thermal storages, generic industrial load profiles for steam, hot water and excess heat and simulation-based district heating load profiles. The most relevant results reveal that depending on the district heating setting total annual costs, including fuel costs and annualized investments, increase between 2 and 39% compared to no additional district heating supply by the industrial energy supply system. However, the lowest cost increase does not coincide with the lowest additional energy amount. Thus, synergies such as corresponding temperature levels between energy supply for all domains have been identified as crucial criteria for economic success. Also, unit integration for excess heat recovery occurs always combined with thermal storages adapting the temporal occurrence of excess heat. Results for the evaluated use case highlight the importance and relevance of combined considerations for sector coupling measures. Thus, methods, as presented in this work, can contribute crucial information for future assessments. However, further development of the model, e.g. a larger set of generation technologies, and further use cases with other temperature levels, demand profiles are identified as relevant next steps.

A natural gas-based eco-friendly polygeneration system including gas turbine, sorption-enhanced steam methane reforming, absorption chiller and flue gas CO2 capture unit

A natural gas-based eco-friendly polygeneration system including gas turbine, sorption-enhanced steam methane reforming, absorption chiller and flue gas CO2 capture unit

Plant system study of France–Japan common concept on Sodium-cooled Fast Reactor

This paper provides an overview of plant system studies to establish a common technical view for Sodium-cooled Fast Reactor (SFR) concept (the common SFR concept) between France and Japan based on ASTRID 600 and the new concept with downsized output (ASTRID150). One of important issues on a reactor structure design is to enhance seismic resistance to be tolerable against strong earthquake such that postulated in Japan. A concept of High Frequency Design (HFD) is shared, in which the natural frequency of the reactor structure should be higher than that of peak acceleration of vertical floor seismic response with a horizontal seismic isolation system. The design options related to HFD have been examined and design recommendations are established. ASTRID 600 adopted a gas power conversion system to strictly eliminate the chemical reaction risks due to the proximity of sodium and water in the steam generator units. On the other hand, a steam generator (SG) is thought to be a concept with high technical readiness level and is a reference option in Japan and a backup option in France. Then, design comparison of the SG with single-walled helical coil tubes was mainly conducted in this study from the viewpoint of safety and so on. A common concept of a decay heat removal system is discussed to achieve practical elimination of loss of decay heat removal function. A fuel handling system studies are performed to eliminate and ex-vessel storage of spent fuels in sodium to reduce a construction cost. An adequate confinement system is investigated to achieve practical mitigation of large radiological release to the environment even under the condition of core destructive accident.

Multi-objective optimization of power, CO2 emission and exergy efficiency of a novel solar-assisted CCHP system using RSM and TOPSIS coupled method

Multi-objective optimization of power, CO2 emission and exergy efficiency of a novel solar-assisted CCHP system using RSM and TOPSIS coupled method

INSTALLED BASE SAFETY UPGRADE AT POWER GENERATION STATION

The study case power-generation plant comprises four steam generation units, commissioned in the 1990's, it is one of the largest in Italy and one of major in Europe, contributing to base load demand to the country south region. Age and limited availability of replacement parts for original medium voltage air magnetic circuit breaker, now in obsolete life cycle phase, is an operation concern on such mission critical equipment, as well as racking operation procedure on original 50kA rated installation not internal arc classified. The owning Utility strategy drives energy transition towards an increasingly sustainable model and the plant electrical installed base modernization, focusing on efficiency, health and safety as the three key elements. Innovative retrofit solutions have been designed and fully type tested to enable original installed base modernization with latest circuit breaker technology, providing withdrawable motorized execution for safety and easy maintenance. The benefits in terms of safety upgrade and installation are described. Furthermore, operation benefits such as standardization of spare parts, replacement of mechanical to electrical signalling and easiness of racking procedure is discussed.

Assessment of the economic efficiency of occupational safety and health measures

The issue of occupational safety is studied by assessing working conditions and calculating the economic effect of labor protection measures. The paper describes criteria for improving the economic efficiency by increasing the level of labor protection. It describes measures aimed to ensure the occupational safety and health of workers. The economic efficiency of measures aimed to improve working conditions and ensure the safety is calculated on the example of a steam generation unit. The methodology for calculating technical, economic and social indicators of labor protection takes into account the costs of improving safety and calculating the economic damage caused by accidents. The methodology can be used to evaluate the effectiveness of industrial measures, and takes into account the social effect of labor protection and envi ronmental protection measures. To calculate the effectiveness, the cost of losses, damage, localization costs, environmental damage, and measures is calculated. The occupational safety assurance measures can reduce the cost of production due to the increased labor productivity and improved quality of working capacities in favorable working conditions. An objective assessment of the measures aimed to improve safety conditions contributes to the development of recommendations and can justify management decisions made to ensure the occupational safety.

Difference oxidation behaviors of Ni8Al and Ni25Cr coatings in air with water vapor at 650∘

The oxidation behaviour of Ni8Al and Ni25Cr coatings produced by high velocity oxygen fuel spray (HVOF) which were deposited on Fe-based alloys (CB2) was investigated. We simulated the service environment of the steam generator unit, and put the samples in a thermostatic tube furnace at 650[Formula: see text] in air with 20 wt.% water vapor for 1000 hours of cyclic oxidation. The formation mechanism are explained using SEM, XRD, and EDX. There were no spallations and obvious cracks in both coatings. Ni25Cr coating generated a better protection oxides scale than that scale on Ni8Al. The behavior and mechanism of the oxide scale formation had an important influence in coatings and we have discussed these phenomenons in the study.

Influence of Pre-Ratcheting Fatigue on Tensile Behavior of Modified 9Cr-1Mo Steel at Ambient Temperature

Modified 9 Cr-1Mo steel is a material of prime significance in power plants used for components of steam generation units. The phenomenon of ratcheting involves aggregation of plastic strain in each cycle during asymmetric cyclic stressing. In the present study, the role of prior ratcheting has been studied on tensile behavior of this steel at ambient temperature. Cyclic tests were performed under uniaxial stress under the three parameters namely mean stress (σm), stress amplitude (σa) and stress rate $$(\dot{\sigma })$$ for 200 cycles. Tensile behavior of the pre-ratcheted samples was evaluated at ambient temperature at a strain rate of 10−4 s−1. It was found that pre-ratcheting enhanced the yield strength (SYS) and tensile strength (SUTS) but reduced the ductility. The results are discussed in terms of cyclic hardening resulting from the pre-ratcheting under different variables, and the internal microstructural changes are revealed by transmission electron microscopy.

A novel triple pressure HRSG integrated with MED/SOFC/GT for cogeneration of electricity and freshwater: Techno-economic-environmental assessment, and multi-objective optimization

A novel triple pressure HRSG integrated with MED/SOFC/GT for cogeneration of electricity and freshwater: Techno-economic-environmental assessment, and multi-objective optimization

Overall performance of steam system used in garment industries in Bangladesh: a case study–based approach

The fabric or garments production activities starting from raw material preparation to the finishing process are energy-intensive. Steam generation and distribution system is part of all the major processes involved here. Therefore, this study aims to assess the overall performance of the steam system used in the textile or garment industry in Bangladesh. The quantity of heat loss through different sources both at steam generation and distribution unit was computed. The amount of in-process heat energy consumption was also determined. Current practices in steam system management were investigated, and opportunity for improvement was addressed. Finally, the genetic algorithm approach was used to optimize the process parameters of steam generation unit thermodynamically. The average efficiency of the steam generation units used in the fifteen studied factories was found 76%. The dyeing and ironing processes were found as the most heat energy–intensive process. Among the sources of heat losses, maximum loss was found occurring through the dry flue gas during steam generation. At distribution unit, most heat is lost through the steam line and in-process distribution. Based on the analysis, daily 694 GJ heat passes away through a steam system resulting in 13 tons and 31 tons of fuel wastage and greenhouse gas emission, respectively. Considering the occurring losses, the remedial measures were focused on excess air and stack temperature control, improvement in boiler operating condition, steam leakage and trap maintenance, insulation enhancement, etc. Moreover, by optimizing the thermodynamic process parameters, it is possible to increase energy efficiency by almost 3.0%.