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Design Of Dual Pressure Heat Recovery Steam Generator For Combined Power Plants
Abid-Al-Rahman.H.AL-Hobo Ass.prof : Mechanical Engineering Department Mosul University Mosul ,Iraq
Maher.Saab.Salamah M.Sc. Student : Mechanical Engineering Department Mosul University , Mosul , Iraq
E-mail: [email protected]
ABSTRACT
Heat recovery steam generator is considered as one of the most important components of combined cycle
power plants. Any change in its design would directly affect the performance of the steam cycle and therefore
the performance of combined cycle power plants. In current research focuses has been made to a suitable
engineering design of heat recovery steam generator to be used in simple gas turbine unit of a power output of
150MW such as those in Beijie gas turbine unit in north of Iraq .The study of heat transfer coefficient effect
between the exhaust gases leaving the turbine and the working fluid in steam generated was adopted for
engineering design . Results show, that the maximum heat transfer is occurred in the evaporator section for
high pressure level and it occurred in the economizer section for low pressure level. However ,the optimum
design pressure for high pressure level of steam generator is 60 bar ,while low pressure level is found to be
6.0bar . Moreover ,table (2) and (3) give the design results for heat recovery steam generator for high and low
pressure levels .
Keywords: combined cycle power plant; Design of HRSG; heat transfer coefficients
NOMENCLATURE
Transverse space between tow pipes(m) Exposed bare pipe outside surface area per unit length (m2/m)
Ab
Longitudinal space between tow pipes(m) pipe outside surface area among fins per unit length (m2/m)
Afo
Space between tow fins Fins surface area per unit length of pipe(m2/m)
Af
Temperature (k) T Total cross section area of the duct enclosing bundle(m2)
An
Velocity (m/s) V Total outside surface area of heat exchanger (m2)
AT
(m2.k/kw )Overall heat transfer coefficient U Total outside surface area of pipe(m2) At
Vapor fraction x HRSG width (m) b
Number of fins per meter length(1/m) Z Specific heat capacity (KJ/kg.k) cp
Greek symbols Header fluid diameter (m) D f
Friction pressure drop(pa) Hydraulic gas diameter (m) Dg
hydrostatic pressure drop (pa)
Fin diameter (m) d2
Momentum pressure drop (pa) Outer pipe diameter (m) do
Fin efficiency inner pipe diameter (m) di
-
I. Introduction
The electrical energy demand worldwide in the
developed countries and under developed countries is
growing significantly as a result of rapid industrial
expansion and high population growth. Thus,
reduction of energy costs and pollutant emissions ,all
these demands encouraged researchers and engineers
to look for different efficient and environmentally
acceptable technologies for power generation[1]
.Among these technologies are Combined Cycle
Power Plants (CCPPs) which consist of gas cycle or
Brayton cycle (topping cycle) and steam cycle or
Rankine cycle (bottoming cycle) ,two cycles linked
by heat recovery steam generator (see fig 1). Exhaust
heat from the gas turbine is recovered in a Heat
Recovery Steam Generator(HRSG) to produce steam
at suitable pressure and temperature. The produced
steam is then used to produce further electricity in
steam turbines. HRSGs are classified into single,
dual, and triple pressure types depending on the
number of drums in the boiler. Dual pressure HRSGs
have been widely used because they showed higher
efficiency than single pressure systems and lower
investment cost than triple pressure HRSGs[3,4].The
power generation and thermal efficiency of
Combined Cycle Power Plants (CCPPs) depend
strongly on the Heat Recovery Steam Generator
design which links the gas cycle with the steam cycle.
Therefore, the HRSG must be carefully designed in
order to maximize the heat exchanged and to improve
the overall performance of the plant [6].The main
challenge in designing of the HRSG is proper
utilization of a gas turbine exhaust heat in the steam
cycle with minimum heat exchange area. Many
authors have directed their researches to improve the
performance of CCPP through the suitable design of
operative parameters for HRSG .P.K.Nag and
S.De[5]has done design and operation of a heat
recovery steam generator generating saturated steam
for a combined gas and steam power cycle with
minimum irreversibility .They concluded that,
operating the HRSG at full load reduces entropy
generation, and also increases the number of transfer
units of evaporator and economizer beyond certain
cut-off values will have marginal benefit .C.Casarosa
and Franco [7] investigated the thermodynamic
analysis to design the operating parameters for the
various configurations of HRSG systems to minimize
Exergy losses, taking into account only the
irreversibility due to the temperature difference
Effectiveness Economizer Eco
(kg/m.s) Viscosity Evaporator Ev
(kg/m3) density Thickness of fin (mm) e
(kg/m3 )at mean temperature density Friction parameter
(Kg/m3.s) Evaporation rate mass fluid velocity (kg/ m2.s) G
Tow phase Multiplier High pressure HP
(N/m2) Shear stress
(m2.k/kw)heat transfer coefficient h
(N/m) surface tension (KJ/Kg) Enthalpy h
Subscripts
(kw/m.k) Thermal conductivity k
design des Low Pressure LP
fluid Pipe length (m) L
g gas Fin height (m)
inlet i Mass flow rate(kg/s)
Liquid phase Number of pipes in each row N
outlet o Number of rows in direction of flow nr
tow phase flow tp heat rate (kw) Q
Vapor phase v Reynolds number, dimensionless Re
Super heater SH
-
Fig 1. shows the sketch of combined cycle power plant (ccpp) with a dual pressure heat recovery steam generator
between the hot and cold streams (pressure drop not
accounting). All the solutions lead to the zero pinch
point and infinite heat transfer surface. B.V.Reddy et
al. [8] analyzed a single pressure HRSG to observe
the effects of various non-dimensional operating
parameters on the entropy generation number. They
showed that, the temperature difference between hot
gases and water has dominating effect on the entropy
generation rate. Franco and Giannini [9] show a
method based on hierarchical strategy for design of
the HRSG considering the maximization of the
compactness of the heat transfer sections and
minimization of the pressure losses. Valdes et al. [10]
proposed a methodology to identify the most relevant
design parameters that impact on the thermal
efficiency and the economic results of CCPP focusing
on the HRSG design. They proposed two different
thermoeconomic models aimed to determine whether
an increase in the investment is worthy from the
economic viewpoint .Zhixin Sun et al. [11] designed
conditions of A single pressure waste heat recovery
system when the temperature or flow rate of exhaust
gas fluctuates ,the results show that systems designed
at the upper boundary of fluctuation range of exhaust
gas could generate more power. Manassaldi et al. [6]
proposed a methodology for the HRSG design. Their
methodology applies a mixed nonlinear program
model to obtain the design according to three criteria:
net power maximization, the ratio between net power
and material weight maximization, and net heat
transfer maximization. From literature review, the
authors take some parameters in account and neglect
other else . The present study, aims to find the
suitable engineering design for dual pressure heat
recovery steam generator to reduce the Exergy losses
where the design included the dimensions of finned
tubes in each heat exchanger with minimum heat
exchange area and pressure drop.
II. HRSG description
The dual pressure heat recovery steam generator is
a series of heat exchangers, it consists of three heat
exchangers(economizer, evaporator ,Superheater) for
every pressure level (see fig 2). Economizers are used
to heat water close to saturation, evaporators to
produce saturated steam and superheaters to produce
superheated steam. Every heat exchanger is a bundle
tubes placed in-line or staggered arrangement
according to the manufacture. The flow of working
fluid(water or steam) in the pipes is horizontal flow
and the flow of exhaust is vertical flow that's mean,
each heat exchanger in the HRSG could be
considered a cross flow heat exchanger. The type of
circulation fluid in the evaporator is a forced
circulation by circulated pump for each pressure level
(fig2). Steam drums are used in HRSG to separate the
water from outlet steam from evaporator .The exhaust
gases of the gas turbine consider are a wake heat
transfer coefficients comparison with heat transfer
coefficients of working fluid in evaporator and
economizer therefore, finned tubes are used in HRSG.
Fins can be sold or serrated .The most important
parameters of HRSGs are pinch point, approach point
and gas side pressure drop through the heat recovery
system, which affect the effectiveness of heat
exchange. Pinch point is the difference between the
gas temperature leaving the evaporator section of the
-
Fig 2 .The dual pressure heat recovery steam generator with temperature distribution on (Temperature - Enthalpy) diagram.
system and the saturation temperature corresponding
to the steam pressure in that section. Approach point
is the difference between the saturation temperature
of fluid and inlet temperature of fluid in evaporator.
Temperature-Enthalpy diagram showing the
temperature profiles with two pressure levels is
illustrated in Fig. 2.
III. Design of the HRSG
The design of HRSG depend on thermodynamic
parameters of exhaust gases from gas turbine in
simple cycle mode such as temperature ,pressure and
mass flow rate of gases to evaluate the operations
parameters and geometric design of HRSG .In this
research, operation parameters of gas turbine type
V94.2 Siemens are depended and listed below in
table 1 (sample at 27C ) .
table 1 Technical data and operation parameters of
gas turbine at 27C
A. Assumed assumptions
some of the main assumptions to derive the
mathematical model are listed as follows:
The system is assumed to be steady state.
The exhaust gas mass flow rate, temperature and chemical composition are obtained during the
simulation of simple gas cycle at different
atmospheric conditions.
Unfired HRSG is considered.
No cooling between heat exchangers is considered
Stack temperature no less than 100C while feed water temperature 30C to avoid dew point[13] -
The forced circulation is assumed for horizontal
tubes in evaporator.
The pressure drop in exhaust gas side and working fluid side are taken into accounts.
In-line tubes with solid fins are considered .
Mass flow rate of working fluid in ECO,EV,SH are taken equal in each pressure level.
B. Mathematical model
The simulation of the system can be achieved when
the actual processes are represented by mathematical
model .The modeling of HRSG depend on mass and
heat transfer ,fluid dynamics and energy balance. By
adopting the assumptions listed above the following
mathematical model was derived .the nomenclature
of the main geometric variables are illustrated in
fig.3.
Base load Unit Type :V94.2
Distillate
oil Natural
gas Fuel
4200 42217 KJ/kg Low heat value LHV
.. .. KJ/kg Fuel enthalpy
0 0 ppm Vanadium concentration
1 1 . Fuel factor f
134.7 138.6 MW Nominal output at generator
33.0 33.3 % Nominal efficiency at
generator
480 481 Kg/s Exhaust gas flow
545 545 C Exhaust gas temperature
9.7 9.9 Kg/s Fuel consumption
100 % Inlet guide vanes
-
Fig 3.Deatails of main geometric variables in HRSG.
C. Energy balance
The first step to simulate the design of HRSG is to
balance the mass and energy between the hot and cold
streams(gas side and water/steam side) on different
heat exchangers where the designed parameters (the
flow rate, temperature, pressure of superheated steam
and outlet temperature of exhaust gases ) can be
obtained .From fig 2,energy balance can be expressed
as equations below:
= + (1)
= = . ( - ) (2)
= = . ( - ) (3) = = . ( - ) (4)
= = . ( - ) (5) = = . ( - ) (6) = = . ( - ) (7)
C .Modeling heat transfer coefficients and heat
exchange area
The designing method in this study is based on heat
transfer coefficients to obtain the heat transfer area
for each heat exchanger in high and low pressure
level of HRSG. Overall heat transfer coefficient U
by the total heat exchange area is calculated as flows:
( 8)
Where j: refer to ECO, EV,SH in L.P&H.P and F is a
correct factor
F: calculated from charts in reference [18]
logarithmic mean temperature difference estimated
from following equation:
[( ) ( )
[ ( )
]
] (9)
Effectiveness of heat exchanger in high and low
pressure are obtained as flows:
(10)
(11)
The overall heat transfer coefficient for each pipe is
obtained from Eq. (12).
(
) (
(
)
)
(12)
The thickness of pipe is considered very small but it
has high thermal conductivity therefore, its resistance
can be neglected and eq.(12) become as flows:
(
)
(13)
Several methods have been implemented in the model
to evaluate the heat transfer coefficient on the gas
side. Eq. (14) is a general equation, which evaluates
the Nusselt number in cross flow over pipes.[15]
-
= .
(14)
Equation. 14 can be written in another form :
(
)
(
)
(15)
The velocity of exhaust gases is function of a cross
section area of HRSG and written as flows:
= . (16)
Sub eq. (16) in eq. (15) we get :
(17)
For a heat recovery, , and are 0.3, 0.625 and 1/3 respectively (Weir [15])
Effective heat transfer coefficients for gas side
calculated from following equation:
(18)
Where is the effectives of heat exchange surface
and calculated as flows[13] :
( ) (
) (19)
Fins efficiency is estimated from following equations:
[14]
(20)
(21)
(
) (
)
The ratio between surface of bare tube and finned
tube is estimated from following equation:
(
)
(23)
Total heat transfer area in each heat exchanger is
calculated as flow:
) (24)
To estimate the Heat transfer coefficient of working
fluid ,the following equation can be used [15]
(
) (25)
Where =0. 3 =1/3 =0.625
The width of HRSG is calculated from following
equation:
( ) (26)
D. Gas side pressure drop
The calculation of pressure drop in gas considered is
very important to test the design and to avoid the
back pressure of gas in HRSG. In this case the
number of rows (nr) plays an important role in the
pressure drop evaluation. In this research ESCOA
correlation has been selected to estimate the pressure
drop of the gas inside HRSG as follows:
( )
(
)
(28)
(
) ( 29)
(30)
For solid fins and in-line arrangement for tubes
C2,C4,C6 are calculated as follows[13]:
(31)
(
)
(
)
(32)
(
)
(33)
D. Working fluid side pressure drop
Water pressure drop in economizer is
calculated as flows:
g
(34)
(Laminar),
(turbulent)]
-
Vapor pressure drop in super heater calculated as
flow:
(
)
(
) (35)
But the calculation of pressure drop in evaporator is
considered very complex because different regimes of
two phases flow during transition boiling[12]
.however, the governing equations of pressure drop in
evaporator represented by mass and momentum
equations . mass conservation of the vapor and liquid
phases for the steady flow in one-dimension can be
written as
(vapor) (36)
(liquid) (37)
momentum equation of liquid and vapor phase is
combined
(38)
Total
pressure drop in tow phase flow can be written as:
(39) + + =
[(
)
(
)
]
is void fraction calculated from Rouhani
&Axelsson correlation as follows [16] : where
[( ) (
)
(
)]
The LockardMartinelli formulation is used to
estimate the friction term:[17]
(
)
(
)
(42)
(41)
neglected in horizontal pipes[12]. Phs
IV. Simulation of the design
Engineering Equation Solver program was used in the
simulation .EES program is one of modern program
in mechanical engineering applications, Moreover, it
has large data base of physical conditions for a lot of
fluids such as(enthalpy ,density, thermal
conductivity..etc.).The simulation used in two stages
the first included simulate the operation parameters of
HRSG, and the second stage used to simulate the
geometric variables where one pipe is selected in
each bundle relative to another neighbor pipe in the
same row. In each iteration (UA) product is
calculated and compassion with( UAT) in equation (8)
and the iterations continuous until (UA) desired is
achieved .Successive substitute iterative method was
used in simulation. After the design of each heat
exchanger for both levels, the gas side pressure drop
calculated to test the design with different conditions
of gases from turbine . working fluid pressure drop in
economizer and super heater estimated directly from
eq. (33) and(34) but in evaporator, the pipe is divided
into many equal increments and uses the finite
difference to solve the governing equations
numerically ,Gauss-Seidel iterative method was
implemented.
V. Results and discussion:
The results showed that the heat transfer coefficient
of gas decrease when pipe length increase with
different numbers of fins fig (4) ,this case can be
explained that increase length pipe leads to increase
the hydraulic diameter of gas reduced the velocity
which caused decrease Reynolds number leading to
decrease heat transfer coefficient. From fig (5),it can
be noticed that pressure drop increase while fin
diameter increase with different number of rows
because of increasing friction parameter of gas with
the surfaces. Heat exchange area increase directly
with increase the designed stem pressure fig (6)
when the inlet feed water temperature about 420k
,this means that the enthalpy of working fluid
decrease with increase designed steam pressure,
therefore the heat exchange area is required to
achieve steam at designed conditions. Fig (7) shows
the effectiveness of heat exchangers are reduced
when the designed pressure increase with constant the
area and different inlet feed water temperature
-
050
100
150
200
250
300
350
0.045 0.05 0.055 0.06 0.065 0.07 0.075 0.08 0.085
diameter of Fin (m)
gas p
ressu
re d
rop
(p
a)
nr=10nr=20nr=30nr=40
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0 5 10 15 20 25 30 35 40
Length of pipe (m)
he
at
tra
ns
fer
co
eff
icie
nt(
KW
/m.
k)
Z=150Z=180Z=210
53600
53800
54000
54200
54400
54600
54800
55000
40 50 60 70 80 90 100
pressure design (bar)
Are
a (
m )
TW=420(k)
0.7
0.72
0.74
0.76
0.78
0.8
0.82
0.84
0.86
40 50 60 70 80 90 100
Pressure design (bar)
eff
ecti
ven
ess H
P H
RS
G
TW=300(K)
TW=350(K)
TW=400(K)
TW=430(K)
370
372
374
376
378
380
382
384
386
40 50 60 70 80 90 100
Pressure design (bar)
Sta
ck
te
mp
era
ture
(k
)
Tw=420 (k)
SH HP
EV HP
ECO LP
SH LP
ECO LP
EV LP
0
20000
40000
60000
80000
100000
120000
1 2 3 4 5 6
He
at
Ex
ch
an
ge
(k
W)
because the heat exchange isnt sufficient to recover
the required heat. In fig (8) the stack temperature
increase with increase designed steam pressure when
the area and mass flow rate of working fluid are
constant where the heat transfer from gas becomes
little. Fig (9) and fig (10) show the heat transfer rate
and heat exchange area respectively in each heat
exchanger. Table (2) and(3) show results of
geometric design in both levels. .
Fig.4. Effect length of pipe on heat transfer
coefficient of gas.
Fig.5. Effect diameter of fin on gas pressure drop.
Fig.6. Effect of pressure design an heat exchange
area .
Fig.7. Effect pressure design on the effectiveness of
heat exchangers.
Fig.8. Effect pressure design on the stack temperature Fig.9. Heat transfer rate in each heat exchanger for both
pressure levels
-
SH HP
EV HP
ECO HP
SH LP
EV LPECO LP
0
5000
10000
15000
20000
25000
1 2 3 4 5 6
AR
EA
(m
2)
VI .Conclusion
The main conclusions of this research can be listed
below:
1)The heat transfer coefficients of gas are weak
therefore ,the HRSG designed at large heat exchange
to produce steam at high pressure and temperature.
2) Increase the heat exchange area about 2% lead to
increase heat transfer rate about (721kw) and in the
same time the pressure drop increase about (3pa)
3) According to exhaust gases conditions at different
ambient temperature, from the simulation the
optimum design pressure for high pressure level of
steam generator is 60 bar ,while low pressure level is
found to be 6.0bar.
4)The simple cycle gas turbine which is depended in
this research proved agreement to work in a
combined cycle used dual pressure heat recovery
steam generator.
SH EV ECO parameter
0.078 0.079 0.078 (m) 192 190 210 z(1/m)
20 21 20 N
0.053 0.0565 0.053 (m) 22.78 22.78 22.78 (m)
13 44 26 nr 498 1616 1078 UA(Kw/k)
0.0598 0.0624 0.069 hg(kw/ k) 5.12 5.12 5.12 b(m) 60 Drum H.P(bar)
791 Superheated temperature(k)
63.82 63.82 63.82 Steam mass flow
(kg/s)
142 307.8 144.7 P gas(pa) 0.62 1.54 0.723 P in
water/steam(bar)
SH EV ECO parameter
0.0705 0.08 0.08 (m)
124 190 204 z(1/m)
19 20 20 N
0.0531 0.0565 0.0535 (m)
22.78 22.78 22.78 (m) 16 32 26 nr 25.66 1001 1099 UA(Kw/k)
0.0586 0.0611 0.0692 hg(kw/ .k) 5.12 5.12 5.12 b(m)
6 Drum high pressure (bar)
466.8 Superheated temperature(k)
13.79 13.79 13.79 Steam mass flow
(kg/s)
108.9 129.4 85.95 P gas(pa) 0.09 0.13 0.124 P in
water/steam
(bar)
Fig.10. Heat exchange area in each heat exchanger for
both pressure levels.
Table.3. Details geometric design of high pressure level
Table.2. Details geometric design of low pressure level
-
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