Design of HRSGs for Industrial Application & Advanced ... P... · Design of HRSGs for Industrial...
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Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Design of HRSGs for Design of HRSGs for
Industrial Application & Industrial Application &
Advanced Class GTsAdvanced Class GTs
Technical Session I :Thermal System-Design, Selection &
Statutory Requirements
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Overview of PresentationOverview of Presentation
Ø About HRSGs & GT based Plants
Ø HRSGs for Industrial Applications
§ Oil & Gas (Refinery /Petrochemicals / Gas)
§ Fertilizers / Chemicals
Ø HRSGs for Advanced Class GTs
§ Large Capacity, High Efficiency Combined Cycle Plants
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Tube to HeaderModuleØ Natural circulationØ Horizontal configuration Ø Modular construction Ø Top SupportedØ Single row modulesØ Complete internal insulationØ Composite Angle Inlet Transition ductØ Dispatched as Loose ModulesØ Insulation at Site
Salient Features of Salient Features of HRSGsHRSGs for GT Applicationfor GT Application
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
BHEL Experience BHEL Experience -- HRSGsHRSGsLeading supplier in IndiaLeading supplier in India
GT Combined Cycle - 64GT Cogeneration
Unfired - 9Fired - 77
Waste Heat Recovery - 9Total - 159
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Combined CyclePlant
GT ST
HRSG
CogenerationPlant
Combined Cycle Cogeneration Plant
GT ST
HRSG
Gas turbine based plant Efficiency Simple Cycle
Combined Cycle Cogen Combined
Cycle Cogen 28 - 38 % 41 – 57 % 75 – 90 % 50 – 70 %
GT
HRSG
Steam to Process
Steam to Process
Simple CycleGT Plant
TC GT
Air Exhaust Gas
GT based Plants for Maximum Efficiency from Clean FuelsGT based Plants for Maximum Efficiency from Clean Fuels
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
HRSGsHRSGs for Industrial Applicationsfor Industrial Applications
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Options for Meeting Power/Heat requirements in IndustryOptions for Meeting Power/Heat requirements in Industry
CentralPowerPlant
Trans-mission
Standbygenerator
BoilerHeat
Demand
Cogeneration Plant
Trans-former
PowerDemand
Fuel
Fuel
Fuel
FACILITY
Export /Import Electricity
Export Heat / Steam
Fuel
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Power / Steam RequirementsPower / Steam Requirements
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Power & Steam Generation System OptionsPower & Steam Generation System Options
FuelSteam
Air
Flue gas
GT
HRSG
HP StmHdr
ST
TC
IP StmHdr
Boiler
LP StmHdr
PRDS
PRDS
PROCESS
• Power & Steam demands are unique for each industrial application• Power demand can be met through GT(s) or ST(s) or both • Steam demand can be met through HRSGs(s) or Boiler(s) or both
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Plant operating Scenarios & their influencePlant operating Scenarios & their influenceon design/selection of Equipmentson design/selection of Equipments
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Design Considerations for Cogeneration PlantDesign Considerations for Cogeneration Plant
Assessment of Power Demand(Electric load-Demand Curve)
0
5
10
15
20
25
1000 2000 3000 4000 5000 6000 7000 8000
Hours
Pow
er(M
W)
Assessment of Heat-Steam Demand(Heat load-Demand Curve)
020406080
100
1000 2000 3000 4000 5000 6000 7000 8000
Hours
Stea
m Qt
y (ton
/hr)
§ Assessment of Power Demand
§ Assessment of Steam Demand
§ Assessment of Fuels
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Ø GT based cogeneration plants are preferred due to
§ Higher efficiency
§ Lower emissions
§ Faster Startup / response
Ø HRSGs are custom built to meet specific process requirements
Ø Proper definition of operating envelope of GT & HRSG are required for selecting the most suitable type among Unfired , Duct Fired & Furnace Fired HRSGs
GT Based Cogeneration Plant GT Based Cogeneration Plant
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
HRSG OptionsHRSG OptionsØ Unfired HRSGs are suitable only when
• Power & Steam demand fluctuations are minimal
• Dependence on steam flow, temperature from HRSG is minimum
Ø Fired HRSGs are suitable for meeting Constant/variable steam flow demand at rated steam temperature at varying
• Ambient conditions
• GT Power Output
Ø Depending on the HRSG fuels & extent of augmentation of unfired HRSG steam output, supplementary HRSGs fall into two categories
• Duct Fired HRSGs
• Furnace Fired HRSGs
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Duct Fired HRSGDuct Fired HRSG
For For Gaseous FuelsGaseous Fuels
For For Liquid FuelsLiquid Fuels
01 Bypass Stack02 Diverter Damper03 Expansion Joint04 Superheater III05 Internal Insulation06 Duct Burner
07 Superheater II08 De-Superheater09 Superheater I10 Evaporator11 Economiser12 Stack
01 02 03 04 05 06 07 0908 10 11 12
Ø Suitable for nominal augmentation (~2 times unfired output) of steam output
through supplementary firing of common Liquid / Gaseous Fuels
Ø Duct burners not suitable for difficult to burn fuels
Ø Very high augmentation of steam output not possible in Duct Fired HRSGs
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Furnace Fired HRSG for difficult to burn FuelsFurnace Fired HRSG for difficult to burn Fuels
ØBurners located in water cooled
membrane wall enclosure, due to
very high flue gas temperatures
ØHeat transfer bundles located
downstream in internally
insulated duct enclosure
ØSpecialised industrial burners for
difficult to burn fuels
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
HRSGsHRSGsfor for
Advanced Class Advanced Class GTsGTs
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Evolution of Combined Cycle Units in BHELEvolution of Combined Cycle Units in BHEL
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Typical Combined Cycle ParametersTypical Combined Cycle Parameters
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Growth of HRSG Unit Sizes with GTGrowth of HRSG Unit Sizes with GT
Fr5 Fr6FA
Fr9E
Fr9FA
Fr6
GT Exhaust Flow (ISO) Comparison
1.0 1.17 1.66 3.34 5.29
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
IP LP
HP Drum
HPSH
II
RH
II
HPSH
IB
RH
I
HPSH
IA
HPEV
HPEC
II
IP Drum
IPEV
IPEC
LP Drum
LPSH
LPEV
IPSH
HPEC
I
CPH
HP Main Steam
Cold Reheat
Hot Reheat
IP Main Steam
LP Main Steam
HP
To Deaerator
Triple Pressure Reheat SystemTriple Pressure Reheat System
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
v Superior HP / RH Steam
Parameters due to superior GT
exhaust parameters
v Sandwiching of SH and Reheater
sections to achieve high HP & HRH
steam temperatures
v Proper disposition of various heat
transfer sections for optimum heat
recovery
HPSH
RH
HPSH
RH
HPSH
Sandwiching of SH & RH Sections
Triple Pressure Reheat HRSG FeaturesTriple Pressure Reheat HRSG Features
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
9th Energy Efficiency Summit 2010, Chennai Session I (3rd Sep 2010)
Thank You