Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering...

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Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly Utilize Enthalpy of Flue Gas….

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Transcript of Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering...

Page 1: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Final Audit :Utilization of Flue Gas Energy

P M V Subbarao

Professor

Mechanical Engineering Department

Minimize Final Exhaust Gas Temperature….Properly Utilize Enthalpy of Flue Gas….

Page 2: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

s

1

2

3

4

5

6

2f

2s

4523 hhmhhm mreheatsteafmainsteam

Page 3: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

DPNL SH

Platen SHT

R

RHTR

LTSH

Economiser

APH ESP ID Fan

drum

Furnace

BCWpump

Bottom ash

stack

screentubes

Thermal Structure of A Boiler Furnace

Page 4: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Furnace ater wall absorption

Platen SH

Pendent SHCSH

Reheater

Combustion Losses C & R losses

Hot Exhaust Gaslosses

Page 5: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Sequence of Energy Exchange from Flue Gas to Steam

PLATEN SH

FLUE GAS

EVAPORATORWater Wall

COVECTIVE LTSH

RH PENDENT SH

Page 6: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Fuel Power

Furnace absorption

Platen SH

Final SHLTSH

Reheater

Combustion Losses C & R losses Hot Exhaust Gaslosses

~4000C

Page 7: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Details of 500 MW(e) Capacity Indian Power Unit

• Main steam Flow rate: 425 kg/s.

• Main Steam Temperature: 5400C

• Reheat Steam Flow rate: 38.7 kg/s.

• Air Flow Rate: 577.06 kg/s.

• Coal Flow Rate: 73.8 Kg/s.

Page 8: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

500 MW

Page 9: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Gas Temperatures

• Platen Super Heater:• Inlet Temperature: 1236.4 0C• Outlet Temperature: 1077 0C• Final Super Heater:• Inlet Temperature: 1077 0C• Outlet Temperature: 962.4 0C• Reheater:• Inlet Temperature: 962.4 0C• Outlet Temperature: 724.3 0C• Low Temperature Super

Heater:• Inlet Temperature: 724.30C• Outlet Temperature: 481.3 0C

Steam Temperatures

• Platen Super Heater:• Inlet Temperature: 404 0C• Outlet Temperature: 475 0C• Final Super Heater:• Inlet Temperature: 475 0C• Outlet Temperature: 540 0C• Reheater:• Inlet Temperature: 345 0C• Outlet Temperature: 5400C• Low Temperature Super

Heater:• Inlet Temperature: 3590C• Outlet Temperature: 404 0C

Page 10: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

    Design Calculated

1 Adiabatic Flame Temp (K) 1957 1966

2 FEGT (0C) 1102 1117

3 Platen SH-I Outlet (0C) 932 951

4Platen SH-II Outlet-I outlet (0C) 859 878

5 RH 3rd & 2nd outlet (0C) 595 604

6 RH 1st Stage outlet (0C) 510 531

7 Economiser outlet (0C) 385 398

8 APH Outlet (0C) 138 151

Flue Gas Temperature At different regions of Furnace:210 MWe)

Page 11: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Steam and Gas Paths

Page 12: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Suggested Fluid Velocities

• Flue gas velocities: 10 – 18 m/s.

• Steam in super heaters & reheaters: 10 – 25 m/s.

• Water Wall circulation : 0.35 – 3.5 m/s.

Page 13: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

500 MW

Page 14: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

LMTD for various Devices

Page 15: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Surface Area of Heat Exchangers: 500 MW

Page 16: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Economizer

• The economizer preheats the feed water by utilizing the residual heat of the flue gas.

• It reduces the exhaust gas temperature and saves the fuel.

• Modern power plants use steel-tube-type economizers.

• Design Configuration: divided into several sections : 0.6 – 0.8 m gap

Page 17: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Tube Bank Arrangement

Page 18: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.
Page 19: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Thermal Structure of Economizer

• Out side diameter : 25 – 38 mm.

• Tube thinckness: 3 – 5 mm

• Transverse spacing : 2.5 – 3.0

• Longitudinal spacing : 1.5 – 2.0

• The water flow velocity : 600 – 800 kg/m2 s

• The waterside resistance should not exceed 5 – 8 %. Of drum pressure.

• Flue gas velocity : 7 – 13 m/s.

Page 20: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Thermal Balance in Economizer.

• The energy absorbed by steam

• The convective heat lost by flue gas

• Overall Coefficient of Heat Transfer, U

)( ,,, inecooutecosteamconabs hhmQ

TUAQ ecolosscon

,

Page 21: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Mean Temperature Difference

• The average temperature difference for parallel flow and counter flow is expressed as

• It is also called log mean temperature difference• When tmax /tmin > 1.7, the average temperature may be expressed as:

• Generally, the flow direction of the flue gas is perpendicular to the axes of tubes.

• If number of bends are more than four, the flow can be treated as counter or parallel flow.

min

max

minmax

log3.2t

t

ttt

2minmax tt

t

Page 22: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Complex Flow

• Parallel flow and counter flow may simultaneously exist in one section of an economizer.

• This is called complex flow.

Page 23: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

• For a given set of inlet and outlet temperatures of the fluids,

• The temperature difference of parallel flow is the greatest,

• The temperature difference of counter flow is the lowest

• And that of complex flow is in between.

• The average temperature difference in a complex flow can be calculated as:

• When

• Otherwise, the temperature difference is determined by

• The value of Ktd is determined by flow type and the thermal parameters.

copa ttt 5.0

copa tt 92.0

cotd tKt

Page 24: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.
Page 25: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.
Page 26: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Gas Temperatures

• Platen Super Heater:• Inlet Temperature: 1236.4 0C• Outlet Temperature: 1077 0C• Final Super Heater:• Inlet Temperature: 1077 0C• Outlet Temperature: 962.4 0C• Reheater:• Inlet Temperature: 962.4 0C• Outlet Temperature: 724.3 0C• Low Temperature Super Heater:• Inlet Temperature: 724.30C• Outlet Temperature: 481.3 0C• Economizer:• Inlet Temperature: 481.3 0C• Outlet Temperature: 328.5 0C

Steam Temperatures

• Platen Super Heater:• Inlet Temperature: 404 0C• Outlet Temperature: 475 0C• Final Super Heater:• Inlet Temperature: 475 0C• Outlet Temperature: 540 0C• Reheater:• Inlet Temperature: 345 0C• Outlet Temperature: 5400C• Low Temperature Super Heater:• Inlet Temperature: 3590C• Outlet Temperature: 404 0C• Economizer:• Inlet Temperature: 254 0C• Outlet Temperature: 302 0C

Page 27: Final Audit :Utilization of Flue Gas Energy P M V Subbarao Professor Mechanical Engineering Department Minimize Final Exhaust Gas Temperature…. Properly.

Furnace absorption

Platen SH

Pendent SHCSH

Reheater

Economizer APH

Combustion Losses C & R losses Hot Exhaust Gaslosses


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