HRSG TECHNOLOGY

HRSG TRAINING
BENI SUEF, BURULLUS & NEW CAPITAL
WILLEM JAN DOMENIE & MARTIJN VAN GAMEREN
NEM ENERGY BV

21050/51/52
CONTENT

• Types of HRSG
1.

• HRSG Technology
2.

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TYPES OF HRSG
TYPES OF HRSG: HORIZONTAL NC - DRUM

Horizontal HRSG NC Drum type Steam turbine

Condenser

Stack

Air Fuel

Gas turbine HRSG

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TYPES OF HRSG: VERTICAL NC - DRUM

Vertical HRSG NC Drum type

Stack

Steam turbine

Fuel
Air
Condenser

Gas turbine HRSG

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TYPES OF HRSG: VERTICAL - ONCE THROUGH

Vertical HRSG once through (Benson) Stack

Separator

Steam turbine
Fuel
Air
HRSG
Condenser
Gas turbine

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WHICH TYPE OF HRSG ?

Selection of boiler type is based on many factors, such as:

 Flexibility in operation (fast start/cycling or base load)

 Pressure level of HP section
 Fuel composition
 Construction site and available area
 Client preference

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TYPE OF HRSG: BENI SUEF, BURULLUS & NEW CAPITAL

Vertical HRSG
3 Pressures
Low (LP), Intermediate (IP)
and High (HP)
Reheater
LP & IP  Drum type
HP  Once Through (Benson)

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COMBINED CYCLE CONFIGURATION
COOLING WATER HRSG

Condensate
CONDENSATE
FEED WATER
LP STEAM
IP STEAM
PREHEAT
PREHEATER
system
HP STEAM
REHEAT STEAM
LP
System LP DRUM

LP

IP
System IP DRUM
IP

HP HP
BOILER
FEEDWATER
CONDENSATE

System HP SEPARATOR PUMP

EXTRACTION
PUMP

RH REHEAT

System
GT HP IP LP

STEAM TURBINE CONDENSER

AIR

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HRSG TECHNOLOGY
PROPERTIES OF WATER

Example heat capacity:

Means to recover energy: Water
When increasing 1°C of 1 kg of
Why?
Water 4.184 KJ
- Special characteristics:
• Availability
Air 1.01 KJ
• Not harmful
• Very high heat capacity
Gold 0.13 KJ

Water can absorb a lot of Energy

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PROPERTIES OF WATER

Means to recover energy: Water

Why?
P= 0.7 bar
- Special characteristics: Boiling T= 90 °C
• Availability
• Not harmful P= 1 bar
• Very high heat capacity Boiling T= 100 °C

• Relation Pressure & Temperature

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RELATION PRESSURE AND TEMPERATURE (BOILING WATER)

For Water and Steam

Boiling temperature is different at
different pressures
Relation is fixed
Saturation Pressure and Temperature
Example:

Pressure Boiling
(atm) Temperature (°C)
1 100
10 180
100 311

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HEAT TRANSFER SECTIONS

Condensate Preheater (LP Economizer):

Condensate is preheated
Economizer :
Water is heated close to boiling
Condensate
temperature Preheater
Evaporator : Economizer
Water evaporates to steam
Superheater: Evaporator
Steam is superheated
Reheater: Reheater
Steam from HP Steam turbine is reheated Superheater

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HEAT TRANSFER CONCEPT

Heat transfer concept

Direction of heat

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HEAT TRANSFER

Heat transfer in HRSG

From the exhaust gas Water / steam

Water and steam: inside tubes

Flue gas: outside tubes

From flue gas to tube: convection

Through tube: conduction
From tube to water or steam: convection
Exhaust gas
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HEAT TRANSFER IN HRSG

Heat transfer (Q) depends on a number of factors:

Q= A x k x ΔT
• A = Surface area (more area = more heat can be transferred)
• k = Heat Transfer Coefficient (rate for how quick heat moves)
• ΔT = Temperature difference (larger difference means faster heat transfer)
Gas - Solid Liquid - Solid Through solid

Heat transfer Heat transfer Heat transfer

relatively slow relatively fast fast

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FINNED TUBES

Finning of tubes  Increase outside heat transfer surface

 Improve heat transfer from the flue gas to the metal tube

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HRSG TECHNOLOGY – DRUM

3 Drum

4 2 Stack

Superheater Evaporator Economizer

1
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DENSITY

Density is the amount of

mass in a volume

Separation: lower density “floats”

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DENSITY OF WATER AND STEAM

Effect of Pressure and

Temperature
on density of water and
steam

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NATURAL CIRCULATION

Water & steam circulation without pump steam

DRUM

water
Weight of water is larger than steam

height
Evaporator

Communicating vessels tend to equilibrium Evaporator

Downcomer

* Also applicable to vertical boiler

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ONCE THROUGH (BENSON) TECHNOLOGY

Separator

4 3 Stack

Superheater Evaporator Economizer

1
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DRUM COMPARED TO ONCE THROUGH (BENSON)

Drum Once through (Benson)

Separation water/steam No separation water/steam required

Easier control system Complex control system
Natural circulation Forced circulation
High pressures
(not supercritical by definition)
Less structural requirements

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MATERIAL STRENGTH

Each construction material has certain strength

Steel is strong, but when temperature and pressure get
high, even steel has a limit
Regular carbon steel can be used up to 400 °C
Low alloy carbon steel, for example T22, is stronger (and
more expensive) and can be used up to around 580 °C
For HP SH and RH sections P91 is used, which is suitable
up to 600 °C

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HRSG CONFIGURATION VIDEO
 QUESTIONS

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