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Article history:
Received 4 November 2013
Accepted 24 February 2014
Available online 15 March 2014
Keywords:
Heat recovery steam generator (HRSG)
Heat exchanger
Layout analysis
Thermodynamic performance
a b s t r a c t
Changes of heat exchangers layout in heat recovery steam generator (HRSG) will modify the amount of
waste heat recovered from ue gas; this brings forward a desire for the optimization of the design of
HRSG. In this paper the model of multi-pressure HRSG is built, and an instance of a dual pressure HRSG
under three different layouts of Taihu Boiler Co., Ltd. is discussed, with specied values of inlet temperature, mass ow rate, composition of ue gas and water/steam parameters as temperature, pressure etc.,
steam mass ow rate and heat efciency of different heat exchangers layout of HRSG are analyzed. This
analysis is based on the laws of thermodynamics and incorporated into the energy balance equations for
the heat exchangers. In the conclusion, the results of the steam mass ow rate, heat efciency obtained
for three heat exchangers layout of HRSGs are compared. The results show that the optimization of heat
exchangers layout of HRSGs has a great signicance for waste heat recovery and energy conservation.
2014 Elsevier Ltd. All rights reserved.
1. Introduction
In recent years, with soaring energy price and increasing
demand for reducing fuel consumption, much attention has been
paid to the utilization of industrial waste heat. Different grades
of waste heat are commonly available in metallurgy, oil, petrochemicals and other industries. The main carrier of waste heat resources is sensible heat in the ue gas, and the most frequent
approach for recovery is to produce steam that can be used directly
or further used to generate electricity. The design of HRSGs is organized at three levels: rst it put forward the overall strategy for
heat recovery, which enables to obtain pressure levels and the
main operating parameters of the HRSG; the second step involves
a general layout to meet the process requirements, including the
layout of heat exchangers and the net absorbed heat of each heat
exchanger; the third step leads to the detailed design of the geometric variables of the heat exchangers, such as tube types and
diameters, the number of tubes per row. The main goal is to increase heat efciency and decrease the equipment cost with the
prerequisite of guaranteeing safety and reliability. For specic values of the ue gas parameters, many different choices are possible
regarding the heat recovery scheme and the general layout of heat
283
Nomenclature
g
s
i
j
i
o
Mg
Ms
M js
cpg
hs
P0
Ps
DT jpp
DT jsatw
DT jgo;B
DTmin
DTi
DTmin,i
Tg
gas
steam
the ith heat exchanger
the jth pressure level
inlet
outlet
ue gas mass ow rate (kg/s)
total steam mass ow rate of public economizer (kg/s)
steam mass ow rate of the jth pressure level (kg/s)
specic heat at constant pressure (kJ/kg K)
working uid enthalpy (kJ/kg)
ambient pressure (MPa)
working uid pressure (MPa)
pinch point temperature difference of the jth pressure
level (K)
water saturation temperature of the jth pressure level (K)
gas outlet temperature of the evaporator of the jth pressure level (K)
minimum temperature difference (K)
temperature difference of the ith heat exchanger (K)
the minimum temperature difference of the ith heat exchanger (K)
gas outlet temperature at the outlet of the economizer
(K)
bottoming cycles. The evaluation showed that the increasing number of pressure levels of steam generation will reduce the losses
due to heat transfer in the HRSG. In reference [11], a combined
power cycle with HRSG is analyzed. Through exergy analysis, the
exergy of the exhaust streams and the irreversibility of each component in the cycle are determined. In this paper [12], it is shown
that important relationships among optimal objective functions
and decision variables can be discovered consequently. Casarosa
et al. [13] studied thermodynamic optimization based on the minimization of the total HRSG cost, after the reduction to a common
monetary base of the costs of exergy losses and of installation. In
[14] a CCPP with a supplementary ring system is analyzed
through energy and exergy, the optimal design of operating parameters of the plant is then performed by dening an objective function and applying a generic algorithm (GA) type optimization
method. This paper [15] shows a methodology to achieve thermoeconomic optimizations of CCGT power plants taking into account
the frequent off-design operation of the plant. In [16] a complete
economic and thermodynamic study for dual pressure, triple pressure with and without reheat has been reported. Therefore, they
investigated the effect of the pressure levels of steam generation
in HRSG on exergy efciency of combined cycle. Mohagheghi and
Shayegan [17] combined with the genetic algorithm calculated
the optimal thermodynamic performance conditions for HRSGs.
Ahmadi et al. [18,19] performed the exergoenvironmental optimization of a CHP system, they showed that reducing the irreversibility of an HRSG increases the steam cycle efciency due to
increasing the produced steam temperature. In this study [20], a
comprehensive thermodynamic modeling of a dual pressure CCPP
is performed, an optimization study to nd the best design parameters is carried out. Behbahani-nia et al. [21] considered a small
cogeneration system including a gas micro turbine and a re tube
HRSG, the results show that the thermodynamic optimization does
not lead to major improvement of the total cost of the HRSG due to
decrease in the pinch point. In conclusion, the results show that the
use of several pressure levels in HRSGs increases the power
production in the steam cycle. The researches listed above mainly
Tacid
T0
gh
Q
284
the water/steam parameters are constant, different heat exchangers layout brings forward changes in DTi, so that results in the
changes of DTmin,i and different thermodynamic performance.
Therefore, an optimized design of HRSG heat exchangers layout
is of great importance for maximizing waste heat recovery.
3. Model equations
3.1. Control equations of the unit model
Fig. 2a. Schematic diagram of dual pressure HRSG 2.
285
As mentioned above, on ue gas side, the temperature difference between the ue gas inlet temperature and water/steam outlet temperature would be changed with the change of heat
exchanger layout. Therefore, the minimum temperature differences of each heat exchanger are the constraints:
m
Mm
s hso;1
hsi;pub
M s M 1s M js M m
s
2
3
T g T go;n P T acid
4. Mathematical solution
There are m steam mass ow rates M js and n gas outlet temperatures Tgo,i by the equations listed above, and the steps for calculating the (m + n) unknowns are as follow:
On water/steam side, under jth pressure level, the inlet temperature of kth heat exchanger is the outlet temperature of (k1)th
heat exchanger, and the outlet temperature of kth heat exchanger
is the inlet temperature of (k + 1)th heat exchanger:
8
< hj
so;k
; 1 6 j 6 m; 1 6 k 6 s
j
j
: hj f T j ;Pj hj
si;k
so;k1 f T so;k1 ;P so;k1
si;k
si;k
;1 6 j 6 m; 1 6 k 6 s
6
10
11
cjp;k
Assume
is specic heat at constant pressure in each heat exchanger; slopes of each section in TQ prole are the reciprocal of
Mjs times cjp;k , which can be written as:
T jso;k T jsi;k =Q jk 1=M js cjp;k
12
In TQ prole, when DTi is lower than DTmin,i, DTi and Tgi,i need
to be increased with Eq. (8). Take Fig. 1b for example, parameters
are unchanged, when the temperature difference of heat exchanger
4 increases, M1s could be decreased, so that Q3 decreases, the slope
286
Mjs2 110%Mjs
13
ii. Plug the new steam mass ow rate into energy balance
equations to get new ue gas inlet temperature, if the results
obtained satisfy the constraints, DSA would be used for M jsn :
MjsD1 M js M js2 =2
14
iii. Put into energy balance equations for verication, to get new
ue gas inlet temperature, then verify the constraint, if the
results obtained satisfy the constraints, DSA would be used
for M jsn :
DSA would be used if the results calculated meet the requirement, or decreasing M jsn for certain percent (10% e.g.) until it meets
the demand of constraints. If it could not meet the demand to adjust M jsn , then M j1
would be adjusted and the steps are the same as
s
adjusting Mjsn .
(b) The gas outlet temperature (GOTM):
In step (2), Tacid would be the constraint when Tg calculated is
lower than Tacid, we rst assume Tg is equal to Tacid, then:
1
1
j
j
M g cpg T g1i T g M1s hso hsi Mjs hso hsi
m
m
Mm
s hso hsi
15
16
Table 1
Parameters of a dual pressure HRSG.
Flue gas inlet temperature
Gas mass ow rate (Nm3/h)
Heat loss (%)
Dust content (g/Nm)
Flue gas composition (%)
CO2
H2O
N2
O2
350
1,000,000
0.5
9
0
0
75.42
24.58
287
T jsi;i (C)
T jso;i (C)
P js;i (MPa)
M js;i (kg/s)
Tgi,i (C)
Tgo,i (C)
Mg (kg/s)
Q (kJ/Nm3)
1
2
3
4
5
6
218.6
218.6
161.8
110
161.8
110
320
218.6
230
213.6
161.8
156.8
2.16
2.16
0.55
2.37
0.55
0.6
19.89
20.47
12.06
20.89
12.49
12.67
350
335.5
272.2
266.9
204.1
176.8
335.5
272.2
266.9
204.1
176.8
127.6
176.03
172.11
154.36
153.03
135.36
127.75
64.40
35.96
83.63
6.77
85.30
19.24
Table 3
Gas and water/steam properties of HRSG 2.
HE-No.
T jsi;i (C)
T jso;i (C)
P js;i (MPa)
M js;i (kg/s)
Tgi,i (C)
Tgo,i (C)
Mg (kg/s)
Q (kJ/Nm3)
1
2
3
4
5
6
218.6
218.6
218.6
161.8
110
161.8
218.6
320
218.6
230
213.6
161.8
2.16
2.16
2.16
0.55
2.37
0.55
20.47
19.89
20.64
12.06
20.89
12.5
350
340.5
326.1
272.5
267.3
205
340.5
326.1
272.5
267.3
205
176.7
176.03
173.53
169.64
154.61
153.28
135.75
62.72
37.63
83.63
6.77
72.76
19.24
Table 4
Gas and water/steam properties of HRSG 3.
HE-No.
T jsi;i (C)
T jso;i (C)
P js;i (MPa)
M js;i (kg/s)
Tgi,i (C)
Tgo,i (C)
Mg (kg/s)
Q (kJ/Nm3)
1
2
3
4
5
6
218.6
218.6
161.8
156.8
161.8
110
320
218.6
230
213.6
161.8
156.8
2.16
2.16
0.55
2.37
0.55
0.6
21.83
22.92
10
22.92
11.19
31.33
350
334.2
271.4
267
204.7
176.8
334.2
271.4
267
204.7
176.8
129.3
176.03
171.75
154.14
153.06
135.53
127.75
62.72
37.01
83.63
5.65
85.30
21.12
Fig. 7. Steam mass ow rate in each pressure level of three heat exchangers layout.
288
6. Conclusions
289
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