Industrial Application of Gas
Turbines (IAGT)
Introduction to HRSGs
HRSG
Heat Recovery Steam Generator
Also referred to as waste heat
boiler
Cools hot gases most
commonly the exhaust of a gas
turbine
Generates steam and regains
energy
HRSG
Critical link between the gas turbine and steam turbine in combined
cycle and cogeneration plants
Combined Cycle Plant
Cogeneration Plant
FUNDAMENTAL PARTS OF HRSG
Four Basic HRSG Components
Evaporators (gas to wet
steam heat exchanger)
Economizers (gas to water
heat exchanger)
Superheaters/Reheaters (gas
to dry steam heat
exchanger)
Preheaters (gas to
water/glycol/air etc. heat
exchanger)
EVAPORATOR
Vaporize water and produce
steam
Water/steam circulates from
lower drum to steam drum
Steam exits from the steam
drum after passing through
steam separating equipment
Water level must be
carefully maintained
Steam
Steam
Drum
Feedwater
Gas
Flow
Lower
Drum
ECONOMIZERS
To
Evaporator
Feedwater
Preheats water prior to
entry into the steam drum
Desirable to prevent steam
from forming in the
economizer
Gas
Flow
SUPERHEATERS/REHEATERS
Saturated steam from
evaporator is sent to
superheater to produce dry
steam
Dry steam is required for
steam turbines
SH
Steam
Dry Steam
Gas
Flow
HRSG TYPES
Three (3) Main Types
NATURAL CIRCULATION HRSGs
FORCED CIRCULATION HRSGs
ONCE THROUGH HRSGs
NATURAL CIRCULATION HRSG
Typically horizontal gas flow
and vertical tubes
Tube bundles typically grow
thermally down
For gas turbines less than 50
MW, evaporator is shipped to
site in single pieces
For larger gas turbines the
evaporator is shipped in
multiple sections
Feedwater
SH Steam
Evaporator
Gas
Flow
Superheater
Economizer
INTEGRAL STEAM DRUM
Evaporator shipped to site in
single section (up to approx.
400,000 lbs)
SEPARATE STEAM DRUM
Evaporator shipped to site in multiple sections
Increased field erection costs
FORCED CIRCULATION HRSG
Typically vertical gas flow and
horizontal tubes
Steam/water mixture
circulation through evaporator
tubes and to/from drum with a
pump
Historically common in Europe
due to small footprint
Gas Flow
Feedwater
Economizer
Circulation
Pump
SH
Steam
Evaporator
Superheater
ONCE THROUGH HRSG
Feedwater
Typically vertical gas flow and
horizontal tubes
OTSGs eliminate the need for
steam drums
Phase change from water to
steam is free to move
throughout the bundle
Economizer
Evaporator
Superheater
SH Steam
Gas Flow
HRSG DESIGN PHILOSOPHY
Exchange heat from the exhaust gas to the fluid at the highest
temperature difference available
Accomplished by making the exhaust gas and the fluid (steam/water)
temperature gradients as nearly parallel to each other as possible
900
800
700
700
Temperature (F)
Gas
Steam/Water
Pinch = 20 F
600
517
495
500
400
430
Approach = 10 F
485
300
240
HRSG Temperature Profile - Unfired
Steam Production = 66,850 lb/hr
200
100
0
0
10
20
Number of Rows
30
40
SINGLE VS MULTIPLE PRESSRE HRSG
Adding additional pressure levels in the HRSG can increase the
amount of heat that can be recovered from the exhaust gas
As the saturation temperatures are lower at successive pressures, the
stack temperature can be lowered
Dual Pressure HRSG Temperature Profile
HP Steam Production = 75000 lb/h
LP Steam Production = 100000 lb/h
1000
900
Gas
HP Steam/Water
LP Steam/Water
846
800
Temperature (F)
700
660
635
600
HP Pinch = 165
F
495
500
475
400
410
390
HP Approach = 20 F
375
375
300
331
LP Ap proach = 35 F
200
Common Economizer
230
100
0
0
10
20
30
40
Number of Rows
50
60
70
HRSGs
HRSGs vs Conventional Boilers
Differences between HRSGs and Conventional boilers
HRSGs use exhaust from a gas turbine as a heat source and do not
need a dedicated firing system (burner, fan, motor etc.)
HRSGs typically do not use fans (draft is from gas turbine exhaust)
HRSGs generate steam at multiple pressure levels to improve heat
recovery efficiency
Heat transfer is by convection rather than radiation
HRSGs do not use membrane water walls
HRSGs use finned tubes to maximize heat transfer
HRSGs vs Conventional Boilers
Differences between HRSGs and Conventional boilers
Finned Tubing
Finned tubing is used to increase heat transfer
Two types solid fins and serrated fins
Heat transfer can be adjusted by changing fin height, fin thickness,
fin density, fin materials
Fins are spiral wound onto tubes using various processes:
Brazing
Welding
Finned Tubing
Serrated Finned Tube
Solid Finned Tube
Fabrication of HRSGs
Large HRSGs typically made from pressure part modules referred to
as harps
Significant field assembly
Erection of HRSGs
Shipment of harps, cased or uncased sent to site
Modules stacked up to three (3) wide
Erection of HRSGs
Steam drum sent to site separately
Exhaust stack sent to site in multiple sections
Fabrication of HRSGs
Smaller HRSGs such as the OTSG maximize shop fabrication,
minimizing field assembly
DUCT BURNERS
Add heat to the gas turbine exhaust stream
Exhaust gas typically has enough oxygen to sustain stable
combustion
DUCT BURNERS
Steam demand increases
without any change in the gas
turbine exhaust
Desired steam flow of final
steam temperature cannot be
achieved with the available heat
from the gas turbine
Gas turbine is completely down
but steam is still needed (Fresh
air firing)
DUCT BURNERS
Burners can be configured to burn a variety of different fuels
from natural gas to oil
DUCT BURNERS
Fresh air firing is used to produce steam when the gas turbine is
down
DISTRIBUTION GRIDS
Used to correct flow
maldistribution
Variable porosity plates
and turning vanes
commonly used
Typical gas side pressure
drop for a variable
porosity plate ranges
from 0.5 inches H2O to
3 inches H2O
FLOW MODELING
Gas flow distribution leaving the gas turbine is non-uniform
Proper performance of the HRSG, duct burner and emission
equipment requires uniform flow and temperature profile
NOx REMOVAL PROCESS
Ammonia (NH3) is injected into the gas stream upstream of SCR
catalyst
Catalyst layer decomposes NOx (nitrous oxides, principally NO and
NO2) into harmless N2 and H2O
Steam Out
SCR Catalyst
Economizer
Gas Flow
Evaporator
Superheater
NH3 Injection Grid
Feedwater
SCR LOCATION
100
SCR must be placed in the
appropriate gas temperature
zone for maximum efficiency
Typical medium temperature
catalyst maximum
continuous temperature is
800 F with excursions to
approx. 900 F
D
e
N
O
x
E
F
F
I
C
I
E
N
C
Y,
90
80
70
(%)
.
60
400
500
600
700
GAS TEMPERATURE, (F)
Typical DeNOx Efficiency VS. Gas Temperature
800
CORROSION IN HRSGs
Water dewpoint corrosion
Metal temperatures fall below
the water dewpoint
Can lead to accelerated
corrosion
Acid dewpoint corrosion
Trace quantities of sulphur in
fuel form sulphur trioxide (SO3)
and combine with water to form
acids
Leaves deposits on fin tubes
QUESTIONS ??????
