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HRSG:: Energy Recovery Heat Exchanger Steam Steam Turbine

An HRSG (heat recovery steam generator) recovers heat from hot gas streams to produce steam. It is commonly used in combined-cycle power plants, where the HRSG captures waste heat from a gas turbine to power a steam turbine. HRSGs consist of components like evaporators and superheaters and can be modular, packaged, or once-through designs. They significantly improve power plant efficiency.

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526 views3 pages

HRSG:: Energy Recovery Heat Exchanger Steam Steam Turbine

An HRSG (heat recovery steam generator) recovers heat from hot gas streams to produce steam. It is commonly used in combined-cycle power plants, where the HRSG captures waste heat from a gas turbine to power a steam turbine. HRSGs consist of components like evaporators and superheaters and can be modular, packaged, or once-through designs. They significantly improve power plant efficiency.

Uploaded by

Gaurav
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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HRSG:

A heat recovery steam generator or HRSG is an energy recovery heat exchanger that
recovers heat from a hot gas stream. It produces steam that can be used in a process or used
to drive a steam turbine.

General Usage

A common application for an HRSG is in a combined-cycle power station, where hot exhaust
from a gas turbine is fed to an HRSG to generate steam which in turn drives a steam turbine.
This combination produces electricity more efficiently than either the gas turbine or steam
turbine alone. Another application for an HRSG is in diesel engine combined cycle power plants,
where hot exhaust from a diesel engine, as primary source of energy, is fed to an HRSG to
generate steam which in turn drives a steam turbine. The HRSG is also an important
component in cogeneration plants. Cogeneration plants typically have a higher overall efficiency
in comparison to a combined cycle plant. This is due to the loss of energy associated with the
steam turbine.

Modular HRSGs

HRSGs consist of Four major components: the Evaporator, Superheater, Economizer and
Water preheater. The different components are put together to meet the operating requirements
of the unit. See the attached illustration of a Modular HRSG General Arrangement.

Modular HRSGs can be categorized by a number of ways such as direction of exhaust gases
flow or number of pressure levels. Based on the flow of exhaust gases, HRSGs are categorized
into vertical and horizontal types. In horizontal type HRSGs, exhaust gas flows horizontally over
vertical tubes whereas in vertical type HRSGs, exhaust gas flow vertically over horizontal tubes.
Based on pressure levels, HRSGs can be categorized into single pressure and multi pressure.
Single pressure HRSGs have only one steam drum and steam is generated at single pressure
level whereas multi pressure HRSGs employ two (double pressure) or three (triple pressure)
steam drums. As such triple pressure HRSGs consist of three sections: an LP (low pressure)
section, a reheat/IP (intermediate pressure) section, and an HP (high pressure) section. Each
section has a steam drum and an evaporator section where water is converted to steam. This
steam then passes through superheaters to raise the temperature and pressure past the
saturation point.

Packaged HRSGs

Packaged HRSGs are designed to be shipped as a fully assembled unit from the factory. They
can be used in waste heat or turbine (usually under 20 MW) applications. The packaged HRSG
can have a water cooled furnace which allows for higher supplemental firing and better overall
efficiency.

Variations
Some HRSGs include supplemental, or duct firing. These additional burners provide additional
energy to the HRSG, which produces more steam and hence increases the output of the steam
turbine. Generally, duct firing provides electrical output at lower capital cost. It is therefore often
utilized for peaking operations.

HRSGs can also have diverter valves to regulate in the inlet flow into the HRSG. This allows the
gas turbine to continue to operate when there is no steam demand or if the HRSG needs to be
taken offline.

Emissions controls may also be located in the HRSG. Some may contain a Selective Catalytic
Reduction system to reduce nitrogen oxides (a large contributor to the formation of smog and
acid rain) and/or a catalyst to remove carbon monoxide. The inclusion of an SCR dramatically
effects the layout of the HRSG. NOx catalyst performs best in temperatures between 650 °F
(340 °C) and 750 °F (400 °C). This usually means that the evaporator section of the HRSG will
have to be split and the SCR placed in between the two sections. Some low temperature NOx
catalysts have recently come to market that allows for the SCR to be placed between the
Evaporator and Economizer sections (350 °F - 500 °F (175 °C - 260 °C)).

Once-Through Steam Generators (OTSG)

A specialized type of HRSG without boiler drums is the Once Through Steam Generator. In this
design, the inlet feedwater follows a continuous path without segmented sections for
economizers, evaporators and superheaters. This provides a high degree of flexibility as the
sections are allowed to grow or contract based on the heat load being received from the gas
turbine. The absence of drums allows for quick changes in steam production and fewer
variables to control, and is ideal for cycling and base load operation.

Applications

 Heat recovery can be used extensively in energy projects.


 In the energy-rich Persian Gulf region, the steam from the HRSG is used for desalination
plants.
 Universities are ideal candidates for HRSG applications. They can use a gas turbine to
produce high reliability electricity for campus use. The HRSG can recover the heat from
the gas turbine to produce steam/hot water for district heating or cooling.
 Large ocean vessels (e.g. Emma Maersk) make use of heat recovery

Heat recovery steam generators (HRSGs) are vital components of combined-cycle power
plants; they convert exhaust heat into steam that is used to power the turbines. An HRSG
installation is a major undertaking, requiring extensive expertise in welding, rigging, heavy lifting
and other construction disciplines. At CB&I, we've proven our ability to complete even the most
challenging HRSG projects safely, on time and within budget.
We provide erection and construction management services for new HRSG installations as well
as revamps and upgrades. We offer a variety of contract options to provide the best value for
our customers.
Experts in the power industry. We've served the power industry for more than 70 years,
executing projects for all types of power generation plants. Throughout our history, we've
proven our ability to work effectively in both open- and closed-shop environments; implement
successful safety programs; supervise craftspeople from a variety of trades; and carefully
manage costs, schedules and quality.
For every project, we provide highly skilled technicians and craftspeople who understand our
standards and work processes. They are the best in their field at welding, post weld heat
treating, non-destructive examination, vessel inspection, testing, mechanical erection, blasting
and painting. Our welding and quality assurance groups support our field crews with timely and
practical solutions to the most demanding technical challenges and ensure all work is performed
according to our high standards.

Careful management and planning.


HRSG installations are complex and often must be completed under compressed schedules, so
there is no margin for error. When planning and scheduling our projects, we consider every
detail, including labor requirements, equipment selection, materials staging, installation site
conditions, and heavy-lift and rigging requirements. We continually look for better, more efficient
ways to work, developing specialized equipment for performing heavy lifts in congested work
sites and innovative rigging techniques that make elevated work safer. And our comprehensive
safety program has earned us one of the best safety records in the industry and accolades from
our customers

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