The document describes the design of an inline desuperheater for Bajaj Power Equipment Pvt. LTD. It includes an introduction to desuperheaters and their purpose in reducing steam temperature for process applications. The objectives are to design an effective compact desuperheater and analyze its operation. The methodology involves analyzing steam properties, calculating desuperheater parameters, manufacturing it, and analyzing performance. Key calculations like mass flow rates and nozzle sizing are shown. The proposed design includes a steam pipe, spray nozzles, control valves, and sensors. References on desuperheater design and applications are also provided.

1. SIES GRADUATE SCHOOL OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
GROUP NUMBER -6
DESIGN OF INLINE DESUPERHEATER
GROUP MEMBERS
CHARIT GEDDAM - 218A6064
NIKHILESH MANE - 218A6067
PRATHMESH MOHOL - 218A6068
UMESH POL - 218A6077
GUIDED BY
PROF. PRAJAKTA KANE
2020-21

2. CONTENTS
➔ INTRODUCTION
➔ PROBLEM DEFINITION
➔ OBJECTIVE
➔ LITERATURE REVIEW
➔ METHODOLOGY
➔ DESIGN
➔ REFERENCES

3. INTRODUCTION
Project title -
Company name -
Company Guide -
Company Address -
Company About -
Design of Inline Desuperheater
Bajaj Power Equipment Pvt. LTD.
Mr. Pradip Nagawade (Design Manager)
Survey No : 227/3, Nimblak By-pass, M.I.D.C., (M.S.) India, Ahmednagar - 414111.
Bajaj Power Equipments Pvt. Ltd., (BPEPL) is an IBR approved, ISO 9001: 2008 certified company.
BPEPL is engaged in design, engineering, manufacturing, supply, erection and commissioning of high
pressure multi-fuel boiler for co-generation plant and power plant in India & around the globe.

4. Desuperheater
The Desuperheaters are used to reduce the temperature of steam generated by high pressure/high temperature boilers to levels required in
process operations.
The primary function of a desuperheater is to lower the temperature of superheated steam or other vapors by bringing in contact with the
coolant
Inline direct desuperheater.

5. Classifications of desuperheater are :
● Venturi Desuperheater
● Annular Venturi Desuperheater
● Nozzle (single and multi nozzle)
● Surface Absorption Desuperheater
Multi Nozzle Inline Desuperheater
The multi nozzle desuperheater has several nozzles (orifices of same diameter).
The water sprayed at control rate through the nozzle
Advantages :
1) Higher pressure drop
2) Higher mixing rate
3) High atomisation
4) No problem of critical point occurrence.

6. PROBLEM DEFINITION
Design and manufacturing of Inline Desuperheater as per the Industrial requirements.
Purpose :
The steam from the boiler after expansion in the turbine are exhausted to the atmosphere
The temperature of exhaust steam from boiler is high hence cannot be used directly into an application.
This steam can be used for various applications if the steam is brought to condition required for the application.
This process of bringing the steam to required level can be done by Desuperheater

7. OBJECTIVE
● To design effective and compact inline desuperheater.
● To manufacture the Desuperheater.
● To analyze the operation of Desuperheater.
● To use the superheated steam for various applications.

8. LITERATURE
SR
No
Paper Title Year of publication &
name of the Journal
Finding
1 Desuperheater for waste heat January 1983
International Journal of
Refrigeration.
● Compacting design procedure
2 Desuperheater Selection and Optimization
Academia
Kristin Donahue
● Parameters affecting the design
● Desuperheater material selection parameters
● Styles of desuperheater
3 Advances in Desuperheating Technology
for combine performance of CCPP
January 2005
Research gate
● Approach to Desuperheating
● New developments for reliable prediction of desuperheating
4 Mechanistic modelling of desuperheater
performance
May 1996
Elsevier
● Prediction of desuperheater
● Analytics tool for desuperheater
● Behavioural analysis of steam in the desuperheater.
5 Experimental Increase in the Efficiency of a
Cooling Circuit Using a Desuperheater 24 February 2016
ResearchGate
● Experimental cooling technique using Desuperheater
● Practical application of desuperheater in the circuit and the effect in the
electricity usage, behaviour of desuperheater

9. METHODOLOGY

10. 1- Analysis of steam properties :
The steam properties plays major role in designing. In this we will analyze the exhaust steam and the steam properties required at the outlet
of desuperheater.
2- Calculation and Design of Desuperheater :
In this we will calculate the parameters and prepare the design sheet according the calculation results. This will also include the selection of
type and material for Desuperheater
3- Manufacturing of Desuperheater :
After the design approval from the company authorities the desuperheater will be manufacture
4- Final analysis of the steam properties and desuperheater operation :
After manufacturing the desuperheater will be install at site. The desuperheater observation will be noted and a final analysis report
consisting of comparison between the actual and theoretical output of Desuperheater.

11. Gantt Chart :- Chart depicting the planning of the BE project Design Of Inline Desuperheater

12. DESIGN
Proposed daigram of Inline desuperheater

13. STEPS FOR CALCULATION
1) Calculate the mass flow rate required for the desuperheater
2) Check the steam pipe for the load
3) Calculate the diameter of the water pipe
4) Calculate the nozzle diameter and no of holes
5) Required values in water circuit, stranier, non-return valve, pressure regulating valve, flow control valve
6) Temperature sensor and PID controller programme

14. Calculations :
Given Data by company
Inlet Conditions (Exhaust Steam from boiler)
Mass flow rate of steam = 15 ton/hr
Temperature = 170 c
Pressure = 1.47 bar
Water conditions
Temperature = 105 c
Pressure head = 650 m
Outlet Conditions (Desuperheated steam condition required)
Temperature = 120 c
Pressure = 1.47 bar
Nominal Pipe size (Steam) = 450 mm

15. Step 1) Calculate the mass flow rate required for the desuperheater :
Mass flow rate of steam (Qs) = 15 ton/hr
Superheated steam Temperature = 170 c
Superheated steam Pressure = 1.47 bar
Water temperature for desuperheating = 105 c
Enthalpy of water for Desuperheating (Ew) = 440.274 KJ/Kg
Enthalpy of superheated steam (Ess) = 2813.33 KJ/Kg
Steam saturation temperature (Tss) = 110.744 c
Desuperheating steam required temp (Tds) = 120 c
Enthalpy of saturated steam (Esat) = 2692.19 KJ/Kg
According to Energy Balance Equation :
ENERGY INPUT = ENERGY OUTPUT
(Ess*Mss)+(Ew*Mw)=(Eds)*(Mss) + (Esat*Mw)
(ref temp = 120 c , Esr = 2722.06 KJ/Kg
Eds = 2711.5866 KJ/Kg
Mw = 0.693 ton/hr

16. Step 2) Check the steam pipe for the load
Qs = Asp *V
VSp
Vsp = Specific volume of steam (m3 / Kg)
Asp = Area of steam pipe (m)
Dsp2 = 4.167 * 0.3305 * 4
Π * 27.5
Dsp = 252.5 mm < 450 mm
Dsp (Calculated) < Dsp (Given)
Hence the steam pipe is safe

17. Step 3) Calculate the diameter of the water pipe
(water inlet pipe) Diameter = 0.5 inch to 1 inch
Velocity of water (Vw) = 1.5 m/sec
D = 0.5 inch = 12.7mm = 0.0127 m
Velocity (Vw) =1.5 m/sec
A = π/4 * D2
A = 1.266 * 10^-4 m2
Qw = A * Vw
Qw = Water mass flow rate (m3/sec)
Qw = 1.266 * 10^-4 * 1.5
Qw = 1.899 * 10^-4 (m3/sec) = 0.1403 Kg/sec
Condition of water after Pressure reducing valve
P1 = 15 bar
V1 = 1.5 m/sec
Qw = 0.1403 Kg/sec = 1.899 * 10^-4 cubic meter/sec
Q = A*V
A= Q/V = 1.899 * 10^-4
1.5
A = 1.266 * 10^-4 m2
π/4 * dp2 = 1.266 * 10^-4
dp = diameter of pipe carrying water (m)
dp = 0.0126 m
dp = 12.6 mm

18. Step 4) Calculate the diameter of nozzle and number of nozzle
Assuming the Diameter of nozzle (Dn) = 2.5 mm = 0.0025m
Dn = 2.5 mm = 0.0025 m
A = π/4 * D2
A = 4.908 * 10^-6 m2
Qw = A/V2
V2= Qw/A
V2 = Velocity of water at exit of nozzle
V2 = 38.691 m/sec
Applying Bernoulli's Equation
P1 + V12 = P2 + V22
ρg 2g ρg 2g
P2 = 7.5 bar
Problem occured :
➢ The required pressure drop is not achieved
➢ The required velocity drop is not achieved

19. SR
NO.
COMPONENT QUANTITY MATERIAL
1 PIPE - STAINLESS STEEL
2 NOZZLE SPRAYER 1 (10 orifice) STAINLESS STEEL
3 FCV 1
4 PID 1 -
5 THERMOCOUPLES 2 Type K Thermocouple
(Nickel-Chromium)
6 STRAINER 1
7 NON RETURN VALVE 1
8 PRESSURE REGULATING VALVE 1

20. REFERENCES
➔ Spray Engineering handbook, CTG SH O7 HU,Pnr
➔ Fluid Mechanics and Hydraulic Machines, RK Rajput
➔ Desuperheater for waste heat, International Journal of Refrigeration, January 1983
➔ Kevin G. Schoonover, W.M. Ren, S.M. Ghiaasiaan, S.I. Abdel-Khalik, Mechanistic modeling of desuperheater performance,
ELSEVIER, ISA Transactions 35 (1996) 45-51, May 1996.
➔ Kristin Donahue, Graham Corporation,Engineering Practice, Academia
➔ Peter Borzsony, Sanjay V. Sherikar, Advances in Desuperheating Technology for combine performance of CCPP, ResearchGate
publications, PWR2005-50108, January 2005
➔ Marian Formanek, Jiri Hirs, Josef Diblík, Petr Horak, Experimental Increase in the Efficiency of a Cooling Circuit Using a
Desuperheater, ResearchGate publications,PPci.8399, 24 February 2016,

21. Desuperheater TR Pressure Drop Outlet
Superheat
Cost
Venturi 2:1 Negligible 6.67°c low
Steam atomizing 50:1 Negligible 12.22°c Moderate
Multiple nozzles 50:1 High 12.22°c Moderate to
High
Variable orifice 100:1 Low 12.22°c High
Combined pressure
control valve and
desuperheater
Up to
100:1
Self-regulating 12.22°c Very High

22. THANK YOU