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HEAT RECOVERY STEAM GENERATOR
HRSGs consist of four major components: theeconomizer, evaporator, superheater 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 onesteam 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 anevaporator section where water is converted to steam. This
steam then passes through superheaters to raise the temperature beyond the one at
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 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
affects 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)).
Working principle
HRSG is originated and developed from the conventional boiler and heat exchanger. In terms of
construction, it can be divided into flue gas type and shell & tube type. The flue gas HRSG is
similar to the conventional boiler: the hot fluid in the furnace heats the tube bundle to create
high-temperature steam or hot water. Shell & tube HRSG is similar to shell and tube heat
exchanger: the hot fluid can move through either tube or shell and the heat will be transferred
between the hot and cold fluids through shell wall.
Characteristics
(1) It is capable of running under pressure.
(2) Strong intensity of heat transfer. In order to prevent the fluid from further reaction. It
requires that the temperature of fluid should be dropped down as soon as possible.
(3) Controllable outlet temperature. In some industrial applications, due to the high
temperature of dew point of fluid as well as its strong corrosivity, the outlet temperature
should be under control to keep above the rated value for avoiding corrosiveness.
(4) Strong wear resistance. A special design can improve the wear resistance of heat pipe
bundle to ensure a long-term safe operation.
Process flow diagram:

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Heat recovery steam generator

  • 1. HEAT RECOVERY STEAM GENERATOR HRSGs consist of four major components: theeconomizer, evaporator, superheater 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 onesteam 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 anevaporator section where water is converted to steam. This steam then passes through superheaters to raise the temperature beyond the one at 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 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 affects 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
  • 2. 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)). Working principle HRSG is originated and developed from the conventional boiler and heat exchanger. In terms of construction, it can be divided into flue gas type and shell & tube type. The flue gas HRSG is similar to the conventional boiler: the hot fluid in the furnace heats the tube bundle to create high-temperature steam or hot water. Shell & tube HRSG is similar to shell and tube heat exchanger: the hot fluid can move through either tube or shell and the heat will be transferred between the hot and cold fluids through shell wall. Characteristics (1) It is capable of running under pressure. (2) Strong intensity of heat transfer. In order to prevent the fluid from further reaction. It requires that the temperature of fluid should be dropped down as soon as possible. (3) Controllable outlet temperature. In some industrial applications, due to the high temperature of dew point of fluid as well as its strong corrosivity, the outlet temperature should be under control to keep above the rated value for avoiding corrosiveness. (4) Strong wear resistance. A special design can improve the wear resistance of heat pipe bundle to ensure a long-term safe operation.