UNIVERSIDAD PERUANA DE CIENCIAS APLICADAS

FACULTAD DE INGENIERÍA
CARRERA DE INGENIERÍA INDUSTRIAL

“Heat recovery steam generator (HRSG) with deNOx unit”

CURSO:
Tecnología y Automatización Industrial

INTEGRANTES:
Trujillo Grandez, Ruby (u201212427)
Henriquez Alvarado, Francisco (u201111369)
Espinoza Tejada, Edson (u201215043)

DOCENTE:
POWER PORTO, GEORGE FELIX

2018-1
1. Theoretical background, objectives and legal framework

One of the main problems presented by a combined cycle thermal power plant is the steam
generator. This is responsible for taking advantage of the heat contained in the exhaust gases
and converting it into potential energy, in the form of steam, with a pressure and a certain
temperature.
Its most important parts are:

- Degasser: is responsible for eliminating gases that were dissolved in the feed
water, mainly oxygen.

- Feeding water tank: there is the water that feeds the entire system. The water
that is there must be very pure, to avoid impurities.

- Boiler: from this boiler the water evaporator and the steam boiler are fed.

- Feeding pumps: these are responsible for carrying the water, from the feed
water tank, to the corresponding boiler.

- Economizers: they are responsible for preheating the water with the residual
heat of the exhaust gases.

- Evaporators: take advantage of the heat of the intermediate temperature

exhaust gases to evaporate the water at the corresponding circuit pressure. The
circulation of water can be forced or natural.

- Superheater: they are located at the inlet of the gases coming from the
combustion in the gas turbine. The temperature and pressure of the steam must
be controlled, so that thermal stress can be avoided in the different
components.
Figurette: Heat recovery steam generator (HRSG)
Where:
1) Compressor.
2) Gas turbine.
3) By-pass
4) Superheater
5) Evaporator.
6) Economizer.
7) Boiler.
8) Gas turbine
9) Capacitor.
10) Steam by-pass.
11) Feed water tank / Degasser.
12) Feed pump.
13) Condensate pump.

Objectives:
 ✓ Generate steam
✓ Inject water or steam into the combustor of the gas turbine, to limit the
formation of NOx.
✓ Supply steam to processes

2. Process description
HRSG boilers are made to handle large flows of gases and with minimum pressure drops.
The heat recovery steam generator is a heat exchanger with countercurrent flows, which is
composed of a series of sections, as mentioned in the previous chapter, of superheater,
boiler or vaporizer and the economizer, which are located so that heat recovery and supply
of the value at the right pressure and temperature can be maximized.

The installation scheme of a HRSG can be visualized in the following way:

In the upper part there is the gas turbine, the lower part of the steam turbine and the
recovery boiler. The recovery boiler has three heating phases:
 - Economizer: Warms the liquid to saturation conditions.
- vaporizers: Make the phase change
- Superheater: Overheat the steam

The boiler, performs the function of separating the liquid and steam. That is to say, it
allows by decanting to make sure that the vaporizers are being fed with liquid and the
superheater with steam. Also, as mentioned above, the heat recovery steam generator is
countercurrent, that is, the configuration of the recovery boiler is, the gases are cooled from
top to bottom and the water is heated in the downstream direction upwards.
It is shown in a graph, how heat transfer is carried out:

Maximum recovery:
In this system you can maximize the recovery of the heat that is made, this can be achieved
by minimizing the value of the temperature at the point of exit of the gases from the boiler.
The idea is to have phase changes at different temperatures and pressures, with this, heat
recovery can be maximized. Several pressure levels must be introduced into the recovery
boiler to have different phase and temperature changes.
In the following graph it can be seen that the operating conditions are equivalent in both
referring to water. Water, in the second graph, has two different curves and this is because
there are two levels of pressure. Thanks to this, it is achieved that the gases are at a lower
temperature and, therefore, more heat is recovered.

Cycles of two or three levels of pressure give a higher performance than that obtained with
a single level of pressure, but definitely the installation cost is higher. It is the best choice
when the cost of fuel is high and can also be in the case of specific applications. Here is an
example of two levels:

Although it is true, this model would apply to the greater reduction of heat, but also, a more
complex design, the set that is visualized in the phase with a level of pressure would have
to double or triple, it depends if it is done with two or three levels of pressure.
Types of steam generators:

The heat recovery steam generator (HRSG) is a heat exchanger with countercurrent flows,
which is composed of a series of sections formed by the superheater, boiler (or vaporizer)
and economizer, located in a way that maximizes the recovery of heat and steam supply at
the right pressure and temperature. For the most economical design, the following
parameters should be evaluated:
According to the mode of circulation of the exhaust gases, steam generators for heat
recovery are categorized into two types: horizontal and vertical. In the horizontal type, the
exhaust gas circulates horizontally through vertical tubes, while in the vertical, the exhaust
gas circulates vertically through horizontal tubes.

- Horizontal heat recovery boilers

The horizontal boiler is one in which the gas, at the exit of the turbine, follows a horizontal
path through the various modules of overheating, reheating, vaporization and water heating,
until its conduction to the evacuation chimney.

They do not need support structure, being together a more compact and cheap boiler, since
it requires little metallic support structure when the roof elements are hung.

- Vertical heat recovery boilers.

In this type of boiler, the insulation is usually internal, with protection of the insulating
layer, or mixed, with internal ceramic fiber coating in the upper part where the gases are
colder.

Although operationally these boilers are not so special, the requirements of quality control
during construction and the purity of the feed water are similar requirements to those of
horizontal boilers, as well as the limitations and precautions in loading ups and downs.

The normal form of operation in this type of boiler is in sliding pressure, where the vapor
pressure fluctuates according to the steam flow, the turbine valves remaining completely
open. This form of operation maximizes the performance of the boiler at partial loads,
since, if steam production decreases, as the flow rate and the temperature of the gas turbine
exhaust gases are reduced, the pressure is also reduced, and it saturation temperature, which
achieves high vaporization and the recovery of most of the energy of the gases.

Likewise, if required by environmental regulations, a selective catalytic reduction (SCR)

system can be integrated in the steam generator to control NOx emissions, which is
particularly attractive, because this catalyst can be located in an enclosure of optimal
temperature within (HRSG). Below is a simplified schematic and circuit of a combined
cycle system:
3. Analysis of control loops, measured and manipulated variables

Economizador
The TC-003 controller acts directly on the TCV-003, to maintain the supply water input to
the boiler in the desired conditions.
The process variables required to obtain this control are: the water temperature of the boiler
feed after the economizer (TIT-003) and the boiler pressure (PIT-007).
The PY-007 controller calculates the saturation temperature minus 3 ° C based on the boiler
pressure.
Boiler
 Boiler control in the HRSG

The boiler has control LC-003 A / B. One of its functions is to keep the level of the water
supply within certain pre-set limits through the FCV-001 A / B, to feed the evaporator
tubes and prevent them from overheating. Another function is to ensure that the steam
reaches the turbine through the superheaters, preventing water or cold steam from reaching
it.
The following controllers can be observed:
• LIT-003 A/B/C: Calder level
• FIT-002 A/B/C: High pressure steam flow
• FCV-001 A: Feed water flow
• FCV-001 B: Water flow reserve power
• FY-002: Calculate the average of the three readings FIT-002 A / B / C
• PY-008: Calculate the average of the three readings PIT-008 A / B / C
• TY-012: Calculate the average of the three readings TIT-012 A / B / C
• FY-002 A: Measurement of the superheated steam flow delivered to steam turbine
compensated with pressure and temperature.
• LY-003: Calculator of the average with the value of 3 readings LIT-003 A / B / C
• FY-001: Average calculator with the value of 3 readings FIT-001 A / B / C
• FY-001 A: Send the output value to the control valves.
Steam temperature control
The recovery boiler has to generate steam well above the saturation temperature (452 ° C),
which ensures the proper functioning of its consumers. Because the working regime of the
boiler can vary and work in different loads, a tempering valve that produces steam at the
desired temperature must be included in the superheaters.

Steam temperature controle

The following controllers can be observed:

• TIT-012 A/B/C: Superheated steam
• TCV-010: Adjustable valve position
• TY-012: Calculator of temperature, the median is obtained through three readings
TIT-012 A / B / C
• PY-008: Pressure calculator. Gets the average of three readings PIT-008 A / B / C
• TY-012 A: Compare the temperature of the final superheater with the saturation
temperature.
• TC-012: PID controller with reverse action
• TC-010: PID controller with direct action

Continuous and intermittent purge tank

When the measured conductivity exceeds the desired limits, the valve will open to increase
the purge flow. The purge of the boiler will be set as a percentage of the flow of feed water.
The purge tank level control will be carried out by the LC-007 controller acting on the
LCV-007 valve to keep the continuous purge tank at the desired level.

Continuous purge level

On the other hand, the level control of the intermittent purge tank would be:
 Intermittent purge tank
level control

The following controllers can be observed:

• LIT-007: Continuous purge tank level
• LIT-009: Intermittent purge tank level
• LCV-007: Continuous purge level control valve
• LCV-009: Intermittent purge level control valve
• LC-007: PI controller with direct action
• LC-009: PI controller with direct action
4. Instrumentation

Instruments Description Figure

Flow Sensor This sensor is a air
velocity, thermometer
with a fairly small
footprint that is
designed to measure the
most smallest level of
velocity. These devices
are factory calibrated
using an exclusive wind
tunnel to obtain the
lowest velocity
Self – regulating Self actuated pressure
valve control valves do not
depend on any external
signal for pressure
control. As the name
suggests, pressure in the
process line itself is
used as an actuating
signal to open or close
the pressure control
valve.
Termal flow meter It is used to measure the
flow of oxygen, natural
gas, methane, and other
gases, These are
connected by means of
insertion pipes.

Temperature control If the temperature rises

the valve opens to
provide more water.
However, in most
installations this type of
control is not sufficient
 to maintain the steam
temperature in the
required margins
They are classified as
mechanical pressure
Bourdon manometer measuring instruments,
and thus operate without
any electrical power.
This type of sensor
satisfies the need for a
local indication sensor,
easy maintenance and
low cost. In addition to
its high precision,
strength and long
service life. It is the
most used in the
industry
Temperature A temperature
transmitter transmitter is an
electrical instrument
that interfaces a
temperature sensor, for
example thermocouple,
thermistor, to
measurement or control
device. Typically
temperature transmitters
isolate, amplify,filter,
noise, linearize, and
convert the input signal
from the sensor then
send a standardized
output signal to the
control device.
CHAPTER 5: INVESTMENT AND OPERATING COSTS

The total cost of generating a steam recovery boiler is composed of investment, fuel, operation and
maintenance costs1. The charge for fuel is a level cost, which depends on the evolution scenario of
the energy price in question, the internal reference price and the discount rate used.

The heat recovery steam generator (HRSG) is also known as the "Waste heat recovery boiler (WHRB)
and as the turbine exhaust gas boiler (TEG).

The HRSG is a key point in a combined cycle plant, since it affects and contributes a lot to the cost
of investment (capital), the cost of operation and the overall efficiency of the cycle. The HRSG are
flexible in design for specific applications. As is known, the gas flow through the unit can be vertically
or horizontally, with the exchange between soil cost, for a horizontal flow arrangement and
structural steel cost requirements for a vertical flow unit, but what is most handled and is best
known is the unit with horizontal gas flow. It is feasible to design this unit to operate with multiple
systems or steam water circuits of different pressures, in order to meet the application
requirements and improve heat recovery.

Mostly, the investment cost (capital) of the system is relatively low, since there are fewer
components of modular construction, rapid delivery, short construction and minimal costs of
support systems.2 At the time of selecting the system, these benefits are regulated against the
higher fuel costs for the gas turbine and the maintenance and availability issues, and the load
requirements.

Mentioning the factors that contribute to the economic performance of the Heat Generation are
the following:3

- High thermal performance

- Low installation cost

- Low operation and maintenance cost:

a. Steam generation in the process conditions.

1
León, Gabriel (2010) Pg. 72
2
Prieto, Ismael (2006) Pg. 7
3
Prieto, Ismael (2006) Pg. 8
b. Steam turbines for condensation / extraction.

c. Non condensing turbines with escape to the process.

d. Heat recovery steam generator with combustion and without combustion.

e. Nox DLN low emission gas turbine / steam injection.

- High electric power / heating power ratio.

- High reliability / availability ratio.

- Installation in a relatively short period of time.

Taking into account some technical considerations for these systems, the following can be detailed:

The heat recovery steam generator, better known as HRSG, is basically a heat exchanger with
countercurrent flows, which is composed of a series of sections, which are: superheater, vaporizer
and economizer. These three sections are located from the entrance to the gas outlet, this in order
to maximize heat recovery and supply the conditioned steam flow at the right pressure and
temperature.4

The most economical design of the system consists of the following five parameters: Admissible
back pressure, steam pressure and temperature, approach point, superheater and economizer
approach temperatures and chimney exit temperature. These parameters as a whole are evaluated
and determined based on experience and economic considerations.

The first parameter, the back pressure, is significantly influenced by the area of the straight section
of the flow in the HRSG. The high backpressures lower the cost of the HRSG, but also reduce the
performance of the gas turbine and increase the exhaust pressure.

The approach point parameters and the approach and approach temperatures have a significant
impact on the overall size of the unit. For a low approach point and a reduced superheater
approximation temperature, larger heat exchanger surfaces and a higher investment cost are
required. On the other hand, at an economizer approach point, it is peculiarly established to avoid
vaporization in the economizer, for the design conditions.

4
Prieto, Ismael (2006) Pg.11
Also, the pressure and steam temperature parameters are chosen to simplify the design and be
economical. Although it is true, high pressures increase the efficiency of the system, but often limit
the global recovery of the heat of the gases. This happens in the case of a single pressure HRSG,
because of the high saturation temperature it handles. The solution to this, is done by a HRSG of
various pressures, this is usually between 1 and 4 sections with different independent pressures.
The sections of superheater, boiler and economizer, each at their respective pressure, allow to
reduce the overall cost and increase heat recovery.

In the case of power generation through combined cycles, several provisions are possible that can
handle a wide range of fuels, these depend on their cost. This makes it possible to select the most
suitable steam cycle for each application, which responds correctly to the operational and economic
needs. The steam cycles used can be the following:

A. Simple pressure, without overheating, with heating of the feed water:

This is the simplest steam cycle that can be used in a combined cycle and the most common is a
cycle without combustion, with superheater, evaporator and fin tube economizer. The installation
cost is low, although maximum efficiency is not obtained with it. It is a correct selection when the
fuel is economical and when it is used in consumption tips or when burning fuels with high sulfur
content.

Figure 1: Schematic of a HRSG with a single pressure level

Figure 2: Temperature profile in a single pressure HRSG

B. Multiple pressure, without overheating, with heating of the feed water:

This system is used to achieve maximum heat recovery from the exhaust gases of the gas turbine.
Cycles of two or three levels of pressure give a higher performance than that obtained with a single
level of pressure, but definitely the installation cost is higher. This is the best selection when the
cost of fuel is high and can also be in the case of specific applications.

The graph shown below corresponds to a heat recovery steam generator (HRSG) scheme with three
pressure levels and without superheater.
Figure 3: Three-level HRSG heat recovery steam generator without superheater

C. Three pressure levels, heat recovery reheater, water heating feed:

The steam cycle with reheat is applicable when using gas turbines with an exhaust gas temperature
of 593 ° C or more that supply enough energy to the heat recovery steam generator, so that the
superheater can be easily used. In the following figure you can see what is mentioned:

Figure 4: Diagram of a combined cycle with HRSG of three pressure levels and reheater.
Investment costs

Defining the investment costs, usually three types are handled:

- Direct cost:

It is the sum, in constant currency, of the corresponding expenditures of a plant (it does not include
the cost of the electrical substation), divided by the gross capacity of the same, which is equivalent
to all the investment costs of the work being Installed overnight (overnight cost).

- More indirect direct cost:

It is the result of adding to the direct cost the corresponding engineering, administration and control
of the work, and those incurred in the central offices of the CFE.

- Cost updated at the start of the operation:

From the "most indirect direct cost" and by using a real annual discount rate of 12%, the value of
the updated investment is calculated at the start of the commissioning of the plant. This discount
rate includes the cost of interest accrued during the construction process.

Indirect costs for different technologies

type of plant percentage of indirect
thermoelectric 9.9
combined cycle 5.3
turbogás 2.5
diesel 5.3
carboelectric 12.5
nuclear power 5.3
geothermal 25.5
hydroelectric 12.4

Likewise, the updated cost at the start of the operation results from assigning a value to money over
time through a discount rate, that is, the construction term and the investment schedule are taken
into account. This concept includes the cost of interest accrued during the construction of the work.
Investment programs are estimated based on the construction and equipment payment schedules
of each technology. The percentage profile for each year is the sum of the quotients of the monthly
disbursement between the total sum of disbursements. It should be noted that all amounts are in
constant currency. The years associated with the construction period are denominated with
negative numbers in order to call zero the first year of operation of the plant; this convention is only
of notation and does not imply conceptual differences with any other.5

The following figure shows the three investment costs according to the type of generating plant:

Figure 5: Three investment costs and updated at the start of operation according to each type of
plant

Fuel costs

The cost of the fuel reflects the imputed value to the energy resources necessary to obtain, by
means of the different technologies, a net MWh generated. In the calculation of these costs internal
reference prices are used, corrected with the evolution scenario thereof.

5
León, Gabriel (2010) Pg. 74
6. Conclusions

• The thermal efficiency of the recuperator boilers decreases with the increase of the pinch
point, due to the fact that the temperature of the gas at the entrance of the economizer will
be greater, reducing the heat transfer in all the sections of the boiler, obtaining boiler
exhaust at a higher temperature, which indicates a low heat recovery in the boiler. All this
directly influences the generation of superheated steam in the boiler.
• The generation of superheated steam increases with the inlet temperature of exhausted
gases, since there is a greater energy available at the inlet of the recovery boiler, and an
increase in the energy efficiency of the same is achieved. This temperature value will be
conditioned by the thermal resistance of the construction materials of the boiler.
• The increase of the inlet temperature to the gas turbine provides greater power delivered
by it. On the other hand, the temperature of entry to the gas turbine is strongly related to
other characteristics of the same as the materials used for the combustion chamber and
vanes of the first stages as well as the cooling system.
• The temperature of the exhaust gases of the gas turbine is another fundamental
characteristic in the case of combined cycles, since, although it could be thought that this
should be as low as possible, it must be taken into account that in This type of cycle, there
is a great energy recovery of the exhaust gases, so it does not matter that it is too low.
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