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Heat Recovery System Generator

Heat Recovery System Generator (HRSG)

A Heat Recovery System Generator (HRSG) helps save energy. It takes heat from machines and uses it again. This allows us not to waste energy. HRSG works with many machines. It helps keep things running well. It saves power. It is easy to use. It allows machines to work better. It is used for small and big jobs. It is simple and helps in many ways.

  • Application industries: Power Plant
  • Certificate: ISO, ASME, CE
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What is heat recovery system generator?

A Heat Recovery System Generator (HRSG) is a key component in combined heat and power (CHP) systems or combined cycle power plants. It is used to capture and recover waste heat from exhaust gases produced by industrial processes or power generation, and then use that heat to generate steam. This steam can be used for power generation, heating, or other industrial processes.

Here’s how it works:

  1. Waste Heat Capture: The HRSG takes in hot exhaust gases, usually from a gas turbine or other high-temperature processes.
  2. Heat Transfer: These gases pass through the HRSG, which has tubes filled with water or another fluid. The heat from the gases transfers to the fluid, turning it into steam.
  3. Steam Production: The generated steam can then be used to power a steam turbine, which generates electricity, or for other heating purposes.

HRSGs are commonly found in power plants, refineries, and other industrial settings. They improve energy efficiency by making use of heat that would otherwise be wasted, helping to reduce fuel consumption and environmental impact.

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A Heat Recovery Steam Generator (HRSG) is a critical component in combined cycle power plants or industrial settings, designed to capture waste heat from exhaust gases and convert it into useful steam, which can then drive a steam turbine to generate additional power. The specification of an HRSG includes several key features and parameters that are important for its design, operation, and performance.

Key Specifications of HRSG:

1. Design Type

  • Vertical or Horizontal Configuration: Based on the space constraints and the plant layout, HRSGs can be designed in either a vertical or horizontal configuration.
  • Modular or Custom Built: Some HRSGs are built modularly for easy integration into existing systems, while others are custom-designed to meet specific plant requirements.

2. Heat Recovery Process

  • Exhaust Gas Inlet Temperature: The temperature of the exhaust gas from the gas turbine entering the HRSG. This typically ranges between 450°C to 650°C (842°F to 1202°F).
  • Steam Generation: The primary function of an HRSG is to generate steam by recovering heat from the exhaust gases. The steam generated is used for power generation or other industrial processes.
  • Heat Transfer Surface: The HRSG has a series of heat exchangers like economizers, evaporators, superheaters, and reheaters to effectively transfer heat from the exhaust gas to water to produce steam.

3. Steam Production Parameters

  • Steam Pressure: Common pressures for the produced steam can range from 20 bar (290 psi) to 90 bar (1300 psi) or more, depending on the application.
  • Steam Temperature: The temperature of the steam can range from 250°C (482°F) to 600°C (1112°F), with specific temperatures depending on the plant’s needs.
  • Steam Flow Rate: This will depend on the size of the HRSG, typically ranging from a few tons per hour to several hundred tons per hour.

4. Gas Turbine Exhaust Conditions

  • Exhaust Gas Flow: The flow rate of exhaust gas entering the HRSG is typically measured in terms of cubic meters per second (m³/s) or cubic feet per minute (CFM).
  • Exhaust Gas Temperature: The temperature at which exhaust gases enter the HRSG impacts the efficiency of heat recovery. Typical temperatures range from 450°C to 650°C (842°F to 1202°F).

5. Heat Recovery and Efficiency

  • Thermal Efficiency: HRSGs are designed to recover as much heat as possible from the exhaust gases. Efficiency typically ranges between 80% to 90% based on the specific design and application.
  • Fuel-to-Steam Efficiency: This indicates how effectively the heat from the combustion gases is converted into steam, which is essential for combined cycle operations.

6. Operating and Design Parameters

  • Material of Construction: HRSGs are typically constructed using high-quality, heat-resistant alloys such as carbon steel, stainless steel, and occasionally more specialized materials like Inconel or other nickel-based alloys, especially for high-temperature applications.
  • Pressure Drop: The HRSG design needs to consider the pressure drop across the system due to friction losses, heat exchange, and resistance to gas flow, typically in the range of 5-10% of the gas turbine’s pressure.

7. Environmental Considerations

  • Emission Control: HRSGs in combined cycle plants often include mechanisms for reducing emissions such as NOx, CO, and particulate matter. This is critical for compliance with environmental regulations.
  • Heat Recovery Impact on Carbon Footprint: By increasing the efficiency of a power plant, HRSGs contribute to reducing the overall carbon footprint.

8. Auxiliary Systems

  • Stack and Ducting: Proper ducting and exhaust stacks must be designed for effective exhaust gas flow, minimizing losses and ensuring safe discharge of flue gases.
  • Blowdown System: A system to remove concentrated impurities from the water in the HRSG system, preventing scaling and corrosion of heat exchangers.
  • Bypass System: Many HRSGs include a bypass stack to allow exhaust gas to bypass the HRSG in low load conditions or during startup.

9. Control and Monitoring Systems

  • Temperature and Pressure Sensors: These sensors monitor the steam conditions, exhaust gas temperature, and pressure to ensure the HRSG operates within safe and efficient limits.
  • Automated Control Systems: These systems manage the operation of the HRSG to optimize steam production, maintain temperature and pressure, and integrate with the broader power plant control system.

10. Maintenance and Durability

  • Cleaning and Inspection: Periodic cleaning of heat exchange surfaces is required to maintain efficiency. HRSGs often come with features that allow for easy access for inspection and maintenance.
  • Longevity: HRSGs are designed for long-term operation, with lifespans that can range from 20 to 30 years with proper maintenance.

Features

The Heat Recovery Steam Generator (HRSG) is an essential component in combined-cycle power plants and other industrial applications that efficiently recovers waste heat from exhaust gases and converts it into steam. This steam can then be used to generate additional power or for other industrial processes. Here are the key features of an HRSG:

1. Heat Recovery Efficiency

  • The primary function of an HRSG is to recover heat from exhaust gases, typically from a gas turbine, and convert it into useful steam.
  • HRSGs have high thermal efficiency, often between 80% to 90%, depending on design and operational conditions.

2. Modular Design

  • Many HRSGs feature modular designs, making them adaptable for various plant sizes and configurations. This allows for easier installation and flexibility in upgrading or expanding power generation capacity.

3. Multiple Heat Exchange Surfaces

  • HRSGs include several heat exchange sections, such as economizers, evaporators, superheaters, and reheaters. Each section plays a specific role in recovering heat and producing steam at the desired temperature and pressure.
    • Economizers: Preheat the feedwater using exhaust gases before it enters the boiler.
    • Evaporators: Convert water into steam.
    • Superheaters: Increase the steam temperature to a required level for use in turbines.
    • Reheaters: Increase the steam temperature after partial expansion in the turbine for optimal efficiency.

4. Steam Production

  • HRSGs generate steam that can be used for electricity generation in steam turbines or in industrial processes.
  • The steam pressure and temperature can be customized based on the plant’s requirements, ranging from moderate pressures (20–30 bar) to high pressures (up to 90 bar or more).

5. Flexible Operating Conditions

  • HRSGs are designed to handle variable operating conditions. They are capable of operating efficiently across different load levels, from full load to partial load, which is common in power plants that use gas turbines with fluctuating power demands.

6. Material Durability

  • The construction materials of HRSGs are selected to withstand the high temperatures and pressures encountered during operation. Materials such as carbon steel, stainless steel, and sometimes nickel-based alloys are used for components exposed to high heat and corrosion.

7. Stack and Bypass System

  • HRSGs are often equipped with a bypass system that allows exhaust gases to bypass the heat recovery process when the HRSG is not needed, such as during plant startup or when operating at low load. This ensures that the gas turbine can still operate efficiently without overloading the HRSG.
  • The stack is used for the safe discharge of exhaust gases after the heat recovery process.

8. Integrated Control and Monitoring Systems

  • HRSGs are equipped with advanced control and monitoring systems that track parameters such as temperature, pressure, and steam flow rate. These systems optimize performance, ensure safe operation, and can adjust operation to meet varying demands.
  • Automated systems can adjust steam production based on load changes, maintaining efficient heat recovery.

9. Reduced Environmental Impact

  • By recovering waste heat from exhaust gases, HRSGs reduce fuel consumption and increase the overall efficiency of power generation, thus lowering greenhouse gas emissions.
  • HRSGs often incorporate emissions control systems to reduce harmful emissions, including NOx, CO, and particulate matter, meeting environmental regulations.

10. Compact and Space-Efficient

  • HRSGs are designed to be compact and space-efficient, making them ideal for installations where space is limited or where there is a need for a modular system.

11. Heat Recovery from Multiple Sources

  • HRSGs are capable of recovering heat from multiple sources, including gas turbines, reciprocating engines, or industrial furnaces, depending on the specific design and application.

12. Operational Flexibility

  • HRSGs can operate in different modes, including once-through (single pass) and multi-pressure systems, depending on the steam requirements and the configuration of the plant.
  • The multi-pressure system can handle different steam pressures at various stages of the steam cycle, improving overall efficiency.

13. Maintenance and Inspection

  • HRSGs are designed with accessibility features for maintenance and inspection. Regular maintenance of components like heat exchangers, drums, and water treatment systems is crucial for ensuring long-term operation and preventing efficiency losses due to scaling or corrosion.

14. Condensing and Non-Condensing Options

  • HRSGs can be designed for condensing applications (where steam is condensed back to water) or non-condensing applications (where steam is used directly for process or mechanical work).

15. Corrosion and Scaling Protection

  • HRSGs include features to protect against scaling and corrosion, which can degrade the heat transfer efficiency. Regular blowdown and water treatment systems help maintain performance.
Heat Recovery

Structure and Work Principle Heat Recovery System Generator (HRSG)

HRSG has many tubes. Hot gas moves through the tubes. The heat goes to the water in the tubes. The water turns into steam. The steam is used to make power. HRSG is like a heat recovery ventilator. It takes heat and reuses it. This saves energy. HRSG helps machines work better. It is easy to use. It needs little care. It is simple. HRSG works with many machines and helps keep them running well.

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Finned Tube

Fins on Tubes (HRSG)

Tubes have fins. Fins are little metal pieces. They help move heat away. This makes the tubes work better. Fins are essential. With fins, tubes work well. There are three ways to put fins on tubes. These ways are called extrusion, embedded, and welding.

1. Extrusion

In extrusion, the fins come from the tube itself. The metal of the tube is pushed out to make fins. The fins and the tube are one piece. This makes the fins very strong. They do not come off. Extruded fins last a long time. They stay on well.

2. Embedded

In the embedded way, the tube is cut to make slots. The fins are put in these slots. This makes the fins fit tightly. The fins touch the tube, so they move heat well. The fins stay in place, even when it gets very hot. This helps the tube work well for a long time.

3. Welding

In welding, the fins are joined to the tube with heat. This makes the fins stick very well. The fins do not fall off. Welded fins stay in place, even when it is very hot. Power plants use welded fins because they are strong. Welded fins help move heat and make the tubes work well. They do not break easily and stay on very well.

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Heat Recovery System Generator (HRSG) Types

Single-Pressure HRSG

This type has one part that makes steam. It is simple and easy to use. It is best for small jobs. It does not make much steam, but it works for minor uses. It is suitable for small factories or power plants. It is easy to set up and needs little space. It saves energy without needing much equipment.

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Dual-Pressure HRSG

This type has two parts that make steam. It makes more steam than the single-pressure HRSG. It is better for bigger jobs. It is used in more giant factories or power plants. It saves more energy by making more steam. It makes more power and does not waste energy. It is more efficient.

Triple-Pressure HRSG

This type has three parts that make steam. It is used for huge jobs. It makes a lot of steam. It is used in big power plants and factories. It uses all the waste heat. It is potent and efficient. It makes sure no energy is wasted.

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Product Advantages of Gelan Heat Recovery System Generator (HRSG)

    • Energy Recovery: HRSG helps with energy recovery. It uses heat that would be wasted. This saves energy. It also saves money. It makes sure we save energy. By using waste heat, HRSG helps make the system more efficient.

    • Suitable for the Earth: HRSG is good for the environment. It saves energy, which means less pollution. It helps us use resources better. By using waste heat, it lowers pollution and makes the air cleaner. It helps save natural resources.

    • Heat Ventilation: HRSG also works as a heat ventilation system. It helps manage the extra heat. It keeps machines from getting too hot. It keeps everything safe and helps machines work well. It uses extra heat to make steam, so no heat is wasted.

    • High Efficiency: HRSG uses waste heat well. It helps make extra power. This heat recovery unit makes sure energy is not wasted. It helps save money and use energy better.

    • Small Size: HRSG only takes a little space. It is easy to fit into many setups. It can be used in small or big places. It is easy to set up and does not need much space.

    • Solid and Long-Lasting: HRSG is made from strong materials. It lasts a long time. It needs little care. It has been working well for many years. It does not require much fixing. This helps save money on repairs.

    Energy Saving: HRSG works like an energy recovery ventilator. It uses heat that is already there. This helps save energy and money. It allows the use of resources well. It makes the system more efficient.

Applications of Heat Recovery System Generator (HRSG)

HRSG units are used in power plants, factories, and refineries. They are used in places with a lot of heat. These places need to reuse the heat. HRSG helps reuse the heat. It saves energy. It keeps machines from getting too hot. This helps keep things safe. HRSG is very useful. It helps save energy in power plants, factories, and refineries. It keeps everything working well.

FAQ

It is a machine that takes waste heat and makes steam. The steam makes power. This helps save energy and make more power. HRSG makes sure heat is not wasted.

It uses heat that would be wasted. This heat makes steam, and the steam makes power. This means more power with less energy. It helps save money and makes the system efficient.

It is used in power plants, factories, and refineries. It helps save energy in these places. It uses waste heat to make power.

A fin fan cooler takes heat away fast. It is suitable for places like power stations and commercial refrigeration where strong cooling is needed.

Yes, HRSG is easy to take care of. It is made from solid materials. It lasts a long time. It needs little care. It keeps working well without much fixing.

HRSG takes hot air and uses it again. This saves energy. The air exchange system helps keep the temperature right. HRSG uses waste heat to warm other parts of the system. This helps save energy and money.

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