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Generators:
Understand the Basics
Gas turbines with heat-recovery - steam The HRSG generates steam utilizing the
generators(HRSGs) can be found in energy in the exhaust from the gas
By understanding virtually every chemical process turbine. However, some plants also have
industries (CPI) plant. They can be the capability of producing steam when
how gas-turbine operated in either the cogeneration mode the gas turbine is shutdown. This is done
or the combined-cycle mode (Figure 1). using a separate forced-draft fan along
heat-recovery steam with a burner to generate hot gases, which
In the cogeneration mode, steam produced
from the HRSG is mainly used for are then used to generate steam. An
generators differ isolating damper system (also called a
process applications, whereas in the
bypass damper) with seal air fans is re -
from conventional combined-cycle mode, power is generated
quired in these units to ensure that hot
via a steam turbine generator.
steam generators, Gas turbines have several advantages as a gases do not leak to the fan when the gas
power source: they can be started up turbine is running and that maintenance
engineers can quickly; they come in packaged modules, can be performed on the gas turbine when
with power outputs ranging from 3 MW the fresh air fan is operating. Bypass
design and operate to 100 MW, that can be easily assembled dampers are also used in some units to
and erected; they have high efficiencies of ensure that the gas flow to the HRSG can
HRSG systems that 25% to 35% (on a lower heating value be modulated in order to match steam
[LHV] basis); and they require little or no generation with steam demand. However,
produce steam cooling water. Recent developments in- if fresh air firing is not used, an isolating
clude large-capacity units of up to 250 damper is not required.
efficiently. MW, with low emission characteristics Recent trends in HRSG design include
(less than 10 ppmv NOx), as well as high multiple-pressure units for maximum en-
combustor operating temperatures (in the ergy recovery, the use of high-
range of 2,200°F), which results in effi- temperature superheaters or reheaters in
V. Ganapathy, ciencies higher than 35%; the exhaust gas combined cycle plants, and auxiliary
ABCO Industries temperature is also higher, which helps to firing for efficient steam generation. In
generate high-pressure/high-temperature addition, furnace firing is often employed
superheated steam, making the Rankine in small capacity units when the exhaust
cycle efficient. gas is raised to temperatures of 2,400-
The HRSG forms a major part of the 3,000°F to maximize steam generation
steam system. In the combined-cycle and thus improve fuel utilization.
mode, the efficiency of the combined gas- This article highlights some of the basic
turbine-plus-HRSG system can reach 55- facts about gas turbine HRSGs. This
60% (LHV basis) with today's advanced information can help plant engineers,
machines, while in the cogeneration consultants, and those planning co-
mode, system efficiency can be as high as generation projects make important deci-
75-85%. sions about the system and performance
related aspects.
Turbine exhaust
characteristics
Two important variables that affect flow
rate and temperature of the gas turbine
exhaust are ambient temperature and
load, as mentioned earlier. These
parameters, in turn, affect HRSG
performance. At higher ambi ent
temperatures, the exhaust gas flow is
lower and the exhaust gas temperature is
higher, and vice versa. As the gas turbine
load decreases, the exhaust gas
temperature also decreases but the mass
flow does not vary much.
As a result of the variations in exhaust
gas flow and temperature, the HRSG
steam flow and temperature will also be
affected (Figure 12). Therefore, engineers
should analyze HRSG performance at
various cases and ensure that the plant
performance is not impacted by the
varying steam production in the HRSG.
Supplemen tary firing of the HRSG, as
well as steam and water injection in the
gas turbine, may have to be considered to
ensure steady steam production.
can be reconciled with any performance further to 9-15 ppm. Catalysts, in the Steam injection is becoming more
guarantees. form of selective catalytic reduction widespread. In addition to controlling
One way to answer these questions (SCR) systems (9), can be used in the NO, emissions from the gas turbine
is through HRSG simulation. One can HRSG to achieve this lower emission combustor, it also increases the gas
use the operating data to simulate the level. turbine power output as well as the
design pinch and approach points, and Catalyst performance is affected by gas HRSG output. This is due to the high er
then use this information to predict the temperature at the catalyst. Catalysts mass flow as well as the higher specific
HRSG off-design performance at the operate efficiently over a narrow range heat of the gas. In the Cheng cycle (3),
conditions specified in the proposal or of gas temperatures. For NOx catalysts, for example, steam injection is significant,
guarantee. A comparison between the the gas temperature range is typically raising the amount of water vapor from
two sets of data can confirm whether 600-750°F; for CO catalysts it is 900- 7% in uninjected units to 25%, with a
or not the HRSG original design is 1,200°F. The catalyst supplier specifies corresponding increase in the gas turbine
adequate (8). this temperature window, which power output from 3.5 to about 5.5 MW.
depends on the materials used. In order In summer months the gas turbine
Use of catalysts to achieve temperatures within this power output drops off, which may not
With stringent environmental reg- window at all loads of the HRSG, the be tolerable in some plants. Evaporative
ulations for carbon monoxide and ni- heat-transfer surfaces may have to be cooling or some other form of air cool-
trogen oxides, the use of catalysts for split to find a good location for the ing can be used in these plants to main-
controlling emissions is becoming SCR (Figure 11). tain a low and steady inlet air tempera-
commonplace. Steam and water in- Provision should be made for an ture to the compressor throughout the
jection and modifications to the gas ammonia injection grid upstream of the year. This results in a constant power
turbine combustor can reduce NOx NOx catalyst. The catalyst also has a output and steam generation, and
levels to 30-40 ppm. However, some high gas pressure drop, in the
states require that NO, be reduced