HRSG CFD design

Introduction

Heat Recovery Steam Generators (HRSGs) are critical components in combined cycle power plants and combined heat and power (CHP) systems. They recover heat from exhaust gases to generate steam, improving overall energy efficiency. Computational Fluid Dynamics (CFD) is a powerful tool used to optimize HRSG design and performance by simulating fluid flow, heat transfer, and combustion processes.

Key Insights

Porous Media Modeling for Tube Banks:
- Modeling heat exchangers as porous media zones can simplify simulations and provide accurate pressure drop correlations for tube banks .
Uniform Flow and Temperature Distribution:
- Ensuring uniform axial velocity and temperature distributions at the HRSG inlet is crucial to prevent overheating of the first rows of boiler heat exchanger tubes. This can be achieved using correction devices like perforated plates and burner elements modeled by porous jump boundary conditions .
Impact of Low-Load Operations:
- Low-load operations can lead to tube failures due to flow imbalances and elevated tube temperatures. CFD can identify these risks and suggest mechanisms like flow-conditioning devices to mitigate them.
Steam Drum Design:
- Proper sizing and positioning of steam drum internals, such as demisters, are essential for efficient steam separation. CFD can help determine the velocity distribution inside the drum to optimize its design.
Explicit Modeling of Tube Banks:
- Advances in computational power allow for explicit modeling of tube banks, providing a more realistic representation of fluid flow and heat transfer, which is beneficial over the porous media approach.
Control System Design:
- Implementing advanced control systems, such as fuzzy self-adapting control algorithms, can improve the reliability and precision of HRSG operations, ensuring safe and economical performance .
DeNOx Facilities Optimization:
- Optimal design and positioning of Ammonia Injection Grids (AIG) can enhance the performance of DeNOx facilities in HRSGs. CFD analysis can guide the installation and adjustment of AIGs to achieve uniform flow and effective ammonia injection.

Conclusion

CFD plays a pivotal role in optimizing HRSG design and performance. Key strategies include using porous media models for tube banks, ensuring uniform flow and temperature distributions, addressing low-load operation risks, optimizing steam drum design, leveraging explicit tube bank modeling, and implementing advanced control systems. Additionally, CFD aids in the optimal design of DeNOx facilities, enhancing overall HRSG efficiency and reliability.

Summary

Introduction

Key Insights

Conclusion

Sources and full results

CFD Analysis of the Flow Through Tube Banks of HRSG

This study developed a new procedure to define main porous-medium non-dimensional parameters using accurate three-dimensional simulations of flow through tube banks in HRSGs, improving energy usage and limiting ineffectiveness due to non-homogeneous flow patterns.

STEAM DRUM DESIGN FOR A HRSG BASED ON CFD

CFD simulations can predict velocity distributions in HRSG steam drums, aiding in steam drum design and ensuring proper separation performance.

The CFD Modeling of Heat Recovery Steam Generator Inlet Duct

CFD modeling can effectively simulate Heat Recovery Steam Generator inlet duct flow correction and temperature distributions, ensuring uniform outlet velocity and temperature profiles.

CFD Simulations of Heat Recovery Steam Generators Including Tube Banks

Including tube banks in CFD models of HRSGs can provide a more realistic representation of fluid flow and heat transfer, improving performance optimization in combined cycle power plants.

On the Use of Computational Fluid Dynamics (CFD) to Assess the Impact of Low-Load Operations on Heat Recovery Steam Generator (HRSG) Tube Module Integrity

CFD can help identify conditions that lead to tube failures in Heat Recovery Steam Generators, and potential solutions to reduce the risk, such as flow-conditioning devices.

Control system design of fuzzy self-adapting on water level of HRSG

The fuzzy self-adapting control algorithm improves the control quality of HRSG systems, ensuring reliable, secure, and economical boiler operation.

Automatic Control Design and Instrument Supervision of HRSG

The paper highlights the importance of automatic control design and instrument supervision in Heat Recovery Steam Generator (HRSG) design, using technology imported from ALSTOM.

The Design of Controlling System for Heat Recovery Steam Generator(HRSG)

The PLC-based controlling system for heat recovery steam generators (HRSG) provides highly reliable, precise, and economical operation, ensuring safe and efficient operation.

A Study for Optimal Design of the AIG to Improve the Performance of DeNOx Facilities Installed in Combined Cycle Plant

Optimal design of the AIG in HRSGs can improve DeNOx performance in combined cycle plants, with uniform flow distribution and flow correction devices recommended for optimal performance.

Application of CFD Modeling in HRSG Evase Design

The air flow optimized evase in HRSG systems provides more uniform velocity profiles and reduces pressure drop compared to single angle and dual angle roofs.

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