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Understanding HRSG temperature profiles Page 2 of 2
For steam generation to occur and for a thermodynamically feasible temperature profile,two conditions must be met: tg3>ts,ts being saturation
temperature and tg4>tw1.If pinch and approach are arbitrarily selected,it is likely one of them can fail.Hence all these values are intimately related.
Table below shows typical K values and exit gas temperatures at various pressures.
EFFECT OF STEAM PARAMETERS ON EXIT GAS TEMPERATURE
press,psig steam temp,F sat temp,F K exit gas temp,F
100 338 338 0.904 300
150 366 366 0.8754 313
250 406 406 0.8337 332
400 448 448 0.7895 353
400 600 450 0.8063 367
600 490 490 0.74 373
600 750 492 0.7728 398
[basis: pinch point=20 F,approach point=15 F,inlet gas=900 F,feed water=230 F]
The following points may be noted:
1.As steam pressure and steam temperature increase,the exit gas temperature increases. That is,we cannot get 300 F exit gas when generating 600
psig,750 F steam! Hence the purpose of Hrsg simulation is to arrive at the proper gas/steam profiles and steam generation. I have seen several
specifciations written by consultants,where a 300 F economizer exit gas temperature is specified in a high pressure system. If one computes steam
generation based on 300 F exit gas,he will be in a rude shock as 300 F cannot be thermodynamically achieved at high pressures!
2.Why can't we get 300 F exit gas at 600 psig,750 F steam conditions?
K=0.7728 Let us try to compute tg3 from tha above equation for K.
0.7728=(900-tg3)/(900-300) or tg3=436 F,which is below the saturation temperature of 492 F.This is called Temperature Cross!!
3.What should be done to achieve 300 F in the above case?
Increase tg1 by supplementary firing. say tg1=1600 F. Then (1600-tg3)/(1600-300)=0.7728 or tg3=595 F. pinch point=(595-492)=103 F. Note that as
inlet gas temperature increases the pinch point increases and the exit gas temperature decreases.This aspect was discussed in the article on
Generating steam efficiently in cogeneration plants .
4.Let us say that at 1600 F gas inlet someone selected 20 F pinch.What happens?
tg3=492+20=512 F
(1600-512)/(1600-tg4)=0.7728 or tg4=192 F,which is below the feed water temperature of 230 F and hence not feasible if the approach point were 20
F. So let us calculate what should be the approach point.
At 600 psig,750 F,hs2=1379 btu/lb. hw1=200 btu/lb. K=(1600-512)/(1600-1300)=0.836 or hw2=393 btu/lb. This corresponds to a water temperature
of 416 F or an approach point of 76 F. This is the reason we select pinch and approach in unfired modes as we have no clue as to the exit gas
temperature or pinch point or approach point in fired conditions!
Now in order to estimate the correct gas/steam temperature profile we first obtain the steam flow from equation(1)above.All other variables are
known except steam flow. Then using (2),the exit gas temperature is found.This is the "DESIGN" profile.The HRSG simulation program may be
used to determine the steam generation,temperature profiles in unfired "Design" as well as in unfired,fired "Off-Design" conditions for complex
Hrsgs.
Boilers,HRSGS,Steam Plant Calculations
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