US20160102926A1 - Vertical multiple passage drainable heated surfaces with headers-equalizers and forced circulation - Google Patents

Vertical multiple passage drainable heated surfaces with headers-equalizers and forced circulation Download PDF

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Publication number
US20160102926A1
US20160102926A1 US14/878,186 US201514878186A US2016102926A1 US 20160102926 A1 US20160102926 A1 US 20160102926A1 US 201514878186 A US201514878186 A US 201514878186A US 2016102926 A1 US2016102926 A1 US 2016102926A1
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Prior art keywords
drain
header
heated surfaces
headers
tubes
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Abandoned
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US14/878,186
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English (en)
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Vladimir S. Polonsky
Stanislav V. Polonsky
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D21/0001Recuperative heat exchangers
    • F28D21/0003Recuperative heat exchangers the heat being recuperated from exhaust gases
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01KSTEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K7/00Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating
    • F01K7/16Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating the engines being only of turbine type
    • F01K7/30Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating the engines being only of turbine type the turbines using exhaust steam only
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01KSTEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K7/00Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating
    • F01K7/32Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating the engines using steam of critical or overcritical pressure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22STEAM GENERATION
    • F22BMETHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B1/00Methods of steam generation characterised by form of heating method
    • F22B1/02Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
    • F22B1/18Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
    • F22B1/1807Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines using the exhaust gases of combustion engines
    • F22B1/1815Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines using the exhaust gases of combustion engines using the exhaust gases of gas-turbines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22STEAM GENERATION
    • F22BMETHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B29/00Steam boilers of forced-flow type
    • F22B29/06Steam boilers of forced-flow type of once-through type, i.e. built-up from tubes receiving water at one end and delivering superheated steam at the other end of the tubes
    • F22B29/067Steam boilers of forced-flow type of once-through type, i.e. built-up from tubes receiving water at one end and delivering superheated steam at the other end of the tubes operating at critical or supercritical pressure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22STEAM GENERATION
    • F22BMETHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B37/00Component parts or details of steam boilers
    • F22B37/02Component parts or details of steam boilers applicable to more than one kind or type of steam boiler
    • F22B37/10Water tubes; Accessories therefor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22STEAM GENERATION
    • F22DPREHEATING, OR ACCUMULATING PREHEATED, FEED-WATER FOR STEAM GENERATION; FEED-WATER SUPPLY FOR STEAM GENERATION; CONTROLLING WATER LEVEL FOR STEAM GENERATION; AUXILIARY DEVICES FOR PROMOTING WATER CIRCULATION WITHIN STEAM BOILERS
    • F22D1/00Feed-water heaters, i.e. economisers or like preheaters
    • F22D1/32Feed-water heaters, i.e. economisers or like preheaters arranged to be heated by steam, e.g. bled from turbines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D7/00Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D7/08Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being otherwise bent, e.g. in a serpentine or zig-zag
    • F28D7/082Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being otherwise bent, e.g. in a serpentine or zig-zag with serpentine or zig-zag configuration
    • F28D7/085Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being otherwise bent, e.g. in a serpentine or zig-zag with serpentine or zig-zag configuration in the form of parallel conduits coupled by bent portions
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28FDETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/22Arrangements for directing heat-exchange media into successive compartments, e.g. arrangements of guide plates
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01KSTEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K7/00Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating
    • F01K7/16Steam engine plants characterised by the use of specific types of engine; Plants or engines characterised by their use of special steam systems, cycles or processes; Control means specially adapted for such systems, cycles or processes; Use of withdrawn or exhaust steam for feed-water heating the engines being only of turbine type
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F22STEAM GENERATION
    • F22BMETHODS OF STEAM GENERATION; STEAM BOILERS
    • F22B1/00Methods of steam generation characterised by form of heating method
    • F22B1/02Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers
    • F22B1/18Methods of steam generation characterised by form of heating method by exploitation of the heat content of hot heat carriers the heat carrier being a hot gas, e.g. waste gas such as exhaust gas of internal-combustion engines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28HEAT EXCHANGE IN GENERAL
    • F28DHEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D21/00Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
    • F28D2021/0019Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
    • F28D2021/0061Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for phase-change applications
    • F28D2021/0064Vaporizers, e.g. evaporators
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00Technologies relating to chemical industry
    • Y02P20/10Process efficiency

Definitions

  • the present invention is the heated surfaces (HS) for application in the different technical fields—power industry, metallurgy, chemical industry, etc. Below the invention is considered in the context of power industry.
  • the main problems of once through units and units with forced circulation are corrosion/erosion, temperature regime of heated surfaces, and hydrodynamic instability.
  • the suggested invention can improve the effectiveness and reliability of multiple passage heated surfaces and increase TE of whole units.
  • HS water preheaters
  • EC economizers
  • EV evaporators
  • SH superheaters
  • RH reheaters
  • each circuit goes like a single tube from inlet header to outlet header. It allows increasing mass velocity of steam/water or steam-water mixture for subcritical pressure (or supercritical fluid) and improves stability of flow and temperature regime of tubes.
  • each header serves for drain of the adjacent tube passes.
  • the header can serve as equalizing header of pressure/flow.
  • bypass flows It will help to decrease multivaluedness and maldistribution of flow between parallel tubes of the module. Besides such design of HS noticeably decreases the corrosion when the units are not in operation.
  • FIG. 1 is a scheme of Benson HRSG with once through evaporator
  • FIG. 2 is a scheme of conventional boiler with N-shaped evaporator panel and forced circulation
  • FIGS. 3 a -3 h are multiple passage panels of conventional once through boilers
  • FIG. 4 is a typical vertical serpentine drainable coil with bottom header and forced circulation
  • FIG. 5 is a vertical serpentine coil of HRSG with drainable header-equalizer
  • FIG. 6 shows varying drain stub and drain pipe diameters for a vertical serpentine coil of HRSG with drainable header-equalizer
  • FIG. 7 is a multiple passage panel of convention once through boiler with drainable header equalizer.
  • FIG. 1 shows the Benson HRSG with feed water inlet 104 , star distributor 105 , downcamera 106 , a first evaporator 103 , a second evaporator 102 , separator 107 , and super heater 101 .
  • Benson HRSG has some serious problems with evaporator (EV) design—the very small velocities of flow in cold section and EV instability; a very complex design of hot EV section with not good temperature regime of tubes; two-phase flow distribution by star-distributor on the hot EV section inlet is very complex and not reliable, etc.
  • EV evaporator
  • FIG. 2 shows a scheme of a conventional boiler with N-shaped evaporator panel and forced circulation having a feed water pump 201 , economizer 202 , evaporator 203 , circulation pump 204 , second stage evaporator 205 , super heater 206 , outlet for super heater 207 , separator 208 , and valve 209 .
  • FIGS. 3 a -3 h show multiple passage panels of conventional once through steam generators.
  • FIG. 3 a show a N-shaped panel with vertical tubes.
  • FIG. 3 b shows a modified N-shaped panel.
  • FIG. 3 c shows a standard panel with horizontal tubes.
  • FIG. 3 d shows a modified panel with horizontal tubes.
  • FIG. 3 e shows a vertical multiple passage panel.
  • FIG. 3 f shows a modified vertical multiple passage panel.
  • FIG. 3 g shows vertical panels with even number of passages.
  • FIG. 3 h shows vertical serpentine panels.
  • Each type of panels has the advantages and disadvantages. Many problems were resolved regarding heat transfer and hydrodynamics of flows in such panels.
  • One of the main problems of multiple passage panels with vertical tubes (types—a, b, e, f, g, and h) is corrosion of internal surface of tubes. As it can be seen from FIG. 3 in these panels there are some non-drainable passages. During the shutdown period some water can accumulate in the bottom bends of these passages that result in strong corrosion.
  • the tubes of HRSG heated surfaces are the finned tubes usually. In the case of relatively big heat fluxes some rows of HRSG can be manufactured from the bare tubes.
  • a principal peculiarity of suggested heated surfaces for HRSG conditions is the vertical serpentine coil from some rows of straight tubes with connections between them by top and bottom U-bends 506 ( FIG. 5 ).
  • a direction of water flow in the coil could be counter flow or parallel flow with exhaust gas flow.
  • a tube (finned or bare) layout could be a staggered or an inline.
  • FIG. 5 shows gas baffle keeper 515 connected to gas baffle 516 .
  • An inlet header 502 and outlet header 501 are contained within gas baffle 516 .
  • Inlet header 502 and outlet header 501 are connected by evaporator coil 503 .
  • the evaporator coil has bottom U-bends 506 .
  • the bottom U-bends 506 are connected to drain stubs 507 which are connected to elemental header-equalizer 509 which are connected to drain bypass 508 which are then connected to bellows 513 .
  • drain box 517 The bottom U-bends 506 , drain stubs 507 , elemental header-equalizers 519 , drain bypasses 508 , integral header-equalizers 509 , water cooled wall inlet header 510 , water cooled wall outlet header 511 , and water cooled wall tubes 504 are all contained within drain box 517 .
  • Water cooled wall inlet header 510 and water cooled wall outlet header 511 are connected by water cooled wall tubes 504 .
  • Drain box 517 has water cooled wall 505 (which is adjacent to water cooled wall tubes 504 ) which is connected to a gas baffle keeper 510 sitting on top of liner 518 .
  • Liner 518 sits on top of casing 514 .
  • the drain bypasses 508 pass through the liner 518 and casing 514 into the bellows 513 .
  • the header can serve as equalizing header of pressure/flow.
  • the header can serve as equalizing header of pressure/flow.
  • the header can serve as equalizing header of pressure/flow.
  • bottom portion of coil from the hole in bottom bend to drain pipes
  • water for subcritical EV
  • heavy phase for supercritical EV.
  • centrifugal force which in many times more than force of gravitation.
  • both vectors of centrifugal force and force of gravitation are coincided (both are acting in downward direction). Both forces are proportional to density of medium.
  • drain system is situated in the area of relatively hot exhaust gas.
  • the drain system should have the proper temperature regime. It can be achieved by circulation of small amount of water (or supercritical liquid) through drain system.
  • two adjacent drain lines are connected by drain cross over (drain bypass) pipe ( FIG. 5 ).
  • the diameter of drain cross over pipe is noticeably less than EV tube diameter and should be calculated in such a way to guarantee the proper temperature regime of the drain system.
  • the design of drain assembly could be as it is shown on FIG. 5 . All pipe penetrations are realized with help of bellows.
  • drain headers are depicted for cold conditions (unit is not in operation). In hot conditions (unit in operation) the headers will move down to bottom liner as result of coil expansion with temperature. In the case the temperature regime of drain system will be normal even with relatively small water flow in drain bypass lines.
  • Temperature regime of drain system can be reliable under small water bypass if it is situated out of the main exhaust gas flow (in the area of relatively stagnant gas flow).
  • Such scenario can be realized with help of gas baffle plates ( FIG. 5 ).
  • Upper portion of plates should be fixed on the EV (EC, SH, etc.) tubes above bottom bends. Lower part should be situated in the baffle keeper.
  • EV (EC, SH, etc.) coil is fixed on the top of HRSG (at some designs a coil can be fixed in the bottom). In this case the coil will expand in downward direction.
  • a height of the sealing assembly (baffle keeper) should guarantee the coil expansion in all operational conditions.
  • the upper portion of baffle plates should have such height to minimize exhaust gas flow through the box with drain system.
  • the drain box includes bottom bends, drain stubs, headers-equalizers, drain pipes and confined by gas baffle plate.
  • the box of drain system has to have the gas baffle plates on all four sides. In the case of multi wide HRSG the gas baffle plates are installed between the modules as well to decrease the gas bypass.
  • the temperature regime of drain system can be kept on reliable level with help of water cooled walls.
  • the walls could be fabricated from membrane tubes to minimize gas bypass. Water for the wall is used after EC before going to EV. It is possible as well to take water for the wall between the sections of EC. Thermodynamic efficiency is taken into account in each case. A direction of water flow in the wall could be counter flow, parallel flow, or perpendicular with exhaust gas flow. Designer has to take into account the peculiarities of temperature regimes of the coil and water cooled wall in the contact area of tubes with different wall temperatures. In the case of multi wide HRSG the gas baffle plates should be installed between the water cooled boxes of the different modules. In most cases the water cooled walls will not be necessary.
  • Temperature regime of once-through HRSG EV tubes could be different from HRSG EV tubes with natural circulation.
  • subcritical or supercritical pressures could be a zone with deterioration of heat transfer. It means that under any enthalpy of fluid there is a jump in tube wall temperature. The value of temperature jump depends on parameters of exhaust gas flow, as well of water pressure, mass velocity, and heat flux for given geometry of coil tubes. For any combination of these parameters temperature jump could be strong enough.
  • intensificators can be used (rifled tubes, inserts, etc.).
  • drain stubs FIG. 5
  • the drain system should be a flexible enough to compensate the possible difference in expansions of the coil and drain system.
  • the HRSG can be operated under supercritical and subcritical pressures. Under nominal conditions a unit can be supercritical but under part loads the pressure in system can be subcritical. Besides on the EV outlet a two-phase flow could be, but not superheated steam. To prevent a steam-water mixture going in superheater the special separators should be on the outlet of EV (see FIG. 2 ). At the same time the assembly of the separators and the water tanks can help to manage the proper temperature regime of EV under partial loads of HRSG. A control of water mass velocity and steam quality on the EV outlet can be done by the feed water pump(s) or by the special recirculation pump(s). Exploitation of the feed water pump(s) or the special recirculation pump(s) should be chosen based on technical/economical evaluations of the proper schemes (price of pumps, price of electricity, relative duration of part loads, etc.).
  • FIG. 5 shows an inlet and outlet header that may be connected to one or more vertical evaporator coils.
  • the evaporator coils have bypass drains connected to the bottom of the evaporator coil. The drain bypasses ultimately lead to a bellows on the other side of the casing.
  • the vertical evaporator coil may further have a water cooled inlet header and water cooled outlet header connected by water cooled wall tubes contained within a water cooled wall and connected to the casing by a gas baffle keeper.
  • FIG. 6 shows the bottom U-bend 606 of the vertical evaporator coil.
  • the bottom U-bends 606 can be connected by drain stubs 607 .
  • the drain stubs 607 do not all need to be the same diameter, the drain stubs 607 and bypass lines 608 can vary in diameter across the vertical evaporator coil.
  • the widest diameter drain stub 607 can be either on the inlet header or outlet header side of the vertical evaporator coil.
  • the drain stub 607 and the bypass line 608 are connected at the elemental header-equalizer 609 .
  • thermo-mechanical situation is in the header—equalizer and the drain system of multiple passage panels of conventional boilers ( FIG. 7 ).
  • the tubes 719 of the panel are connected by tube stubs 707 with header-equalizer 709 .
  • the headers—equalizer are situated outside of casing.
  • the drain pipes 708 are also situated outside of combustion chamber (or gas duct). In this sense the temperature regime of drain system will be reliable because of there is no the additional sources of heat.
  • header should be a horizontal orientation to avoid the effect of possible gravitational component in pressure drop (it is specific of vertical and inclined headers). Header should be situated below the lowest row of the panel. It can guarantee that header will be filled in with water (for subcritical pressure) or heavy fluids (for supercritical pressure). This provision is very important for stability of flow.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Combustion & Propulsion (AREA)
  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Heterocyclic Carbon Compounds Containing A Hetero Ring Having Oxygen Or Sulfur (AREA)
  • Basic Packing Technique (AREA)
US14/878,186 2014-10-09 2015-10-08 Vertical multiple passage drainable heated surfaces with headers-equalizers and forced circulation Abandoned US20160102926A1 (en)

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US14/878,186 US20160102926A1 (en) 2014-10-09 2015-10-08 Vertical multiple passage drainable heated surfaces with headers-equalizers and forced circulation

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US201462062055P 2014-10-09 2014-10-09
US14/878,186 US20160102926A1 (en) 2014-10-09 2015-10-08 Vertical multiple passage drainable heated surfaces with headers-equalizers and forced circulation

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US15/518,168 Active 2036-11-06 US10634339B2 (en) 2014-10-09 2015-10-09 Once-through vertical tubed supercritical evaporator coil for an HRSG

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EP (1) EP3204691B1 (ko)
JP (1) JP6712266B2 (ko)
KR (1) KR102438881B1 (ko)
CN (1) CN107002987B (ko)
CA (1) CA2964166C (ko)
ES (1) ES2839130T3 (ko)
MX (1) MX2017004678A (ko)
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US20220042716A1 (en) * 2020-08-04 2022-02-10 Rheem Manufacturing Company Heat exchangers providing low pressure drop
CN114811948A (zh) * 2022-05-11 2022-07-29 山东晋煤明升达化工有限公司 一种用于合成氨系统预热的开工加热炉

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US10669897B2 (en) * 2017-12-06 2020-06-02 General Electric Company Components and systems for reducing thermal stress of heat recovery steam generators in combined cycle power plant systems
US11047266B2 (en) * 2019-10-30 2021-06-29 General Electric Company Heat exchanger with heat exchange tubes moveable between aligned and non-aligned positions
CN111721148A (zh) * 2020-07-13 2020-09-29 李云 一种管式换热器

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CN107002987B (zh) 2020-03-31
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