Heat Recovery Steam Generator | DaeKyung Energy Eng.

HAD-HRSG ] Heat Recovery Steam Generator

This program is called HAD-HRSG, which is a program to design a heat recovery steam generator for high-temperature exhaust gas or waste gas at the exhaust of gas-turbine. The program can calculate the following contents.

Flue gas conditions : Weight or volume type
Evaporator : 3-pressure type, Bare tube/Solid finned tube/Serrated finned tube
Superheater : 1st, 2nd and 3rd superheaters with Reheater, Bare tube/Solid finned tube/Serrated finned tube
Economizer : 3 modules economizer, Bare tube/Solid finned tube/Serrated finned tube
Deaerator : Integral / External type
Detail information of Thermal calculation
Detail information of heat transfer
Detail pressure drop of gas side/water side
Detail information of Max. temperature of tube/fin metal tubes
Geometry information
Noise analysis
ASME tube thickness (ASME section I)
Acid dew point
Heat losses of surface for HRSG
Fresh air+/Argumenting Air+/Only Duct Burner Firing Conditions.
Heat flux of per bank tubes for superheater/evaporator/economizer.
Natural water circulation (separate one)
Vibration analysis
WHB with Air-Regeneration System in the PDH Unit R/S
WHB with Non-Leakage Gas-Gas(or Air) Heater
Performance Correction Curves and Data
Calculation the Temperature/Heat/Re/Ri/Bo of Each Tube Row.

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* Supplemental Firing Calculation of Heat Recovery Steam Generators. Ver.2.0 *
* Date of Running 2019/ 3/19/13/32/22 *
*******************************************************************************

= Duct Burner Conditions(Flue gas temp based) =

- Flue Gas Compositions
Before After
(Vol% / Wt%) (Vol% / Wt%)
N2 73.36 72.75 73.28 72.64
O2 13.43 15.21 12.94 14.65
CO2 3.30 5.14 3.58 5.58
H2O 9.04 5.76 9.40 5.99
Ar 0.80 1.13 0.80 1.13
SO2 0.00 0.00 0.00 0.00
CO 0.00 0.00 0.00 0.00

- Fuel Compostion (Vol%,Wt%)
CH4 0.0000 0.0000
C2H6 0.3700 0.2129
C3H8 42.0600 35.4949
N-C4H10 56.6300 62.9925
I-C4H10 0.0000 0.0000
N-C5H12 0.9400 1.2979
I-C5H12 0.0000 0.0000
C6H14 0.0000 0.0000
CO 0.0000 0.0000
H2 0.0000 0.0000
N2 0.0000 0.0000
CO2 0.0000 0.0000
C 0.0000 0.0000
S 0.0000 0.0000
C2H4 0.0000 0.0000
C3H6 0.0000 0.0000
N-C4H8 0.0000 0.0000
C6H6 0.0000 0.0000
H2O 0.0050 0.0017
O2 0.0000 0.0000
H2S 0.0000 0.0000

- Exhuast Gas of Duct Burner Inlet -
Flow Rate kg/hr 488600.03
Nm3/hr 387652.34
Density kg/Nm3 1.2604
Temperature degC 555.60

- Fuel Gas of Duct Burner Inlet -
Flow Rate kg/hr 728.98
Nm3/hr 312.72
Density kg/Nm3 2.3311
Low Heating Value kcal/Nm3 25602.64
kcal/kg 10983.00

- Exhuast Gas of Duct Burner Outlet -
Flow Rate kg/hr 489329.06
Nm3/hr 388097.34
Density kg/Nm3 1.2608
Temperature degC 611.50

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* Thermal Design Calculation of Heat Recovery Steam Generators. HAD *
* Heat Aid Design(had1999@naver.com) *
* Date of Running 2019/ 3/19/13/32/30 *
*******************************************************************************

Customer : J**_G*
Service : Case01_Unfired

Module No = 1 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 2 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 3 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 4 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 5 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 6 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 7 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 8 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

Module No = 9 Gas Analysis (Wei Frac.)/(Vol Frac.)
CO2 SO2 N2 H2O O2 Ar
0.05583 0.00000 0.72642 0.05992 0.14654 0.01130
0.03585 0.00000 0.73276 0.09399 0.12941 0.00799

GAS FLOW 489329. kg/hr 388097. Nm3/hr 1.2608 kg/Nm3 135.92 kg/sec

MODULE NUMBER 1 2 3 4 5 6 7 8 9
GAS SIDE Duct_Burner HP_SH2 HP_SH1 HP_Evap HP_Ec2 LP_Sh HP_Eco1 Int_Deaer CPH
GAS FLOW kg/hr 489329. 489329. 489329. 489329. 489329. 489329. 489329. 489329. 489329.
INLET PRESSURE mmAq 0.0 121.6 118.2 110.3 74.7 60.2 56.6 41.2 29.4
PRESSURE DROP mmAq 0.0 3.4 7.9 35.5 14.5 3.6 15.4 11.8 29.4
INLET TEMPERATURE deg C 611.5 611.5 584.3 496.7 299.0 277.6 273.7 222.8 184.8
OUTLET TEMPERATURE deg C 611.5 584.3 496.7 299.0 277.6 273.7 222.8 184.8 86.1
TEMPERATURE DIFF. deg C 0.0 27.2 87.7 197.6 21.4 4.0 50.9 38.0 98.6
SPECIFIC HEAT kcal/kg-C 0.0000 0.2829 0.2796 0.2713 0.2651 0.2637 0.2629 0.2605 0.2570
HEAT REJECTED KW 0.00 4369.55 13939.26 30491.34 3230.32 595.88 7603.66 5636.25 14413.61
SETTING LOSS % 0.0000 0.7500 0.7500 0.7500 0.7500 0.7500 0.7500 0.7500 0.7500
FOULING FACTOR m2-hr-c/kcal 0.00000 0.00020 0.00020 0.00020 0.00020 0.00020 0.00020 0.00020 0.00020

MODULE NUMBER 1 2 3 4 5 6 7 8 9
TUBE SIDE Duct_Burner HP_SH2 HP_SH1 HP_Evap HP_Ec2 LP_Sh HP_Eco1 Int_Deaer CPH
FLUID FLOW kg/hr 0. 79096. 74407. 74407. 74407. 9285. 74407. 9985. 94476.
INLET PRESSURE(abs) bar 9.81 77.68 80.40 80.40 80.66 9.70 80.93 9.70 11.77
OUTLET PRESSURE(abs) bar 9.81 75.67 77.68 80.40 80.40 9.48 80.66 9.70 10.85
TUBE PRESSURE DROP bar 0.00 1.52 2.72 0.00 0.25 0.21 0.27 0.00 0.92
ADDITIONAL PRESSURE DROP bar 0.00 0.49 0.00 0.00 0.00 0.00 0.00 0.00 0.00
INLET TEMPERATURE deg C 0.0 447.6 295.3 290.8 260.9 178.6 181.6 178.6 48.9
OUTLET TEMPERATURE deg C 0.0 527.1 511.4 295.3 290.8 277.2 260.9 178.6 177.3
TEMPERATURE DIFF. deg C 0.0 79.5 216.1 4.5 29.9 98.6 79.4 0.0 128.4
HEAT ABSORBED KW 0.00 4336.78 13834.72 30262.65 3206.10 591.42 7546.63 5593.98 14305.50
FOULING FACTOR m2-hr-c/kcal 0.00000 0.00010 0.00010 0.00010 0.00010 0.00010 0.00010 0.00010 0.00010
ATEMP FLOW kg/hr 0. 0. 4689. 0. 0. 0. 0. 0. 0.
BLOWDOWN % 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Extraction Flow (Water) kg/hr 0. 0. 0. 0. 0. 0. 0. 0. 0.
Extraction Flow (Steam) kg/hr 0. 0. 0. 0. 0. 0. 0. 0. 0.
Additional Flow (Water) kg/hr 0. 0. 0. 0. 0. 0. 0. 0. 0.
Additional Flow (Steam) kg/hr 0. 0. 0. 0. 0. 0. 0. 0. 0.
Additional Flow Temp deg C 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Pinch Point deg C 611.50 57.24 -14.72 3.73 -13.23 -3.54 -38.11 6.21 -91.15
Aproach Point deg C 0.00 79.50 216.06 4.47 29.94 98.64 79.36 0.00 128.37

Gas Side
Inlet Velocity m/sec 0.0 10.2 10.3 10.0 7.4 6.6 7.1 6.4 5.9
Outlet Velocity m/sec 0.0 9.9 9.3 7.4 7.1 6.6 6.4 5.9 4.7
Max Fin Temp deg C 0.0 562.8 545.3 401.8 295.1 277.6 267.4 199.3 180.8
Max Tube Temp deg C 0.0 539.8 525.8 322.8 292.3 277.6 263.2 184.5 178.6
Min tube Temp deg C 0.0 468.2 335.2 295.8 263.8 229.7 188.8 179.4 55.4
Water Side
Inlet Velocity m/sec 0.0 19.9 12.2 2.2 0.8 14.8 0.7 3.1 0.8
Outlet Velocity m/sec 0.0 23.3 22.8 2.2 0.8 19.3 0.8 3.1 0.8
Steam/Water Density kg/m3 0.0000 23.4833 28.5235 350.5700 760.9394 4.3276 843.8746 128.9057 948.7942

Velocity Requirements : Superheaters

MODULE NUMBER 1 2 3 4 5 6 7 8 9
TUBE SIDE Duct_Burner HP_SH2 HP_SH1 HP_Evap HP_Ec2 LP_Sh HP_Eco1 Int_Deaer CPH
Max Velcity (Sup.) kg/hr-m2 0.0 3906.0 3906.0 2768.7 2215.0 1464.7 2215.0 1433.1 2712.0
Mass Velcity kg/hr-m2 0.0 1829.8 1871.4 2768.7 2215.0 266.5 2215.0 1433.1 2712.0
Min Velcity (Sup.) kg/hr-m2 0.0 1953.0 1953.0 2768.7 2215.0 732.4 2215.0 1433.1 2712.0

Tube & Pipe Pressure drop(kg/cm2-a)

MODULE NUMBER 1 2 3 4 5 6 7 8 9
TUBE SIDE Duct_Burner HP_SH2 HP_SH1 HP_Evap HP_Ec2 LP_Sh HP_Eco1 Int_Deaer CPH
INLET PRESSURE(abs) kg/cm2 10.00 79.21 81.99 81.99 82.25 9.89 82.52 9.89 12.00
OUTLET PRESSURE(abs) kg/cm2 10.00 77.16 79.21 81.99 81.99 9.67 82.25 9.89 11.06
TUBE PRESSURE DROP kg/cm2 0.00 1.55 2.78 0.00 0.26 0.22 0.27 0.00 0.94
ADDITIONAL PRESSURE DROP kg/cm2 0.00 0.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Intergral(or External) Deaerator
DA Heating Steam kg/hr 700.
LP Saturated Steam kg/hr 9285.
FW Saturated Water kg/hr 74407.

Intergral(or External) Deaerator(outlet condition)
LP Saturated Steam kg/hr 9285.
Econ or Evap Feed Water kg/hr 74407.
Desuperheater Water kg/hr 4689.
Extraction Water kg/hr 0.
Extraction Steam kg/hr 0.

DA Inlet Condition
DA Inlet Temp deg C 174.9
DA Inlet Flow kg/hr 88381.

== HEAT BALANCE OF CPH CONDITION (DEW POINT) ==

Name Flow(kg/hr) Temp(deg-C) Pres(bar-a) h(kcal/kg)
Inlet of HRSG 1 88381.0 37.4 19.61 37.83
Only CPH-Inlet 2 94475.6 48.9 19.61 49.29
CPH Outlet Recir 3 7651.4 177.3 11.77 179.41
CPH By-Pass 4 1556.9 37.4 19.61 37.83
Process(=7-3) 5 0.0 0.0 0.00 0.00
Inlet of Deaerator 6 88381.0 174.9 10.85 176.92
Return to CPH outlet 7 7651.4 177.3 11.77 179.41
Inlet of Deaerator 8 88381.0 174.9 10.85 176.92
Cond to Reciculation 9 86824.2 37.4 19.61 37.83
CPH-Outlet(=2-7) 10 86824.2 177.3 11.77 179.41
Make-Up of deaerator 11 0.0 0.0 0.00 0.00

Desuperheater Condition (Feed Water)
HP Dsuperheater bar_a deg C 181.55 80.9
RH Dsuperheater bar_a deg C 0.00 0.0
IP Dsuperheater bar_a deg C 0.00 0.0
LP Dsuperheater bar_a deg C 0.00 0.0