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Heat Recovery Steam Generator

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A heat recovery steam generator or HRSG is a heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process or used to drive a steam turbine. A common application for an HRSG is in a combined-cycle power station, where hot exhaust from a gas turbine is fed to an HRSG to generate steam which in turn drives a steam turbine. This combination produces electricity more efficiently than either the gas turbine or steam turbine alone. The HRSG is also an important component in cogeneration plants. Cogeneration plants typically have a higher overall efficiency in comparison to a combined cycle plant. This is due to the loss of energy associated with the steam turbine

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Modular HRSG

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Modular HRSG GA

HRSGs consist of three major components. They are the Evaporator, Superheater, and Economizer. The different components are put together to meet the operating requirements of the unit. See Modular HRSG GA.

Modular HRSGs normally consist of three sections: an LP (low pressure) section, a reheat/IP (intermediate pressure) section, and an HP (high pressure) section. Each section has a steam drum and an evaporator section where water is converted to steam. This steam then passes through superheaters to raise the temperature and pressure past the saturation point.

Packaged HRSGs are designed to be shipped as a fully assembled unit from the factory. They can be used in waste heat or turbine (usually under 20MW) applications. The packagaged HRSG can have a water cooled furnace which allows for higher supplemental firing and better overall efficieny.

Some HRSGs include supplemental, or duct, firing. These additional burners provide additional energy to the HRSG, which produces more steam and hence increases the output of the steam turbine. Generally, duct firing provides electrical output at lower capital cost. It is therefore often utilised for peaking.

HRSGs can also have diverter valves to regulate in the inlet flow into the HRSG. This allows the gas turbine to continue to operate when there is no steam demand or if the HRSG needs to be taken offline.

Emissions controls may also be located in the HRSG. Some may contain a Selective Catalytic Reduction system to reduce nitrogen oxides (a large contributor to the formation of smog and acid rain) and/or a catalyst to remove carbon monoxide. The inclusion of an SCR dramatically effects the layout of the HRSG. NOx catalyst performs best in temperatures between 650°F and 750°F. This usually means that the evaporator section of the HRSG will have to be split and the SCR placed in between the two sections. Some low temperature NOx catalysts have recently come to market that allows for the SCR to be placed between the Evaporator and Economizer sections (350°F-500°F).

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Packaged HRSG

Applications

Heat recovery can be used extensively in energy projects.
In the energy-rich Persian Gulf region, the steam from the HRSG is used for desalination plants.
Universities are ideal candidates for HRSG applications. They can use a gas turbine to produce high reliability electricity for campus use. The HRSG can recover the heat from the gas turbine to produce steam/hot water for district heating or cooling.

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Block diagram of IGCC power plant, which utilizes the HRSG