Heat Recovery Steam Generator

Heat Recovery Steam Generators: Saving Energy The Smart Way

A heat recovery steam generator is an essential part of power plants that use combined-cycle. Their purpose is to convert waste heat into steam that will be used to power turbines and engines. Setting up a heat recovery steam generator requires extensive expertise and, because the process is very complex and rigorous, there is little room for mistakes and errors. Aspects such as labor requirements, selection of proper equipment, efficiency of work and materials staging are key elements in an effective heat recovery steam generator installation.

The heat recovery steam generator is mainly used for its cost-effectiveness, also changing the entire scheme in terms of efficiency, fuel and capital costs, emission rates, etc. Because the cycle plants’ efficiency is in direct connection with turbine performance, the installation of a heat recovery steam generator seems mandatory; however, this type of installation requires a few steps to be carried out before allowing optimization:

•  Determining the plant objectives and requirements in terms of fuel consumption, emission limits and transmission limitations.

•  Pointing out additional plant requirements in order to have the generation goals met.

•  Developing the design and costs for the initial design.

•  Selecting the best option based on all the above criteria, plus costs and other factors. 

A heat recovery steam generator has natural circulation intended to increase reliability and low power consumption. Moreover, the single drum construction helps reduce thermal stress when the machine is powered or shutdown. Ensuring the purity of the steam and optimal circulation are also important features of the special drum internals. Low thermal loads can be achieved by creating a gas-tight and insulated interior environment which enhances performance and prolongs the life of the machine.

Large quantities of waste energy are released by multiple industrial processes and operations and, if this energy is not collected and reused, then it is released in the atmosphere and eventually lost. Stack exhaust losses are inevitable in all processes powered by fuel and are directly proportional with the temperature and amount of excess air n the exhaust. In many cases, the energy recoverable from waste heat streams can actually displace a significant part if not the entire amount of energy needed for the unit operations in a power plant. This is why recovering the heat means using energy more effectively, while decreasing overall plant consumption and emissions.

There are various methods of recovering the waste heat, but installing a heat recovery steam generator has been proven to be the most effective one. Common methods include direct heat recovery, regenerators, heat boilers and others, but the truth of the matter is not all of these equipments are cost-effective and usually such investments are not justified by the costs required. Equipment defects or thermo dynamical limitations are the main obstacles that prevent the optimal utilization of these heat recovery systems.

In opposition, the heat recovery steam generator is a more affordable and efficient method of recovering waste energy, while optimizing the performance of existing applications and processes and applying to a large number of systems.

Depending on your heating and energy needs, you can consider a steam boiler with applications in all major heating systems, cement production, agriculture or soil steaming, or a heat recovery steam generator with extensive applications in various energy projects, desalination plants, district cooling or heating and many others.

Innovative and affordable methods of producing and recovering energy are possible and quit affordable these days. Their cost-effectiveness and enhanced performance make them an ideal solution for many industries and energy projects.