Professional Documents
Culture Documents
SECTION 5
FEEDWATER HEATING
METHODS
Calculation Procedure:
1. Find the flow rate to the feedwater heater
(a) Construct the flow diagram, Fig. 1. Enter the pressure, temperature, and enthalpy
values using the data given and the steam tables. Write an equation for flow across
the feedwater heater, or (H2 ⫺ H7) ⫽ water (H6 ⫺ H5). Substituting using the
enthalpy data from the flow diagram, flow to heater ⫽ (1 ⫻ 106)(409 ⫺ 324.4) /
(1379.3 ⫺ 449.4) ⫽ 90.977.5 lb / h (41,303.8 kg / h).
5.1
Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com)
Copyright © 2006 The McGraw-Hill Companies. All rights reserved.
Any use is subject to the Terms of Use as given at the website.
FEEDWATER HEATING METHODS
450 psia
1,000,000 lb per hr 1000°F
1,800 psia 1050°F Reheater
H3 = 1,521
H1 = 1,511.3
Intermediate-
pressure
500 psia cylinder
908,900 lb per hr
740°F
High-pressure H2 =
cylinder 1,379.3
91,100 lb per hr
Heater 908,900 lb per hr
1,000,000 lb per hr 1,000,000 lb per hr 200 psia 500°F
2,000 psia 430°F 2,000 psia 350°F H4 = 1,269
H6 = 409 H5 = 324.4
H7 = 449.4
1,000,000 lb/hr (454,000 kg/hr) 1800 psia (12,402 kPa) 1050°F (565°C)
500 psia (3445 kPa) 740°F (393°C) 1379.3 Btu/lb (3214 kJ/kg) 1511.3 Btu/lb (3521 k?
2000 psia (13,780 kPa) 430°F (221°C) 409 (953 kJ/kg) 350°F (177°C) 324.4 (756 kJ/kg)
450 psia (3101 kPa) 1000°F (538°C) 1521 Btu/lb (3544 kJ/kg) 500°F (260°C)
200 psia (1378 kPa) 1269 Btu/lb (2933 kJ/kg) 324.5 Btu/lb (756 kJ/kg)
908,900 lb/hr (412,641 kg/hr) 91,100 lb/hr (41,359 kg/hr) 324.4 Btu/lb (756 kJ/kg)
449.4 Btu/lb (1047 kJ/kg)
FIGURE 1 Feedwater heating flow diagram.
(37.8⬚C). Exhaust steam at 10.3 lb / in2 (gage) (71.0 kPa) saturated flows to the
heater at the rate of 25,000 lb / h (31.5 kg / s). What saving is obtained by using this
heater if the boiler pressure is 250 lb / in2 (abs) (1723.8 kPa)?
Calculation Procedure:
1. Compute the water outlet temperature
Assume the heater is 90 percent efficient. Then to ⫽ tiww ⫹ 0.9wshg / (ww ⫹ 0.9ws),
where to ⫽ outlet water temperature, ⬚F; ti ⫽ inlet water temperature, ⬚F; ww ⫽
weight of water flowing through heater, lb / h; 0.9 ⫽ heater efficiency, expressed as
a decimal; ws ⫽ weight of steam flowing to the heater, lb / h; hg ⫽ enthalpy of the
steam flowing to the heater, Btu / lb.
For saturated steam at 10.3 lb / in2 (gage) (71.0 kPa), or 10.3 ⫹ 14.7 ⫽ 25 lb /
in2 (abs) (172.4 kPa), hg ⫽ 1160.6 Btu / lb (2599.6 kJ / kg), from the saturation
pressure steam tables. Then
100(250,000) ⫹ 0.9(25,000)(1160.6)
to ⫽ ⫽ 187.5⬚F (86.4⬚C)
250,000 ⫹ 0.9(25,000)
Analyze and select a closed feedwater heater for the third stage of a regenerative
steam-turbine cycle in which the feedwater flow rate is 37,640 lb / h (4.7 kg / s), the
desired temperature rise of the water during flow through the heater is 80⬚F (44.4⬚C)
(from 238 to 318⬚F or, 114.4 to 158.9⬚C), bleed heating steam is at 100 lb / in2 (abs)
(689.5 kPa) and 460⬚F (237.8⬚C), drains leave the heater at the saturation temper-
ature corresponding to the heating steam pressure [110 lb / in2 (abs) or 689.5 kPa],
and 5⁄8-in (1.6-cm) OD admiralty metal tubes with a maximum length of 6 ft (1.8
m) are used. Use the Standards of the Bleeder Heater Manufacturers Association,
Inc., when analyzing the heater.
Calculation Procedure:
1. Determine the LMTD across heater
When heat-transfer rates in feedwater heaters are computed, the average film tem-
perature of the feedwater is used. In computing this the Standards of the Bleeder
Heater Manufacturers Association specify that the saturation temperature of the
heating steam be used. At 100 lb / in2 (abs) (689.5 kPa), ts ⫽ 327.81⬚F (164.3⬚C).
Then
(ts ⫺ ti ) ⫺ (ts ⫺ to)
LMTD ⫽ tm ⫽
ln [ts ⫺ ti / (ts ⫺ to)]
where the symbols are as defined in the previous calculation procedure. Thus,
(327.81 ⫺ 238) ⫺ (327.81 ⫺ 318)
tm ⫽
ln [327.81 ⫺ 238/(327.81 ⫺ 318)]
⫽ 36.5⬚F (20.3⬚C)
The average film temperature tf for any closed heater is then
tf ⫽ ts ⫺ 0.8tm
7. Compute the actual number of passes and the actual tube length
Since the tubes in this heater cannot exceed 6 ft (1.8 m) in length, the number of
passes required ⫽ (length for one pass, ft) / (maximum allowable tube length, ft) ⫽
40.6 / 6 ⫽ 6.77 passes. Since a fractional number of passes cannot be used and an
even number of passes permit a more convenient layout of the heater, choose eight
passes.
From the same equation for tube length as in step 6, l ⫽ tube length ⫽ 92.7 /
[(14)(8)(0.1636)] ⫽ 5.06 ft (1.5 m).
⌬ p ⫽ (0.136)(0.761) 冋5.06(8)(14)
(8)(14)
⫹ 5.5(0.527) 册 8
0.5271.24
⫽ 14.6 lb/in2 (100.7 kPa)
A steam power plant operates at a boiler-drum pressure of 460 lb / in2 (abs) (3171.7
kPa), a turbine throttle pressure of 415 lb / in2 (abs) (2861.4 kPa) and 725⬚F
(385.0⬚C), and a turbine capacity of 10,000 kW (or 13,410 hp). The Rankine-cycle
efficiency ratio (including generator losses) is: full load, 75.3 percent; three-quarters
load, 74.75 percent; half load, 71.75 percent. The turbine exhaust pressure is 1
inHg absolute (3.4 kPa); steam flow to the steam-jet air ejector is 1000 lb / h (0.13
kg / s). Analyze this cycle to determine the possible gains from two stages of ex-
traction for feedwater heating, with the first stage a closed heater and the second
stage a direct-contact or mixing heater. Use engineering-office methods in analyzing
the cycle.
Calculation Procedure:
1. Sketch the power-plant cycle
Figure 4a shows the plant with one closed heater and one direct-contact heater.
Values marked on Fig. 4a will be computed as part of this calculation procedure.
Enter each value on the diagram as soon as it is computed.
FIGURE 4 (a) Two stages of feedwater heating in a steam plant; (b) Mollier chart
of the cycle in (a).
(1140.2 kJ / kg). The work at full load on the turbine is: (Rankine-cycle effi-
ciency)(adiabatic available energy) ⫽ (0.753)(490.2) ⫽ 369.1 Btu / lb (858.5 kJ /
kg). Enthalpy at the exhaust of the actual turbine ⫽ throttle enthalpy minus full-
load actual work, or 1375.5 ⫺ 369.1 ⫽ 1006.4 Btu / lb (2340.9 kJ / kg). Use the
Mollier chart to find, at 1.0 inHg absolute (3.4 kPa) and 1006.4 Btu / lb (2340.9
kJ / kg), that the exhaust steam contains 9.5 percent moisture.
Now the turbine steam rate SR ⫽ 3413(actual work output, Btu). Or, SR ⫽
3413 / 369.1 ⫽ 9.25 lb / kWh (4.2 kg / kWh). With the steam rate known, the nonex-
The value of 5900 lb / h (0.74 kg / s) of condensate from the first-stage heater is the
second assumption made. Since it will be checked later, an error in the assumption
can be detected.
Assume a 2 percent heat radiation loss between the turbine and heater. This is
a typical loss. Then
Compare the required extraction, 5950 lb / h (0.75 kg / s), with the assumed ex-
traction, 5900 lb / h (0.74 kg / s). The difference is only 50 lb / h (0.006 kg / s), which
is less than 1 percent. Therefore, the assumed flow rate is satisfactory, because
estimates within 1 percent are considered sufficiently accurate for all routine anal-
yses.
For the second-stage direct-contact heater, condensate flow, lb / h is as follows:
The required extraction, calculated in the same way as for the first-stage heater,
is (90,900)(61.7 / 932.2) ⫽ 6050 lb / h (0.8 kg / s).
The computed extraction flow for the second-stage heater is not compared with
an assumed value because an assumption was not necessary.
Check the assumed condenser flow using nonextraction throttle flow ⫹ addi-
tional throttle flow ⫺ heater extraction ⫽ condenser flow. Set up a tabulation of
the flows as follows:
Compare this actual flow, 83,840 lb / h (10.6 kg / s), with the assumed flow,
84,000 lb / h (10.6 kg / s). The difference, 160 lb / h (0.02 kg / s), is less than 1 percent.
Since an accuracy within 1 percent is sufficient for all normal power-plant calcu-
lations, it is not necessary to recompute the cycle. Had the difference been greater
than 1 percent, a new condenser flow would be assumed and the cycle recomputed.
Follow this procedure until a difference of less than 1 percent is obtained.
7. Determine the economy of the extraction cycle
For a nonextraction cycle operating in the same pressure range,
Give the typical temperatures and flow rates encountered in such installations using
gas and / or oil fuels.
Calculation Procedure:
1. Determine the output ranges possible with today’s diesel engines
Medium-speed Diesel engines are available in sizes exceeding 16 MW. While this
capacity may seem small when compared to gas turbines, it is appropriate for
repowering of steam plants up to 600 MW via boiler feedwater heating.
Modern Diesel engines can attain simple cycle efficiencies of over 47 percent
burning natural gas or heavy fuel oil (HFO). The ability to burn natural gas in
Diesels is a key factor when coupled with coal-fired boilers. Since the Clean Air
Act Amendments of 1990 (CAA) require these boilers to reduce both NOx and SO2
emissions on a lb / million Btu-fired basis (kg / MJ), a boiler feedwater heating sys-
tem that can help make these reductions while simultaneously improving overall
plant efficiency is attractive. Diesel engines offer these reductions when used in
repowering and feedwater heating.
Today Diesel engines convert about 45 percent of mechanical energy to elec-
tricity; 30 percent becomes exhaust-gas heat; 12 percent is lost to jacket-water heat;
and 6 percent is used to cool the lube oil. The remaining energy lost is generally
not recoverable.
2. Show how the diesel engine can be used in the feedwater heating cycle
Modern steam-turbine reheat cycles, Fig. 7, use an array of feedwater heaters in a
regenerative feedwater heating system. The heaters progressively increase the con-
densate temperature until it approaches the steam saturation temperature. Conden-
sate then enters the final economizer and evaporator sections of the boiler.
Using the waste heat from Diesel engines to partially replace the feedwater
heaters is almost completely non-intrusive to the operation of the existing system,
FIGURE 7 In repowering, Diesel exhaust is adjusted in temperature to the same levels expected
from feedwater heaters in the existing plant. (Power.)
but causes several significant alterations in the cycle. Two particular cycle altera-
tions are: (1) Jacket water temperature from a Diesel engine is available at about
195⬚F (91⬚C). The lube-oil cooling system produces water at about 170⬚F (77⬚C).
These temperatures are appropriate for partial displacement of the boiler’s low-
temperature feedwater heaters.
(2) A gas / Diesel engine can operate on about 97 percent natural gas / 3 percent
HFO and has an exhaust temperature of 680⬚F (360⬚C). The exhaust gas can be
ducted through an economizer that is equipped with selective catalytic reduction
(SCR) and has heat-transfer sections that can adjust the exit temperature to match
the preheated-burner-windbox air temperature. The SCR reduces NOx emissions
from the engine to about 25 ppm on leaving the economizer. This exhaust econo-
mizer, Fig. 7, also elevates the temperature of the feedwater after it leaves the
deaerator.
be averaged with the heat rate of the associated plant. Total system heat rate may
be improved by as much as 10 percent as a result of repowering in this fashion.