Applied Thermal Engineering 114 (2017) 993–1001

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Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

Research Paper

Exergy analysis of the dual pressure HRSG for varying physical

parameters
Meeta Sharma a,⇑, Onkar Singh b
a
Mechanical Engineering Department, Amity University, Sector – 125, Noida, U.P., India
b
M. M. M. University of Technology, Gorakhpur, U.P., India

h i g h l i g h t s

Dual pressure HRSG is studied on exergy basis.

Physical parameters & steam conditions are varied for exergy study.

Fin height variation affects exergy loss and exergy efficiency.

Low pressure steam generation variation shows substantial change in exergy loss.

Fin densities and fin thicknesses have slight effect on exergy loss in HRSG.

a r t i c l e i n f o a b s t r a c t

Article history: Heat recovery steam generator (HRSG) is used to capture the heat of gas turbine exhaust gases for gen-
Received 20 June 2016 erating steam to run the steam turbine in gas/steam combined cycle power plant (CCPP). The perfor-
Revised 8 December 2016 mance of HRSG affects the steam turbine output and thus the overall combined cycle performance.
Accepted 10 December 2016
The present study considers operating conditions of a 663 MW, combined cycle power plant at Auraiya
Available online 15 December 2016
(U.P.), India for carrying out the exergy based investigation of a dual pressure HRSG. Different physical
parameters of HRSG such as fin height, fin density and fin thickness are varied for analyzing exergy loss
Keywords:
and exergy efficiency at different steam generation pressures. The exergy analysis shows how the exergy
Combined cycle power plant (CCPP)
Dual pressure (DP)
losses get lowered for LP evaporator and the exergy efficiency improves in LP economizer for higher fin
Exergy efficiency heights and fin densities.
Exergy loss Ó 2016 Elsevier Ltd. All rights reserved.
Heat recovery steam generator (HRSG)

1. Introduction HRSG in terms of its physical parameters and suitable thermody-

namic conditions of operation. Looking upon the role of HRSG in
Presently there is widespread use of gas/steam combined cycle the combined cycle performance it is imperative to improve the
power plants due to their capability to offer enhanced power out- HRSG performance. Therefore, the present study aims at locating
put and better efficiency as compared to the gas turbine power the sources of inefficiency in HRSG through use of second law of
plants or steam turbine power plants operating in isolation. Com- thermodynamics. In the present study, the implications of varia-
bined cycle power plants (CCPPs) have potential of offering tion in the physical parameters namely fin thickness, fin height
enhanced power output through waste heat energy recovery in and fin density and steam generation conditions has been carried
heat recovery steam generator (HRSG) and utilization of steam out for locating sources of inefficiency to arrive at the optimal
generated in the bottoming cycle. Thus, it is evident that the HRSG design of the HRSG.
is the critical important component for augmentation of output Some of the pioneering work done in the field of exergy analysis
and efficiency of the gas/steam based combined cycle plant as and HRSG is briefly discussed ahead. Bejan [1,2] described the basic
the performance of steam turbine cycle depends significantly upon techniques of exergy analysis and also discussed the evaluation
the quantity and quality of steam generated in the HRSG. This methods along with the estimation of irreversibility, entropy
steam generation can be maximized through optimal design of generation or exergy destruction. London and Shah [3] presented
a methodology for connecting economic costs to entropy genera-
⇑ Corresponding author. tion. The method permits an interface with the heat exchanger
E-mail addresses: [email protected] (M. Sharma), onkpar@rediffmail. designer to get insights into the trade-offs allowed between the
com (O. Singh).

http://dx.doi.org/10.1016/j.applthermaleng.2016.12.042
1359-4311/Ó 2016 Elsevier Ltd. All rights reserved.
994 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001

Nomenclature

Ad cross sectional area of the shell (m2) eco economizer

An net free area available for gases (m2) ev evaporator
Cp specific heat of fluid at bulk temperature (kJ/kg K) GT gas turbine
EE exergy efficiency HRSG heat recovery steam generator
EL exergy loss (kW) LP low pressure
h specific enthalpy of the fluid (kJ/kg) HP high pressure
fo friction factor over staggered fin tube arrangement ST steam turbine
Go exhaust gas mass flow rate/area (kg/s/m2) s super heater
Nr number of tube rows w water
p pressure at a point (bar) g gas
DP pressure loss (bar)
R characteristic gas constant (kJ/kg K) Greek symbols
s specific entropy of fluid (kJ/kg K) X exergy flow (kW)
T temperature at a point (K) q density (kg/m3)
/ entropy function
Subscripts and abbreviations w exergy efficiency
b bulk temperature
CCPP combined cycle power plant

thermodynamic irreversibilities. Reddy et al. [4] discussed the sec- analysis and life cycle analysis where there is a trade-off between
ond law analysis of a waste heat recovery boiler. By using suitable energy saving during process and exergy utilized throughout the
non-dimensional operating parameters, an equation for entropy construction of energy system.
generation number is derived and their effects on the entropy gen- The present study has been undertaken to fill up the gap being
eration number are investigated. Reddy and Butcher [5] carried out observed regarding the exergy analysis of the DP HRSG for varying
the study of performance of waste heat recovery power generation physical and thermodynamic parameters viz fin height, fin thick-
system based on second law analysis for various operating condi- ness, fin density and steam generation pressures which shall help
tions and concluded that the first and second law efficiencies of the HRSG designers in reducing sources of inefficiencies. The study
HRSG reduce at higher pinch points. Deng and Chia-Chin [6] dis- considers HRSG having segmented fins in staggered arrangement
cussed the design and exergy analysis of a combustion gas turbine with steam generation at two different pressures and fixed super-
based combined power cycle and described that exergy analysis for heated temperature conditions. The in-process plant data of the
a steam cycle system predicts the plant efficiency more precisely. 663 MW, NTPC (Ltd) CCPP at Auraiya (U.P.), India, has been consid-
Norouzi and Amidpour [7] discussed the optimal thermodynamic ered in this study. It aims at applying exergy analysis to the DP
and economic volume of a heat recovery steam generator by HRSG and knowing the exergy losses, the exergy efficiency at its
entropy generation and cost evaluations. Segmented finned tube sections for varying physical designs and thermodynamic condi-
design details used in the present study have been obtained from tions for quantification of inefficiencies of the DP HRSG. Here after
Escoa finned tube manual [8]. Dincer and Rosen [9] described the mathematical formulation of the considered configuration and
exergy, energy and sustainability development for various systems. HRSG, a computer code has been developed for performing, the
Soo In and Lee [10] explained a single-stage HRSG system and for exergy analysis and the performance at various sections.
the same the optimum evaporation temperature was obtained cor- Figs. 1a and 1b show the schematic diagram of the DP HRSG
responding to maximum useful work for given conditions of water with its essential sections for HP, LP states and corresponding T-
and gas temperature at the inlets of the HRSG system. Rosen [11] Q diagram. HRSG is basically a heat exchanger having crucial sec-
discussed the comparison of the main approaches to second law tions namely super heater, evaporator and economizer in a cross
analysis and its implications for different systems. Moran and Sci- flow arrangement. This study investigates its exergy based perfor-
ubba [12] discussed the principles and practice of the exergy anal- mance for the varying physical parameters for different LP and HP
ysis with emphasis on areas of application. Sharma and Singh [13] steam conditions with thermodynamic parameters of DP HRSG as
presented the effect of varying dead states for dual pressure HRSG detailed in Table 1. The performance of HRSG sections is being
in gas/steam combined cycle power plants. Nag and De [14] assessed by knowing the exergy losses and the exergy efficiency
described the design and optimization of heat recovery steam gen- at different sections of HRSG. The exergy of flow for exhaust gases
erator with minimum irreversibility for generating saturated along the length of HRSG is the function of enthalpy, entropy and
steam in gas/steam combined cycle plant. It shows that an optimal temperature of the surrounding; therefore exergy loss and the
saturation temperature exists for least irreversible operation of an exergy efficiency are examined on the different sections
existing HRSG. Dechamp [15] observed that the dual pressure accordingly.
HRSG offers better heat recovery and the fins on it’s surface supple- The gas property model [13] helps in getting exergy of flow (X)
ment the heat transfer rate but also lead to irreversibilities due to as the function of enthalpy (h), entropy (s) and the gas side pres-
various losses. Carapellucci and Giordano [16] compared two sure drop (DP) along HRSG length.
methodologies for optimizing combined cycle power plants with Z T
first one to minimize the cost of electricity generated and second h¼ Cp ðTÞdT ð1Þ
one to minimize an objective function based on exergo-economic To

principles accounting for the costs related with thermodynamic Z T

inefficiencies. Cornelissen and Hirs [17] illustrated the optimiza- dT
/¼ C p ðTÞ ð2Þ
tion of energy system design through combination of exergy To T
 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001 995

a b c d b1
a1 c1
LP
Drum
LP stream
HP
Drum
HP stream

Exhaust
Exhaust
gases in
gases out

P P

a b c d
HP Pump a1 b1 c1 LP Pump

Section (a-a to b-b) HP super heater

Section (b-b to c-c) HP evaporator
Section (c-c to d-d) HP economizer
Section (d-d to a1-a1) LP super heater
Section (a1-a1 tob1-b1) LP evaporator
Section (b1-b1to c1-c1) LP economizer

Fig. 1a. Schematic diagram of dual pressure HRSG.

Fig. 1b. T-Q diagram for dual pressure HRSG.

 
p The pressure drop at gas side flow surfaces is affected by the
s ¼ /  R ln ð3Þ
po geometry and the flow conditions are evaluated by Eq. (4) above
and taken from Escoa manual [8]. The pressure drop at HP and
The enthalpy, entropy functions and entropy flow (h, / and s)
LP condition are evaluated as per the respective conditions.
are associated with the following relation and can be estimated
for LP and HP conditions of HRSG from Eqs. (1)–(3) respectively. A ¼ ð1 þ B2 Þqb =4Nr ð5Þ
ðf o þ AÞG2o Nr
DP ¼ ð4Þ B ¼ An =Ad ð6Þ
qb  1:083  109
996 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001

Table 1 ðDXi Þw
wiHP ¼ ð10Þ
The combined cycle power plant (NTPC, CCPP, Auraiya, U.P., India) values are taken for ðDXi Þg
the dual pressure HRSG analysis as input conditions.

Input conditions Values taken Exergy loss (for kth section at LP steam pressure condition),
XkLP ¼ ðDXk Þg  ðDXk Þw ð11Þ
Atmospheric Condition 298 K (25 °C) and 1 bar
Cycle Pressure Ratio 14:1 Exergy efficiency (for kth section at LP steam pressure
Turbine Inlet Temperature 1473 K (1200 °C)
Steam Superheat Temperature (High Pressure) 768 K (495 °C)
condition),
ðDXk Þw
Gas Turbine Exhaust Pressure 1.2 bar wkLP ¼ ð12Þ
Condenser Pressure 0.05 bar ðDXk Þg
Polytropic Efficiency of Compressor 90%
Polytropic Efficiency of Gas Turbine 90% The DP HRSG has been examined for the chosen input condi-
Isentropic efficiency of Steam Turbine 90% tions by estimating the exergy loss and the exergy efficiency with
Mass Flow Rate of Exhaust Gases 400 kg/s
varying physical parameters as well as steam pressures.
Temperature at Inlet of HRSG 800 K
Pinch Point Temperature Difference 10
Steam Pressure (HP, Pressure Variation Values) 50, 55, 60, 65, 70 bar 2. Results and discussion
Steam Pressure (LP, Pressure Variation Values) 2, 3, 4, 5, 6 bar
Steam Superheating Temperature (Low Pressure) 437 K (164 °C)
Feed Water Inlet Temperature 315 K (42 °C)
The performance of the DP HRSG has been assessed by varying
physical parameters such as fin heights, fin densities, fin thick-
nesses under LP steam condition in the range of 2–6 bar and HP
steam condition in the range of 50–70 bar through evaluation of
The gas free area (An) and cross sectional area (Ad) are related exergy loss and the exergy efficiency. In order to analyze perfor-
with B and estimated on the basis of some extended surfaces mance of HRSG it’s major components super heater, evaporator
design. The small pressure drop in the inside tubes, with respect and economizer have been analyzed for varying physical parame-
to gas side pressure drop has been ignored as it is insignificant. ters and LP and HP steam conditions. The physical parameters (like
The exergy of flow at salient points in HRSG is given by Eq. (7) fin thickness, fin height and fin density) affect the rate of heat
while neglecting the exergy of flow due to kinetic and potential transfer on its outer surface, pressure and friction losses causes
energy. Since the HRSG in this study is of unfired type therefore various irreversibilities. The thermodynamic parameters such as
exergy of flow due to chemical changes is also not considered. pressure and temperature of steam generation are primarily
The exhaust gas exergy of flow for the HP and LP sections of the responsible for the heat absorption by the water/steam and can
HRSG are evaluated, as XHP and XLP for the given pressure and be associated with internal irreversibilites. In the exergy analysis,
temperature conditions. such associated losses and their performance variations are evalu-
   ated for different sections of HRSG and discussed in detail ahead.
p The results of the dual pressure exergy analysis are based on the
X ¼ h  To s ¼ h  To /  R ln ð7Þ
po physical parameters and thermodynamic conditions as given in
Tables 1 and 2.
Similarly, the exergy of flow for water/steam at the HP and LP
steam generation pressures inside the tubes is estimated through
2.1. LP and HP super heater
properties of the water/steam at given temperature and pressure.
Therefore, at any particular point the exergy balance can be given
The impacts of variations of physical parameters as well as
as follows,
steam generation pressure for LP and HP conditions for super hea-
Exergy in ¼ ðExergy out in products þ Exergy emitted with wasteÞ ter based on the exergy is discussed forthwith.
þ Exergy destruction ð8Þ
2.1.1. Effect of varying fin height in super heater
The exergy of the product is the useful work/energy from the Fig. 2 shows the exergy loss and exergy efficiency variations in
system. The exergy loss consists of the losses to the surround- the LP super heater with varying fin heights (19.05–31.75 mm) and
ings (waste heat and stack gases) and exergy destruction. The LP steam generation conditions (2–6 bar). From the results it is
exergy destructions are mainly due to the combination of observed that the exergy losses increase for the higher fin heights
internal irreversibilities [9]. The exergy efficiency helps in and for higher LP steam generation pressures. It is also found that
assessing the utilization efficiency of energy and is expressed for the considered range of fin heights exergy losses are maximum
as a ratio of exergy output to exergy input [9]. Thus, the exergy at 4 bar and minimum at 6 bar. The least exergy losses at 6 bar
efficiency accounts for the exergy loss which is the function of indicate that the losses due to exergy destruction are minimal
waste heat to the surroundings and exergy destruction. The meaning also thereby that the internal irreversibilities are least.
exergy loss and exergy efficiency for the DP HRSG at its sections It is observed that as the fin height increases from 19.05 to
are given ahead.
The mathematical formulations for exergy loss and exergy effi-
Table 2
ciency for different sections of HRSG such as super heater, evapo-
Physical parameters taken for sensitivity analysis of the HRSG.
rator and economizer being designated in general form as ith and
kth sections at HP and LP steam generation pressure conditions Description Variants of HRSG

is described ahead. Outside diameter of tube (mm) 50.8

Thickness of the tube (mm) 3.05
Tube type Segmented Spiral fins
Exergy loss (for ith section at HP steam pressure condition),
Fin density (no. of fin/m) 79, 119, 158, 198
Thickness of fin (mm) 0.91, 1.27, 1.45, 1.72
XiHP ¼ ðDXi Þg  ðDXi Þw ; ð9Þ Height of the fin (mm) 19.05, 22.23, 25.40, 31.75
Tube bundles Staggered
Exergy efficiency (for ith section at HP steam pressure Longitudinal pitch (mm) 101.6
Transverse pitch (mm) 101.6
condition),
 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001 997

EL, 2 EL, 2 bar

25 5 24 5
bar EL, 3 bar
EL, 3

Exergy Efficiency, % (LP)

Exergy Loss, MW (LP)
bar 4 EL, 4 bar
4

Exergy Efficiency, % (LP)

EL, 4
Exergy Loss, MW (LP)

23 EL, 5 bar
24 bar 3
3 EL, 5 EL, 6 bar
bar
2 EE, 2 bar
EL, 6 22
2 bar EE, 3 bar
23 EE, 2 1
bar EE, 4 bar
1 EE, 3 21 0 EE, 5 bar
bar 79 119 158 198
EE, 4 EE, 6 bar
Fin Density, fins/m
22 0 bar
19.05 22.23 25.40 31.75
Fig. 4. Exergy loss and exergy efficiency variations with varying fin densities and LP
Fin Height, mm
steam pressures in super heater.

Fig. 2. Exergy loss and exergy efficiency variations with varying fin heights and LP
steam pressures in super heater. these pressures for the super heater. The change in the exergy
losses is marginal in both conditions (i.e. for higher fin densities
31.75 mm, the exergy efficiency reduces. Under varying LP steam and higher LP steam generation pressures). As the fin density
generation conditions the exergy efficiency reduces and is maxi- increases the exergy efficiency improves for both higher fin densi-
mum for 6 bar. It is observed that under LP conditions the exergy ties as well as for higher LP steam generation conditions.
losses were large enough, thus poor exergy efficiency is observed Fig. 5 shows the exergy losses and exergy efficiency variations
for the LP super heater. in the HP super heater with varying fin density (79–198 fins/m)
Fig. 3 shows the exergy losses and exergy efficiency variation in and HP steam generation pressures (50–70 bar). It is found that
the HP super heater for varying fin heights (19.05–31.75 mm) and with higher fin densities as well as for higher HP steam generation
HP steam generation conditions (50–70 bar). The graphical illus- pressures, the exergy loss reduces. Therefore, the exergy efficiency
trations depict that for higher fin heights, the exergy loss reduces improves with higher fin densities as well as at higher HP steam
nearly by 7% due to proper utilization of heat by enhanced surface generation pressures.
area. It is also evident that the exergy losses are smaller at HP
steam generation pressure of 70 bar in comparison to 50 bar. The 2.1.3. Effect of varying fin thickness in super heater
decrease in exergy losses is insignificant at these varying HP steam Fig. 6 shows the exergy losses and exergy efficiency variations
generation pressures. It is observed that exergy efficiency increases in the LP super heater with varying fin thickness (0.91–1.72 mm)
by 5% for higher fin heights and by 2% for higher HP steam gener-
ation pressures. It is also found from Figs. 2 and 3 that exergy loss 49.00 32 EL, 50 bar
increases for LP condition of 6 bar for the higher fin heights. It is
48.50 EL, 55 bar

Exergy Efficiency, %(HP)

due to the larger internal irreversibilities at LP steam pressure as
Exergy Loss, MW (HP)

48.00 31 EL, 60 bar

compared HP steam pressure.
47.50 EL, 65 bar
EL, 70 bar
47.00 30
2.1.2. Effect of varying fin density in super heater EE, 50 bar
Fig. 4 shows the exergy loss and exergy efficiency variations in 46.50
EE, 55 bar
the LP super heater with the fin density varying from 79 to 46.00 29
EE, 60 bar
198 fins/m and LP steam generation pressures from 2 to 6 bar. It 45.50
EE, 65 bar
is evident from this graphical pattern that, the increase in the fin
45.00 28 EE, 70 bar
density represents better heat utilization as there is increase in 79 119 158 198
surface area as there is reduction in exergy losses by 2%. The study Fin Density, fins/m
also shows that on varying LP steam generation pressures the
exergy losses increase up to 4 bar and thereafter start decreasing Fig. 5. Exergy loss and exergy efficiency variations with varying fin densities and
HP steam pressures in super heater.
at 5–6 bar. At LP steam generation pressure of 5–6 bar, the entropy
difference becomes small as the exergy destruction is lower at

51 33 EL, 2 bar
24 4
50 32 EL, 50 bar EL, 3 bar
Exergy Efficiency % (HP)

Exergy Effeciency % (LP)

EL, 55 bar
Exergy Loss, MW (HP)

49 32
Exergy Loss, MW (LP)

23 EL, 4 bar
EL, 60 bar 3
48 31 EL, 5 bar
EL, 65 bar
47 31 EL, 70 bar
22 2 EL, 6 bar
46 30 EE, 50 bar
EE, 55 bar EE, 2 bar
45 30
EE, 60 bar 21 1 EE, 3 bar
44 29
EE, 65 bar
43 29 EE, 4 bar
EE, 70 bar
42 28 20 0 EE, 5 bar
19.05 22.23 25.40 31.75 0.91 1.27 1.45 1.72
EE, 6 bar
Fin Height, mm Fin Thickness, mm

Fig. 3. Exergy loss and exergy efficiency variations with varying fin heights and HP Fig. 6. Exergy loss and exergy efficiency variations with varying fin thicknesses and
steam pressures in super heater. LP steam pressures in super heater.
998 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001

EL, 50 bar the exergy efficiency improves by 7% for the higher fin heights
49 33 and by 22% for LP steam generation pressures. At higher fin heights
EL, 55 bar
and LP steam generation pressures the exergy losses are observed

Exergy Efficiency % (HP)

Exergy Loss,MW (HP)

32 EL, 60 bar
48 to be lower, therefore improvement in the exergy efficiency. It is
EL, 65 bar due to enhanced heat recovery and lesser internal irreversibilities
31
EL, 70 bar for the above conditions. Therefore, by placing proper size of fin
47
height in LP evaporator and choosing correct LP steam pressure
30 EE, 50 bar
the exergy losses could be minimized.
46 EE, 55 bar Fig. 9 shows the exergy loss and exergy efficiency variations in
29
EE, 60 bar the HP evaporator with varying fin heights and different HP steam
45 28 generation pressures (50–70 bar). It is observed that for higher fin
EE, 65 bar
0.91 1.27 1.45 1.72 heights the exergy losses reduces by 7%, but these losses increases
Fin Thickness, mm EE, 70 bar for the respective higher steam generation pressure (50–70 bar) by
around 3% due to increase in internal irreversibilites at the tube
Fig. 7. Exergy loss and exergy efficiency variations with varying fin thicknesses and
HP steam pressures in super heater.
inside. It results in the increase in exergy efficiency by 4% for
higher fin heights, but the exergy efficiency reduces marginally
for higher steam generation pressure. This increase in exergy losses
and LP steam pressures (2–6 bar). It is found that the exergy losses for higher HP steam pressure conditions is due to increase in inter-
increase as the fin thickness increases but decreases for the consid- nal irreversibilities and radiation losses.
ered higher LP steam pressures. The variations found for both the
conditions shows marginal changes in the exergy losses. Although 2.2.2. Effect of varying fin density on evaporator
increase in fin thicknesses improves structural stiffness of the fins Fig. 10 shows the exergy loss and exergy efficiency variations in
but there is only minor increase in efficiency, as such there is the LP evaporator with varying fin densities (79–198 fins/m) and
wastage of fin material in correlation to recovery of heat. The different LP steam generation pressures (2–6 bar). It is found that
exergy efficiency decreases for higher fin thicknesses but an as the fin density increases the exergy loss decreases by 3% and
enhancement in exergy efficiency is seen for higher LP steam gen- as the pressure condition changes from 2 to 6 bar the exergy losses
eration pressures. reduce by about 30%. The exergy losses are least for the chosen
Fig. 7 shows the exergy loss and exergy efficiency variations in range at LP steam generation pressure at 6 bar with 198 fins/m.
the HP super heater with varying fin thickness from 0.91 to Therefore, the higher fin density and high LP steam generation
1.72 mm and the different HP steam pressure conditions (50– pressure is better design as it minimizes the exergy losses (internal
70 bar). It is found that for higher fin thicknesses the exergy loss
is nearly constant up to 1.27 mm and then it starts decreasing up
to 1.72 mm. It is also seen that as HP steam pressure increases, 52 50
the exergy loss reduces and therefore the exergy efficiency 49
increases for respective fin thicknesses. 50
48

Exergy Efficiency, % (HP)

Exergy Loss, MW (HP)

47
48
2.2. LP and HP evaporator 46
46 45
The impacts of variations of physical parameters as well as
EL, 50 bar EL, 55 bar 44
steam generation pressure for LP and HP conditions for evaporator 44 EL, 60 bar EL, 65 bar 43
based on the exergy is discussed ahead.
EL, 70 bar EE, 50 bar
42
42 EE, 55 bar EE, 60 bar
2.2.1. Effects of varying fin height EE, 65 bar EE, 70 bar 41
Fig. 8 shows the exergy loss and exergy efficiency variations in 40 40
19.05 22.23 25.40 31.75
the LP evaporator with fin heights ranging from 19.05 to 31.75 mm
Fin Height, mm
and for LP steam generation pressures (2–6 bar). It shows that the
exergy loss reduces for higher fin heights by 15% and by 30% for Fig. 9. Exergy Loss and Exergy Efficiency Variations with Varying Fin Heights and
higher LP steam pressures. It is also illustrated from Fig. 8 that HP Steam Pressures in Evaporator.

EL, 2 bar EL, 3 bar EL, 4 bar

EL, 2 bar
EL, 5 bar EL, 6 bar EE, 2 bar
6 95
10 EE, 3 bar EE, 4 bar EE, 5 bar 90 EL, 3 bar
Exergy Efficiency, % (LP)
Exergy Loss, MW (LP)

9 80 5
Exergy Efficiency, % (LP)

EE, 6 bar EL, 4 bar

Exergy Loss, MW (LP)

8 85
70
7 4 EL, 5 bar
60
6 75 EL, 6 bar
50 3
5
40 65 EE, 2 bar
4
30 2
3 EE, 3 bar
2 20 1 55
EE, 4 bar
1 10
0 0 0 45 EE, 5 bar
19.05 22.23 25.40 31.75 79 119 158 198
EE, 6 bar
Fin Height, mm Fin Density, fins/m

Fig. 8. Exergy loss and exergy efficiency variations with varying fin heights and LP Fig. 10. Exergy loss and exergy efficiency variations with varying fin densities and
steam pressures in evaporator. LP steam pressures in evaporator.
 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001 999

irreversibilities). The exergy efficiency variations with the higher 55 50

fin densities show the improvement by 1.2%, and it increases by 54 48

Exergy Efficiency, % (HP)

46

Exergy Loss, MW (HP)

22% for higher LP steam pressures. Fig. 11 shows the exergy loss 53
and exergy efficiency variations in the HP evaporator with varying 52 44
fin densities (79–198 fins/m) and HP steam generation pressures 51 42
(50–70 bar). It is observed that for higher fin densities the exergy 50 40
losses decrease marginally, whereas for HP steam generation pres- 49 38
sures these losses increase by 3%. It is also observed that for higher 48 EL, 50 bar EL, 55 bar EL, 60 bar 36
fin densities the exergy efficiency increases, whereas for HP steam EL, 65 bar EL, 70 bar EE, 50 bar 34
47
EE, 55 bar EE, 60 bar EE, 65 bar
pressures from 50 to 70 bar the same decreases by around 3%. 46 EE, 70 bar 32
45 30
0.91 1.27 1.45 1.72
2.2.3. Effect of varying fin thickness for evaporator
Fig. 12 shows the exergy loss and exergy efficiency variations in Fin Thickness, mm
the LP evaporator with fin thicknesses ranging from 0.91 to Fig. 13. Exergy loss and exergy efficiency variations with varying fin thicknesses
1.72 mm for different LP steam generation pressures (2–6 bar). It and HP steam pressures in evaporator.
is determined from the graphical illustration that the exergy loss
reduces by around 4% for larger fin thicknesses. Moreover, it is 2.3. LP and HP economizer
noticed that the exergy losses further reduce by 30% with increase
in LP steam generation pressures ranging from 2 to 6 bar. There- The impacts of variations of physical parameters as well as
fore, the fin thickness of 1.72 mm and steam pressure at 6 bar, is steam generation pressures for LP and HP conditions for econo-
the best design obtained in the chosen conditions. The results mizer based on the exergy is discussed ahead.
obtained explain that the exergy efficiency increases as the fin
thickness increases and for higher LP steam conditions, it improves 2.3.1. Effects of varying fin height for economizer
further by 22%. Fig. 14 shows the exergy loss and exergy efficiency variations in
Fig. 13 shows the exergy loss and exergy efficiency variations in the LP economizer with the varying fin heights ranging from 19.05
the HP evaporator with varying fin thicknesses (0.91–1.72 mm) to 31.75 mm and LP steam generation pressures from 2 to 6 bar. It
and HP steam generation pressures (50–70 bar). The results indi- is observed from the results that the exergy loss reduces by 10% for
cate that the exergy loss decreases by 1% for higher fin thicknesses higher fin heights and it further reduces by 10% for the higher LP
and these losses reduces by 3% for the higher HP steam generation steam generation pressures. Whereas results also clarify that the
pressures. Results illustrate that the exergy efficiency for higher fin exergy efficiency increases for higher fin heights as well as for
thicknesses increases by 2% and improves considerably by 20% for higher LP steam generation pressures.
higher HP steam generation pressures. Fig. 15 shows the exergy loss and exergy efficiency variations in
the HP economizer with the fin heights ranging from 19.05 to

56 47 EL, 50 bar 10 30 EL, 2 bar

28 EL, 3 bar
55 EL, 55 bar

Exergy Efficiency, % (LP)

Exergy Efficiency, % (HP)

46 25
Exergy Loss, MW (LP)

9
Exergy Loss, MW (HP)

EL, 60 bar 23 EL, 4 bar

54
45 EL, 65 bar 20 EL, 5 bar
53 8 18
EL, 70 bar EL, 6 bar
52 44 15
EE, 50 bar 13 EE, 3 bar
51 7
43 EE, 55 bar 10 EE, 4 bar
50 8
42 EE, 60 bar 6 5 EE, 5 bar
49
EE, 65 bar 3 EE, 6 bar
48 41 EE, 70 bar 5 0
79 119 158 198 19.05 22.23 25.40 31.75 EE, 2 bar
Fin Density, Fins/m Fin Height, mm

Fig. 11. Exergy loss and exergy efficiency variations with varying fin densities and Fig. 14. Exergy loss and exergy efficiency variations with varying fin heights and LP
HP steam pressures in evaporator. steam pressures in economizer.

25 70 EL, 50 bar
6 100 EL, 2 bar 23 EL, 55 bar
60
Exergy Efficiency, %, (HP)

EL, 3 bar 21
Exergy Loss, MW (HP)
Exergy Efficiency,% (LP)

5 90 EL, 60 bar
Exergy Loss,MW (LP)

EL, 4 bar 19 50
80 EL, 65 bar
4 EL, 5 bar 17
40
15 EL, 70 bar
EL, 6 bar
3 70
13 30 EE, 50 bar
EE, 2 bar
2 60 EE, 3 bar 11 20 EE, 55 bar
EE, 4 bar 9 EE, 60 bar
1 50 10
7
EE, 5 bar EE, 65 bar
0 40 5 0
0.91 1.27 1.45 1.72 EE, 6 bar 19.05 22.23 25.40 31.75 EE, 70 bar
Fin Thickness, mm Fin Height, mm

Fig. 12. Exergy loss and exergy efficiency variations with varying fin thicknesses Fig. 15. Exergy loss and exergy efficiency variations with varying fin heights and HP
and LP steam pressures in evaporator. steam pressures in economizer.
1000 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001

31.75 mm and HP steam generation pressures ranging from 50 to 70 EL, 50 bar

70 bar. It is revealed from the results that the exergy loss decreases 24
EL, 55 bar

ExergyEfficiency, % (HP)
60

Exergy Loss, MW (HP)

by 8% as the fin height increases and reduce further by 20% for the 22
EL, 60 bar
higher HP steam generation pressures. The result shows that the 20 50
EL, 65 bar
exergy efficiency increases by 3% for higher fin heights and by
18 40 EL, 70 bar
20% for the higher HP steam generation pressures.
16 EE, 50 bar
30
14 EE, 55 bar
2.3.2. Effect of varying fin density for economizer
Fig. 16 shows the exergy loss and exergy efficiency variations in 20 EE, 60 bar
12
the LP economizer with varying fin density from 79 to 198 fins/m EE, 65 bar
10 10
and LP steam generation pressure in range of 2–6 bar. The exergy 0.91 1.27 1.45 EE, 70 bar
loss reduces with higher fin densities in addition to varying LP Fin Thickness, mm
steam generation pressures. The exergy efficiency increases by
3% for higher fin densities as well gets enhanced by 30% for varying Fig. 18. Exergy loss and exergy efficiency variations with varying fin thicknesses
and HP steam pressures in economizer.
LP steam generation pressures.
Fig. 17 shows the exergy loss and exergy efficiency variation in
study shows that the exergy efficiency increases by 5% for higher
the HP economizer with the varying fin densities (79–198 fins/m)
fin thicknesses. It is also seen that the exergy efficiency improves
and HP steam generation pressures (50–70 bar). Decrease in the
by 5% for the higher HP steam generation pressures.
exergy loss is observed for varying fin densities is by around 2%
and for HP steam generation pressures by around 18%. Marginal
increase in the exergy efficiency found for higher fin densities
3. Conclusions
however it improves significantly by 18% for higher HP steam gen-
eration pressures.
Following conclusions are drawn in the present study based on
the exergy analysis of the dual pressure HRSG for varying physical
2.3.3. Effect of varying fin thickness for economizer parameters and steam generation pressures at the LP and HP sec-
The exergy loss and exergy efficiency variations for varying fin tions namely super heater, evaporator and economizer.
thicknesses and LP steam generation pressures does not shows
noticeable changes therefore not discussed. Fig. 18 shows the
There are higher exergy losses and poor exergy efficiency at
exergy loss and exergy efficiency variations in the HP economizer varying fin heights and LP steam generation conditions in LP
with varying fin thickness from 0.91 to 1.45 mm and HP steam gen- super heater. In the HP super heater for varying fin heights
eration pressures (50–70 bar). It is observed from the results that these exergy losses get reduced by around 7% and exergy effi-
exergy loss decreases by 9% for higher fin thicknesses and decreases ciency increases 5%.
considerably by 18% for the HP steam generation pressures. The
The marginal reduction in exergy loss and little improvement in
exergy efficiency of the super heater are seen for varying fin
15 25 EL, 2 bar densities and varying LP and HP steam generation conditions.
14
The varying fin thicknesses reduce exergy loss and increases
Exergy Efficiency, % (LP)

EL, 3 bar
13 20
Exergy Loss, MW (LP)

exergy efficiency for LP steam generation conditions, but the

12 EL, 4 bar
varying HP steam conditions show reversed variations in case
11 15 EL, 5 bar of the super heater.
10 EL, 6 bar
The LP evaporator for varying fin heights shows that exergy loss
9 10 decreases by around 15% and the exergy efficiency improves by
EE, 2 bar
8 7% and for varying LP steam conditions the exergy losses reduce
7 5 EE, 3 bar
by 30% and exergy efficiency improves by 22%.
6 EE, 4 bar

In the HP evaporator for varying HP steam generation condi-
5 0 EE, 5 bar
79 119 158 198 tions exergy loss increases by 3% and exergy efficiency
Fin Density, fins/m EE, 6 bar decreases by around 3% for considered fin heights and fin
densities.
Fig. 16. Exergy loss and exergy efficiency variations with varying fin densities and
In case of LP economizer for varying fin heights the exergy
LP steam pressures in economizer. losses decrease by around 10% and result in improvement in
exergy efficiency by 10%. For higher LP steam generation condi-
tions, the exergy losses reduce by 10% with increase in exergy
20 120 EL, 50 bar
efficiency for considered fin heights.
18 110
Exergy Efficiency, %, (HP)

EL, 55 bar

For varying fin density and LP steam generation conditions the
Exergy Loss, MW (HP)

16 100 EL, 60 bar exergy loss reduces marginally and exergy efficiency increases
14 90 EL, 65 bar by around 3% in LP economizer.
12 80 EL, 70 bar
The LP economizer shows negligible change in exergy loss and
10 70 EE, 50 bar exergy efficiency with variation of fin thicknesses.
EE, 55 bar
In case of HP economizer the variation in fin heights shows little
8 60
improvement but for higher HP steam generation conditions
6 50 EE, 60 bar
the exergy losses reduce by 20% and exergy efficiency increases
4 40 EE, 65 bar
by around 20% for considered fin heights.
79 119 158 198 EE, 70 bar
The HP economizer shows negligible changes in exergy loss and
Fin Density, fins/m
exergy efficiency with variation in fin thicknesses, but for the
Fig. 17. Exergy loss and exergy efficiency variations with varying fin densities and HP steam generation conditions, the exergy losses reduce by
HP steam pressures in economizer. 18% and exergy efficiency improves by 5%.
 M. Sharma, O. Singh / Applied Thermal Engineering 114 (2017) 993–1001 1001

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