Abstract
Industrial processes are often accompanied by energy losses. These energy losses can be in the form of exhaust gas or effluents occurring at different temperature levels. All these losses are being curbed, but with an economic disadvantage. However, with the application of various waste heat recovery technologies such as heat recovery steam generator (HRSG) and waste heat boiler (WHB), this lost energy, mainly associated with the exhaust gas, can be recaptured and reused, thus resulting in better energy efficiency. This is also a firm step towards the protection of the environment and other associated gains like small plant size, less power consumption, less water consumption, etc. In this regard, the present paper revisits and reviews the current technology and practices in the context of HRSG and WHB. The future technological needs in this field have also been highlighted.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Adulkar, S. (2012). Modeling and characterization of ammonia injection and catalytic reduction in Kyrene unit-7 HRSG (November 2011). Arizona State University.
Adumene, S., & Nitonye, S. (2016). Assessment of site parameters and heat recovery characteristics on combined cycle performance in an equatorial environment. World Journal of Engineering and Technology, 4(May), 313–324. https://doi.org/10.4236/wjet.2016.42032
Ahmed, A., Esmaeil, K. K., Irfan, M. A., & Al-Mufadi, F. A. (2018). Design methodology of heat recovery steam generator in electric utility for waste heat recovery. International Journal of Low-Carbon Technologies, 13(4), 369–379. https://doi.org/10.1093/ijlct/cty045
Ali, M. S., Shafique, Q. N., Kumar, D., Kumar, S., & Kumar, S. (2018). Energy and exergy analysis of a 747-MW combined cycle power plant Guddu. International Journal of Ambient Energy, 0(0), 1–10. https://doi.org/10.1080/01430750.2018.1517680
Alobaid, F., Postler, R., Ströhle, J., Epple, B., & Kim, H. G. (2008). Modeling and investigation start-up procedures of a combined cycle power plant. Applied Energy, 85(12), 1173–1189. https://doi.org/10.1016/j.apenergy.2008.03.003
Angere, M., & Steffen Kahlert, H. S. (2017). Transient simulations and fatigue evaluation of fast gas turbine startups and shutdowns in a combined cycle plant with an innovative thermal buffer storage. Energy, 130, 246–257.
Angerer, M., Kahlert, S., & Spliethoff, H. (2017). Transient simulation and fatigue evaluation of fast gas turbine startups and shutdowns in a combined cycle plant with an innovative thermal buffer storage. Energy, 130, 246–257. https://doi.org/10.1016/j.energy.2017.04.104
Arpit, S., Das, P. K., & Dash, S. K. (2023). Exergy analysis of naphtha-based combined cycle captive cogeneration plant for a petrochemical complex. Environmental Progress and Sustainable Energy. https://doi.org/10.1002/ep.14149
Bain, D. I., & Christophersen, D. L. (2003). Some common mechanisms leading to failures in heat recovery steam generators. Corrosion, 185–213. https://doi.org/10.1017/CBO9781107415324.004
Barghi Golezani, F., Kishore Annavarapu, R., & Sojoudi, H. (2023). Numerical investigation of the effect of symmetry on evaporation triggered elastocapillary top-gathering of high aspect ratio micropillars. Coatings, 13(2). https://doi.org/10.3390/coatings13020292
Behar, O., Khellaf, A., & Mohammedi, K. (2013). A review of studies on central receiver solar thermal power plants. Renewable and Sustainable Energy Reviews, 23, 12–39. https://doi.org/10.1016/j.rser.2013.02.017
Behbahani-Nia, A., Sayadi, S., & Soleymani, M. (2010). Thermoeconomic optimization of the pinch point and gas-side velocity in heat recovery steam generators. Proceedings of the Institution of Mechanical Engineers, Part A: Journal of Power and Energy, 224(6), 761–771. https://doi.org/10.1243/09576509JPE953
Bonforte, G., Buchgeister, J., Manfrida, G., & Petela, K. (2018). Exergoeconomic and exergoenvironmental analysis of an integrated solar gas turbine / combined cycle power plant. Energy, 156, 352–359. https://doi.org/10.1016/j.energy.2018.05.080
Cengel, Y. A., & Boles, M. A. (2005). Thermodynamics an engineering approach (5th ed.). MCGraw-Hill Science/Engineering/Math.
Chase, D. L., & Kehoe, P. T. (2014). GE combined-cycle product line and performance. In System.
Choudhury, A., Chandra, H., & Arora, A. (2013). Application of solid oxide fuel cell technology for power generation - A review. Renewable and Sustainable Energy Reviews, 20, 430–442. https://doi.org/10.1016/j.rser.2012.11.031
Cobb, D., Glatch, L., Ruud, J., & Snyder, S. (1991). Application of selective catalytic reduction (SCR) technology for NOx reduction from refinery combustion sources. Environmental Progress, 10(1), 49–59. https://doi.org/10.1002/ep.670100116
combined cycle Journal. (2023). Adapt advanced process control for tighter regulation of SH, RH temperatures. Combined Cycle Journal. https://www.ccj-online.com/adapt-advanced-processcontrol-for-tighter-regulation-of-sh-rhtemperatures/#:~:text=The%20typical%20design%20of%20steam,%20for%20the%20at%20temperator%20outlet%20temperature
Corporation, F. (2002). HRSG bypass dampers–eliminating the flap. https://www.forneycorp.com/articles/hrsg-bypassdampers
Darie, G., Petcu, H., Negreanu, G., & Gherghina, V. (2007). Sliding pressure operation of large conventional steam power units. In Proceedings of the 5th IASME/WSEAS Int. Conference on Heat Transfer, Thermal Engineering and Environment (pp. 299–303).
Davis, J. S., & Wells, S. (1986). Selective catalytic reduction impact on heat recovery steam generator design and operation (pp. 1–6). ASME.
Díaz, A. G., Fernandez, E. S., Gibbins, J., & Lucquiaud, M. (2017). Sequential supplementary firing in combined cycle power plant with carbon capture: Part-load operation scenarios in the context of EOR. Energy Procedia, 114(November 2016), 1453–1468. https://doi.org/10.1016/j.egypro.2017.03.1901
Dooley, R. (2008). Flow-accelerated corrosion in fossil and combined cycle/HRSG plants. PPChem, 10(2), 68–89. https://www.structint.com/techpapers/Flow-Accelerated%20Corrosion%20in%20Fossil%20and%20Combined%20Cycle_HSRG%20Plants.pdf
Enadi, N., & Roshandel, K. (2011). Thermodynamic modeling and parametric study and exergy optimization of single, dual and triple pressure combined cycle power plants (CCPP). In 2011 IEEE 3rd International Conference on Communication Software and Networks, ICCSN 2011 (pp. 361–365). https://doi.org/10.1109/ICCSN.2011.6014913
Engineering, B. H. (2009). Difference between heat recovery steam generators (HRSG) & combustion boiler. https://www.brighthubengineering.com/powerplants/42020-how-is-the-hrsg-different-from-a-fossilfuel-fired-boiler/#:~:text=Most%20of%20the%20HRSG’s%20are,%20insulation%20is%20on%20the%20outside
ESTEEM. (2023). Types and configurations of HRSGs. https://www.esteemprojects.com/library/HRSGDesign/page2.html
Fakhari, I., Behinfar, P., Raymand, F., Azad, A., Ahmadi, P., Houshfar, E., & Ashjaee, M. (2021). 4E analysis and tri-objective optimization of a triple-pressure combined cycle power plant with combustion chamber steam injection to control NOx emission. Journal of Thermal Analysis and Calorimetry, 145(3), 1317–1333. https://doi.org/10.1007/s10973-020-10493-5
Farhat, O., Faraj, J., Hachem, F., Castelain, C., & Khaled, M. (2022). A recent review on waste heat recovery methodologies and applications: Comprehensive review, critical analysis and potential recommendations. Cleaner Engineering and Technology, 6, 100387. https://doi.org/10.1016/j.clet.2021.100387
Fontaine, I. P. (2003). Cycling tolerance - Natural circulation vertical HRSGs. In Proceedings of the 2003 International Joint Power Generation Conference (pp. 513–522). https://doi.org/10.1115/ijpgc2003-40114
Franco, A. (2011). Analysis of small size combined cycle plants based on the use of supercritical HRSG. Applied Thermal Engineering, 31(5), 785–794. https://doi.org/10.1016/j.applthermaleng.2010.10.027
Ganapathy, V. (1996). Heat-recovery steam generators: Understand the basics. Chemical Engineering Progress, 92(8), 32–45.
Ganapathy, V. (2014). Steam generators and waste heat boilers: For process and plant engineers.https://doi.org/10.1201/b17519
González Díaz, A., Sánchez Fernández, E., Gibbins, J., & Lucquiaud, M. (2016). Sequential supplementary firing in natural gas combined cycle with carbon capture: A technology option for Mexico for low-carbon electricity generation and CO2 enhanced oil recovery. International Journal of Greenhouse Gas Control, 51(2016), 330–345. https://doi.org/10.1016/j.ijggc.2016.06.007
González-Díaz, A., Alcaráz-Calderón, A. M., González-Díaz, M. O., Méndez-Aranda, Á., Lucquiaud, M., & González-Santaló, J. M. (2017). Effect of the ambient conditions on gas turbine combined cycle power plants with post-combustion CO2 capture. Energy, 134, 221–233. https://doi.org/10.1016/j.energy.2017.05.020
Hajabdollahi, H., Ahmadi, P., & Dincer, I. (2011). An exergy-based multi-objective optimization of a heat recovery steam generator (HRSG) in a combined cycle power plant (CCPP) using evolutionary algorithm. International Journal of Green Energy, 8(1), 44–64. https://doi.org/10.1080/15435075.2010.529779
Hanafizadeh, P., Siahkalroudi, M. M., & Ahmadi, P. (2016). Experimental and numerical investigation of optimum design of semi industrial heat recovery steam generator inlet duct. Applied Thermal Engineering, 104, 375–385. https://doi.org/10.1016/j.applthermaleng.2016.05.024
Hoang, T.-D., & Pawluskiewicz, D. K. (2016). The efficiency analysis of different combined cycle power plants based on the impact of selected parameters. International Journal of Smart Grid and Clean Energy, 1–19. https://doi.org/10.12720/sgce.5.2.77-85
Ibrahim, T. K., & Rahman, M. M. (2013). Study on effective parameter of the triple-pressure reheat combined cycle performance. Thermal Science, 17(2), 497–508. https://doi.org/10.2298/TSCI111016143I
Ibrahim, T. K., Mohammed, M. K., Awad, O. I., Abdalla, A. N., Basrawi, F., Mohammed, M. N., Najafi, G., & Mamat, R. (2018). A comprehensive review on the exergy analysis of combined cycle power plants. Renewable and Sustainable Energy Reviews, 90(July 2016), 835–850. https://doi.org/10.1016/j.rser.2018.03.072
Industries, M. H. (2017). Advanced water treatment technologies (high-AVT) for HRSG corrosion control corresponding to new JIS B8223 (Japanese Industrial Standards). Mitsubishi Heavy Industries Technical Review, 54(3), 63–68.
Jonshagen, K. (2011). Modern thermal power plants. E-huster Tryckeri.
Jouhara, H., Khordehgah, N., Almahmoud, S., Delpech, B., Chauhan, A., & Tassou, S. A. (2018). Waste heat recovery technologies and applications. Thermal Science and Engineering Progress, 6(January), 268–289. https://doi.org/10.1016/j.tsep.2018.04.017
Kakac, S., Bergles, A. E., & Mayinger, F. (1981). Heat exchangers, thermal-hydraulic fundamentals and design. Kluwer Academic Publisher. https://doi.org/10.13182/nt82-a32993
Kakaç, S., Bergles, A. E., F, E. O. (2012). Two-phase flow heat exchangers: Thermal-hydraulic fundamentals and design. Springer Science & Business Media. https://books.google.com.pr/books?id=2yr0CAAAQBAJ
Kaviri, A. G., Jaafar, M. N. M., Lazim, T. M., & Barzegaravval, H. (2013). Exergoenvironmental optimization of heat recovery steam generators in combined cycle power plant through energy and exergy analysis. Energy Conversion and Management, 67, 27–33. https://doi.org/10.1016/j.enconman.2012.10.017
Kim, T. S., Lee, D. K., & Ro, S. T. (2000). Analysis of thermal stress evolution in the steam drum during start-up of a heat recovery steam generator. Applied Thermal Engineering, 20(11), 977–992. https://doi.org/10.1016/S1359-4311(99)00081-2
Kumar, N. R. (2009). Performance simulation of dual pressure HRSG in combined cycle power plant performance simulation of dual pressure HRSG in combined cycle power plant. 8595, 64–78.https://doi.org/10.1080/01998590709509487
Li, B., Deng, Y., Li, Z., Xu, J., & Wang, H. (2022). Thermal-economy optimization for single/dual/triple-pressure HRSG of gas-steam combined cycle by multi-objective genetic algorithm. Energy Conversion and Management, 258(November 2021), 115471. https://doi.org/10.1016/j.enconman.2022.115471
Lind, J., & Fauland, C. (2013). SCR technology for NOx control.
Liptak, B. G. (2005). Process control and optimization. In Instrument engineers’ handbook (4th ed.). Taylor & Francis Group. https://doi.org/10.1201/9781420064001.ch8
Liu, C., Ferrero, E. E., Martens, K., & Barrat, J.-L. (2018a). Creep dynamics of athermal amorphous materials: A mesoscopic approach. Soft Matter, 222(x), 221–236. https://doi.org/10.1001/archpsyc.62.2.199
Liu, C., Ferrero, E. E., Martens, K., Barrat, J.-L., Davis, J. S., Wells, S., Lind, J., Fauland, C., Cobb, D., Glatch, L., Ruud, J., & Snyder, S. (2018). Creep dynamics of a thermal amorphous materials: A mesoscopic approach. Environmental Progress, 222(x), 221–236. https://doi.org/10.1002/ep.670100116
Lugo-Leyte, R., Salazar-Pereyra, M., Bonilla-Blancas, A. E., Lugo-Mendez, H. D., Ruíz-Ramírez, O. A., & Toledo-Velázquez, M. (2016). Exergetic analysis of triple-level pressure combined power plant with supplementary firing. Journal of Energy Engineering, 142(4), 05016001. https://doi.org/10.1061/(ASCE)EY.1943-7897.0000348
Mashal, A. (2015). Failure mode effect analysis (FMEA) on Heat Recovery Steam Generator (HRSG): Water tube boiler. May. http://utpedia.utp.edu.my/id/eprint/16175
Sharma, M., & Singh, O. (2019). Exergy analysis of the dual pressure HRSG for varying physical parameters. Applied Thermal Engineering, 1–9. https://doi.org/.1037//0033-2909.I26.1.78
Mehrgoo, M., & Amidpour, M. (2017a). Configurations and pressure levels optimization of heat recovery steam generator using the genetic algorithm method based on the constructal design. Applied Thermal Engineering, 122, 601–617. https://doi.org/10.1016/j.applthermaleng.2017.04.144
Mehrgoo, M., & Amidpour, M. (2017b). Constructal design and optimization of a dual pressure heat recovery steam generator. Energy, 124, 87–99. https://doi.org/10.1016/j.energy.2017.02.046
Mertens, N., Alobaid, F., Starkloff, R., Epple, B., & Kim, H. G. (2015). Comparative investigation of drum-type and once-through heat recovery steam generator during start-up. Applied Energy, 144, 250–260. https://doi.org/10.1016/j.apenergy.2015.01.065
Mertens, N., Alobaid, F., Lanz, T., Epple, B., & Kim, H. G. (2016). Dynamic simulation of a triple-pressure combined-cycle plant: Hot start-up and shutdown. Fuel, 167, 135–148. https://doi.org/10.1016/j.fuel.2015.11.055
Mohagheghi, M., & Shayegan, J. (2009). Thermodynamic optimization of design variables and heat exchangers layout in HRSGs for CCGT, using genetic algorithm. Applied Thermal Engineering, 29(2–3), 290–299. https://doi.org/10.1016/j.applthermaleng.2008.02.035
Mohamed, A. M. A., Abdullah, A. M., & Younan, N. A. (2015). Corrosion behavior of superhydrophobic surfaces: A review. Arabian Journal of Chemistry, 8(6), 749–765. https://doi.org/10.1016/j.arabjc.2014.03.006
Mohammed, M. S., & Petrović, M. V. (2015). Thermoeconomic optimization of triple pressure heat recovery steam generator operating parameters for combined cycle plants. Thermal Science, 9(2), 447–460. https://doi.org/10.2298/TSCI131124040M
Mokhtari, H., Ahmadisedigh, H., & Ameri, M. (2017). The optimal design and 4E analysis of double pressure HRSG utilizing steam injection for Damavand power plant. Energy, 118, 399–413. https://doi.org/10.1016/j.energy.2016.12.064
Naemi, S., Saffar-Avval, M., Behboodi Kalhori, S., & Mansoori, Z. (2013). Optimum design of dual pressure heat recovery steam generator using non-dimensional parameters based on thermodynamic and thermoeconomic approaches. Applied Thermal Engineering, 52(2), 371–384. https://doi.org/10.1016/j.applthermaleng.2012.12.004
NAES. (2018). Cleaning your HRSG tubes improves performance. https://www.naes.com/news/cleaning-hrsg-tubes/
Nordin, A., & Abd Majid, M. A. (2016). Parametric study on the effects of pinch and approach points on heat recovery steam generator performance at a district cooling. Journal of Mechanical Engineering and Sciences, 10(2), 2134–2144.
Norouzi, E., Amidpour, M., & Rezakazemi, M. (2019). Heat recovery steam generator: Constructal thermoeconomic optimization. Applied Thermal Engineering, 148(September 2018), 747–753. https://doi.org/10.1016/j.applthermaleng.2018.11.094
Ozturk, M., & Dincer, I. (2013). Thermodynamic assessment of an integrated solar power tower and coal gasification system for multi-generation purposes. Energy Conversion and Management, 76, 1061–1072. https://doi.org/10.1016/j.enconman.2013.08.061
Pasha, A. (1988). Gas turbine heat recovery steam generators for combined cycles natural or forced circulation considerations. Proceedings of the ASME Turbo Expo, 4. https://doi.org/10.1115/88-GT-142
Polonsky, V. S., Tarasov, D. A., & Gorr, D. A. (2019). Configuration of evaporators for once-through heat recovery steam generators of combined-cycle units. Thermal Engineering, 66(5), 340–349. https://doi.org/10.1134/S0040601519050082
Prayogo, G. S., Haryadi, G. D., Ismail, R., & Kim, S. J. (2016). Risk analysis of heat recovery steam generator with semi quantitative risk based inspection API 581. AIP Conference Proceedings, 1725. https://doi.org/10.1063/1.4945516
Rahim, M. A. (2012). Combined cycle power plant performance analyses based on the single-pressure and multipressure heat recovery steam generator. 138(September), 136–145. https://doi.org/10.1061/(ASCE)EY.1943-7897.0000063
Rath, D., & Koller, A. (1997). Vertical design HRSG with natural circulation successfull in operation. Proceedings of the ASME Turbo Expo. https://doi.org/10.1115/97-AA-121
Rezaie Navaie, A. (2017). Thermal design and optimization of heat recovery steam generators and waste heat boilers. Technische Universität Berlin. https://depositonce.tuberlin.de/bitstream/11303/6319/5/rezaie_navaie_ali.pdf
Sharma, M., & Singh, O. (2016). Exergy analysis of dual pressure HRSG for different dead states and varying steam generation states in gas/steam combined cycle power plant. Applied Thermal Engineering, 93, 614–622. https://doi.org/10.1016/j.applthermaleng.2015.10.012
Siemens. (2021). Benson® HRSG.
SIEMENS Energy. (2022). Hot start on the fly. https://www.siemensenergy.com/global/en/offerings/services/performanceenhancement/flex-power-services.html#:~:text=Hot%20Start%20on%20the%20Fly%20is%20an%20innovative%20upgrade%20for,30%20minutes
So, H. K., Jo, T. H., Lee, Y. H., Koo, B. C., & Lee, D. H. (2018). Design optimization of HRSG inlet duct geometry for improving flow uniformity using meta-heuristic algorithm. Journal of Mechanical Science and Technology, 32(2), 947–958. https://doi.org/10.1007/s12206-018-0145-x
Soltani, S., Athari, H., Rosen, M. A., Mahmoudi, S. M. S., & Morosuk, T. (2015). Thermodynamic analyses of biomass gasification integrated externally fired, post-firing and dual-fuel combined cycles. Sustainability (Switzerland), 7(2), 1248–1262. https://doi.org/10.3390/su7021248
Starr, F., & Researcher, I. (2015). Background to the design of HRSG systems and implications for CCGT plant cycling. European Technology Development Surrey, UK (Mr Fred Starr works as Principal M. August).
Topolski, J., & Badur, J. (2002). Comparison of the combined cycle efficiencies with different heat recovery steam generators. Transactions of the Institute of Fluid-Flow Machinery, Nr, 111(111), 5–16.
Viessmann. (2010). Steam boilers and waste heat boilers. International Journal of Refrigeration, 69, 232–242. https://doi.org/10.1016/j.ijrefrig.2016.06.021
Volpi, G., Penati, M., & Silva, G. (2005). Heat Recovery Steam Generators for large combined cycle plants (250 MWe GT output): Experiences with different design options and promising improvements by once-through technology development (pp. 1–16).
Walter, H., & Hofmann, R. (2011). How can the heat transfer correlations for finned-tubes influence the numerical simulation of the dynamic behavior of a heat recovery steam generator? Applied Thermal Engineering, 31(4), 405–417. https://doi.org/10.1016/j.applthermaleng.2010.08.015
Zhang, G., Zheng, J., Yang, Y., & Liu, W. (2016). Thermodynamic performance simulation and concise formulas for triple-pressure reheat HRSG of gas-steam combined cycle under off-design condition. Energy Conversion and Management, 122, 372–385. https://doi.org/10.1016/j.enconman.2016.05.088
Zhao, B., Xu, H., Lu, X., & Li, N. (2009). Development and research of HRSG device for power generation. 2009 International Conference on Energy and Environment Technology, ICEET 2009, 1, 584–587. https://doi.org/10.1109/ICEET.2009.148
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Highlights
• This paper address the design issues of HRSG, its controlling aspect and various auxiliary systems required to operate HRSG. All these are rarely available in academic papers.
• Further, this paper presents a detailed discussion of sequential firing, design aspect of HRSG, etc.
• This paper presents a brief description about waste heat boiler (use and its various types).
• Lastly, a comparison between waste heat boiler and heat recovery steam generator is presented.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Arpit, S., Das, P.K. A state-of-the-art review of heat recovery steam generators and waste heat boilers. Energy Efficiency 16, 99 (2023). https://doi.org/10.1007/s12053-023-10179-5
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12053-023-10179-5