HRSG Inlet Duct Diffuser With Curved Walls to Reduce Pressure Loss

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Solution Overview

Problem

The exhaust flow in a heat recovery steam generator (HRSG) can detach from the interior surface of the inlet duct, leading to vortex formation and increased backpressure, which decreases the efficiency of the combined cycle power plant.

Innovation Solution

An exhaust diffuser system with an inlet portion, a transition portion having incrementally angled wall portions, and a coupling portion with a curved wall is used to gradually expand the exhaust flow, mitigating detachment and vortex formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the exhaust flow is directly introduced into the HRSG without a diffuser system, then the system structure is simple, but the exhaust flow detaches from the interior surface causing vortex formation and increased backpressure

Engineering Contradiction:
Improveinlet duct structureVSAvoidpressure loss
Core Design Contradiction:
Device complexityVSLoss of energy

Solution Approach 1:

The diffuser portion employs curved wall portions with incremental angling instead of straight or sharp transitions. The curved geometry guides the exhaust flow smoothly through the expansion section, preventing flow separation and vortex formation while reducing pressure losses.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Solution Approach 2:

The diffuser system changes the geometric parameters of the inlet duct by incorporating wall portions with incremental angles (e.g., 5-15 degrees relative to the axial direction). This gradual parameter change allows the flow to adapt to the expanding cross-section without detachment, optimizing the balance between structural simplicity and flow efficiency.

Inventive Principle:
Principle #35Parameter changes

2Device complexity

If the exhaust flow is directly introduced into the HRSG without a diffuser system, then the device structure is simple, but the backpressure to the turbine increases

Engineering Contradiction:
Improveinlet duct structureVSAvoidbackpressure
Core Design Contradiction:
Device complexityVSStress or pressure

Solution Approach 1:

The curved wall portions in the diffuser system create a smooth transition that maintains attached flow, preventing the formation of vortices that would increase backpressure. The curvature radius and incremental angling are designed to keep the adverse pressure gradient within acceptable limits.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Solution Approach 2:

The diffuser portion is segmented into multiple wall portions with different incremental angles. This segmentation allows the design to optimize the pressure gradient distribution along the diffuser length, gradually expanding the flow area while controlling backpressure increases.

Inventive Principle:
Principle #1Segmentation

3Device complexity

If the exhaust flow detaches from the interior surface of the inlet duct, then vortex formation occurs, but the system structure remains simple

Engineering Contradiction:
Improveinlet duct structureVSAvoidexhaust flow stability
Core Design Contradiction:
Device complexityVSStability of the object's composition

Solution Approach 1:

The curved geometry of the diffuser wall portions stabilizes the exhaust flow by maintaining smooth gradients. The incremental angling ensures that the flow remains attached to the interior surface throughout the diffuser section, preventing vortex formation and flow instability.

Inventive Principle:
Principle #14Spheroidality (Curvature)

Solution Approach 2:

By carefully controlling the incremental angle parameters of the wall portions, the system optimizes flow stability. The gradual parameter change prevents sudden expansions that would cause flow detachment, while still achieving the necessary area increase for diffuser function.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively reduces pressure loss and backpressure, enhancing the efficiency of the combined cycle power plant by stabilizing the exhaust flow.

Implementation Method 1

The diffuser portion includes a plurality of wall portions, and the plurality of wall portions is incrementally angled relative to an axial extent extending from the inlet portion to the outlet portion

Methodology Applied
Scientific EffectDiffuser effect: Pressure Gradient

Data Source

PatentEP4610473A1Inlet duct system for a heat recovery steam generator
Publication Date: 2025.09.03 GENERAL ELECTRIC TECH GMBH
  • EP4610473A1 patent drawingFigure 1
  • EP4610473A1 patent drawingFigure 2
  • EP4610473A1 patent drawingFigure 3

AI summary

A system (10) includes an exhaust diffuser system (22) for a heat recovery steam generator (HRSG) (16). The system (10) includes an inlet portion (23), a diffuser portion (24) axially extending from the inlet portion (23), and an outlet portion (26) fluidly coupled to an axial distal end of the diffuser portion (24), wherein an outlet extent (252) of the outlet portion (26) is greater than an inlet extent (254) of the inlet portion (23). The diffuser portion (24) includes a plurality of wall portions (272), and the plurality of wall portions (272) is incrementally angled relative to an axial extent (258) extending from the inlet portion (23) to the outlet portion (26). The system (10) may further include a gas turbine engine (12) coupled to the inlet portion (23) and the HRSG (16) coupled to the outlet portion (26).