Horizontal Steam Generator Outlet Header Water Separation
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Solution Overview
Problem
Once-through steam generators face limitations in operational flexibility and starting times due to the need for cyclone separators, which restrict the control of live steam temperature and require costly distribution systems, especially during low load modes.
Innovation Solution
Incorporating an integrated water separator element in outlet headers allows for decentralized water-steam separation, enabling the use of superheater heating surfaces for evaporation and shifting the evaporation end point, thus eliminating the need for costly distribution systems and enhancing operational flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cyclone separators are used for water-steam separation in once-through steam generators, then water-steam separation is achieved, but device complexity and cost increase due to required distribution systems
Solution Approach 1:
The patent merges the water separator element directly with the outlet header structure, eliminating the need for separate cyclone separators and complex distribution systems. The outlet header itself performs the water-steam separation function through its integrated separator element, simplifying the overall system while maintaining separation reliability.
Solution Approach 2:
The outlet header is designed to perform multiple functions: it serves as the outlet for evaporating tubes, provides water-steam separation through the integrated separator element, and distributes flow to superheater tubes. This multi-functionality eliminates the need for separate dedicated components for each function.
2Reliability
If cyclone separators are used for water-steam separation, then separation is achieved, but starting time and operational flexibility are reduced
Solution Approach 1:
By integrating the water separator element directly into the outlet header structure, the patent eliminates the time required for water to travel through separate cyclone separators and distribution systems. The decentralized separation occurs at the point of flow exit, significantly reducing starting time and improving operational flexibility during load changes.
3Stability of the object's composition
If outlet headers are oriented parallel to hot gas direction, then flow stability is improved, but water-steam separation efficiency may be reduced
Solution Approach 1:
The outlet header is segmented into functional zones: an inlet section receiving flow from evaporating tubes, a separation section with the water separator element, and an outlet section for superheater tubes. This segmentation allows the header to maintain overall flow stability while creating a dedicated separation zone that efficiently separates water and steam.
Solution Approach 2:
The water separator element is positioned at a specific location within the outlet header where flow conditions are optimal for separation. The local geometry and orientation of the separator element are designed to maximize separation efficiency while the overall outlet header remains oriented parallel to the hot gas direction to maintain flow stability.
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
This solution allows for high operational flexibility and reduced starting and load change times by enabling the use of a larger portion of heating surfaces for evaporation, achieving reliable water separation through inertia-based design and promoting self-stabilizing flow behavior.
Implementation Method 1
reliable water separation through inertia-based design
Implementation Method 2
an evaporative once-through heating surface... leads to an evaporation of the flow medium in the steam generator tubes
Implementation Method 3
the heating of steam generator tubes, which are provided as evaporating tubes, leads to an evaporation of the flow medium
Implementation Method 4
The heat transfer is carried out in a heat recovery steam generator... heating surfaces for water preheating, for steam generation and for steam superheating
Data Source
AI summary
The invention relates to a steam generator whose continuously heating evaporator surface is arranged in a hot gas channel for a hot gas passage in a substantially horizontal direction and which comprises a plurality of steam generating pipes passed through by flowing medium, wherein a plurality of output collectors which are mounted downstream of certain steam generating pipes, on the side of flowing medium, are oriented in the longitudinal direction thereof substantially parallel to the hot gas direction. The invention improves the steam generator such that it is possible to attain a high operational flexibility, a particularly reduced start- and load-alternation time, including starting operation or light load phases and to maintain a low-cost production. Each output collector comprises an integrated water separating element by means of which said collector is connected, on the side of flowing medium, to a plurality of downstream arranged overheating pipes of an overheating surface.