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Modelling of high-temperature tube heat exchangers operating at supercritical pressure

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  • Taler, Jan
  • Taler, Dawid
  • Węglarz, Katarzyna
  • Marcinkowski, Mateusz
  • Węglarz, Marek

Abstract

A new analytical-numerical method for modelling supercritical crossflow superheaters is presented. Steam flows inside the tubes, while flue gas flows perpendicularly outside. The heat exchanger is divided into finite volumes. Analytical formulas were derived to calculate fluid temperatures within a control volume, significantly reducing computation time. The specific heat of steam is a function of pressure and temperature, and the specific heat of flue gas depends on temperature. Steam pressure distribution was determined by solving the momentum conservation equation. A new formula for calculating the friction factor in rough tubes was proposed, along with equations to identify the Reynolds number, above which the friction factor depends only on relative roughness. Convective and radiative heat transfer, including the effects of ash deposits on tube surfaces, are considered. The total circumferential stress from pressure and thermal load in the tube wall was calculated. The method accurately predicts steam and flue gas temperatures in a two-pass live steam supercritical superheater working at 100 % load. Considering that steam at supercritical pressure is a real gas causes an increase in the heat flow rate from exhaust gases to steam by about 2.5 % compared to isobaric steam superheating at a constant average pressure in the superheater.

Suggested Citation

  • Taler, Jan & Taler, Dawid & Węglarz, Katarzyna & Marcinkowski, Mateusz & Węglarz, Marek, 2025. "Modelling of high-temperature tube heat exchangers operating at supercritical pressure," Energy, Elsevier, vol. 317(C).
    • Handle: RePEc:eee:energy:v:317:y:2025:i:c:s0360544225003718
    DOI: 10.1016/j.energy.2025.134729
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    References listed on IDEAS

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    1. Węglarz, Katarzyna & Taler, Dawid & Taler, Jan & Marcinkowski, Mateusz, 2024. "General numerical method for hydraulic and thermal modelling of the steam superheaters," Energy, Elsevier, vol. 291(C).
    2. Xiaobo Cui & Pan Xu & Guohui Song & Haiming Gu & Hui Gu & Liang Wang & Hongxia Zhu, 2022. "PID Control of a Superheated Steam Temperature System Based on Integral Gain Scheduling," Energies, MDPI, vol. 15(23), pages 1-16, November.
    3. Taler, Dawid & Taler, Jan & Wrona, Katarzyna, 2021. "New analytical-numerical method for modelling of tube cross-flow heat exchangers with complex flow systems," Energy, Elsevier, vol. 228(C).
    4. Jin, Donghao & Yan, Jingwen & Liu, Xin & Zhang, Chaoqun & Wang, Heyang, 2023. "Prediction of tube temperature distribution of boiler platen superheater by a coupled combustion and hydrodynamic model," Energy, Elsevier, vol. 279(C).
    5. Taler, Dawid & Sobota, Tomasz & Jaremkiewicz, Magdalena & Taler, Jan, 2022. "Control of the temperature in the hot liquid tank by using a digital PID controller considering the random errors of the thermometer indications," Energy, Elsevier, vol. 239(PE).
    6. Saravana Kumar Tamilarasan & Jobel Jose & Vignesh Boopalan & Fei Chen & Senthil Kumar Arumugam & Jishnu Chandran Ramachandran & Rajesh Kanna Parthasarathy & Dawid Taler & Tomasz Sobota & Jan Taler, 2024. "Recent Developments in Supercritical CO 2 -Based Sustainable Power Generation Technologies," Energies, MDPI, vol. 17(16), pages 1-29, August.
    7. Granda, Mariusz & Trojan, Marcin & Taler, Dawid, 2020. "CFD analysis of steam superheater operation in steady and transient state," Energy, Elsevier, vol. 199(C).
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