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4.4.2 Performance Enhancements In industrial steam turbine systems, business conditions determine the requirements and relative values of electric power and process, or steam for heating. Plant system engineers then decide the extent of efficiency enhancing options to incorporate in terms of their incremental effects on performance and plant cost, and select appropriate steam turbine inlet and exhaust conditions. Often the steam turbine is going into a system that already exists and is being modified so that a number of steam system design parameters are already established from previous decisions, which exist as system hardware characteristics and the turbine must be properly matched to these conditions. As the stack temperature of the boiler exhaust combustion products still contain some heat, tradeoffs are made regarding the extent of investment in heat reclamation equipment for the sake of efficiency improvement. Often the stack exhaust temperature is set at a level where further heat recovery would result in condensation of corrosive chemical species in the stack, with consequential deleterious effects on stack life and safety. 4.4.2.1 Steam Reheat Higher pressures and temperatures along with steam reheat are used to increase power generation efficiency in large industrial (and utility) systems. The higher the pressure ratio (the ratio of the steam inlet pressure to the steam exit pressure) across the steam turbine, and the higher the steam inlet temperature, the more power it will produce per unit of mass flow, provided that the turbine can reliably accommodate the pressure ratio and that the turbine is not compromised by excessive condensation within the last expansion stage. To avoid condensation within the flowpath or to maximize available steam energy, the inlet steam temperature is increased until the economic life limit of turbine materials is reached. This limit is now generally in the range of 900° F for small industrial steam turbines using typical materials. Expanding steam can reach a condition of temperature and pressure where condensation to (liquid) water begins. Small amounts of water droplets can be tolerated in the last stages of a steam turbine provided that the droplets are not too large or numerous. Turbine flowpaths can employ features for extracting a portion of the condensate form the flowpath in order to limit water droplet impingement on the blading. Also, protective blade treatments such as Stellite are often employed to harden the blading surfaces exposed to the droplet impingement and reduce blade material erosion. For turbines using a reheat cycle, steam is extracted after it has partially expanded, heated in a heat exchanger, and returned to the turbine flowpath for further expansion. 4.4.2.2 Combustion Air Preheating In large industrial systems, air preheaters recover heat from the boiler exhaust gas stream, and use it to preheat the combustion air, thereby reducing fuel consumption. Boiler combustion air preheaters are large versions of the heat wheels used for the same purpose on industrial furnaces. 4.4.3 Capital Costs A steam turbine-based CHP plant is a complex process with many interrelated subsystems that must usually be custom designed. In a steam turbine CHP plant burning a solid biomass fuel, the steam turbine generator makes up only about 10 percent of the total plant equipment costs – the solid fuel Catalog of CHP Technologies 4–12 Steam TurbinesPDF Image | EPA CHP Technologies Combustion Turbines Section 4
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