Modeling, multi-objective optimization and comparison of fire and water tube heat recovery steam generators for gas engine cogeneration plants

An innovative modeling and optimizing of fire and water tube heat recovery steam generators (HRSG) for gas engine cogeneration plant are performed here. In modeling section, the equations of e-NTU, LMTD and heat transfer coefficients for one-phase flow and two-phase flow are organized to form a nonlinear system of equations. Furthermore, in the next step, two pairs of objective functions (annual expenses-exergy destruction rate and annual expenses-thermal effectiveness) are selected for multi-objective optimization of HRSG by the use of genetic algorithm for one, two and three MW gas engine cogeneration plants. Results for a 2 MW gas engine (as an example) show that the fire tube HRSG total expenses are 50% lower than that for water tube HRSG. In this situation, for water and fire tube boilers, the effectiveness and cost are 0.9, 40,000 ($/year) and 0.9, 20,000 ($/year), respectively. Furthermore, the exergy destruction rates are close and equal to 1373.45 kW and 1366.2 kW for water tube and fire tube boilers, respectively. Moreover, for each gas engine, six equations with thirty constant coefficients are obtained to explain the behavior of HRSG outlet exhaust gas temperature, pinch temperature difference, steam generation mass flow rate, working pressure, thermal effectiveness and exergy destruction rate at partial load.