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Desuperheaters

The simplest type of desuperheater is an unlagged section of pipe, where heat can be radiated
to the environment. However, apart from the obvious risk of injury to personnel from such a
hot item of plant, and the expensive energy wastage, this approach does not adjust to
compensate for changes in the environmental conditions, steam temperature or steam
flowrate.

Fig. 15.2.1 Typical multi-nozzle spray desuperheater

Several designs of desuperheater are available and it is recommended that the following
properties be considered when sizing and selecting a suitable station for a given application:

• Turndown ratio - 'turndown' is used to describe the range of flowrates over which the
desuperheater will operate, as shown in Equation 4.2.1.

Equation 4.2.1

This is an important parameter, as any variation in inlet pressure, temperature or flowrate will
cause a variation in the requirement of cooling liquid.

In general, the two turndown values may be specified for a particular desuperheater:

Steam turndown ratio - This reflects the range of steam flowrates that the device can
effectively desuperheat.

Cooling water turndown ratio - This reflects the range of cooling flowrates that can be
used. Although this directly affects the steam turndown ratio, the relationship depends on the
temperatures of the superheated steam, the cooling water and the resulting desuperheated
steam.

Equation 15.1.1 is the mass/heat balance equation for this application:

Equation 15.1.1

Where:
mcw = Mass flowrate of cooling water (kg/h)
ms = Mass flowrate of superheated steam (kg/h)
hi = Enthalpy at superheat condition (kJ/kg)
hd = Enthalpy at desuperheated condition (kJ/kg)
hcw = Enthalpy of cooling water at inlet connection (kJ/kg)

It should be noted that the steam and water flowrates are directly proportional to each other;
the constant of proportionality 'k' depends on the enthalpies of the superheated steam, the
cooling water and the required desuperheated steam. Mathematically: cw ∝ k s

If the required turndown cannot be achieved using a single desuperheater, two desuperheaters
can be installed in parallel, with operation switching from one to another; or both can be in
operation depending on steam demand.

It should be noted that the desuperheater itself is only one part of a desuperheating station,
which will include the necessary control system for correct operation.

• Operating pressures and temperatures.


• Steam and water flowrate.
• Amount of superheat before, and amount of desuperheated steam required after, the
process.
• The water pressure available (a booster pump may be required).
• The required accuracy of the final temperature.
• In the case of in-line desuperheaters, the distance travelled by the steam before
complete desuperheating has occurred is also an important consideration. This is
referred to as the absorption length.

The following Sections include descriptions of the common types of desuperheater available,
their limitations and typical applications.

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Indirect contact desuperheaters


Tube bundle type desuperheaters
This type of desuperheater (Figure 15.2.2) consists of a heat exchanger, typically a shell and
tube, with superheated steam on one side, and the cooling medium on the other.

The shell of the first heat exchanger (containing the cooling water) is fixed at both ends on
the inlet side, whereas on the outlet side, it is fixed at the bottom and open at the top. The
floating head allows the pressure in the two sections of the shell to equalise.

The cooling medium is water at saturation temperature and pressure. As superheated steam
enters the first and then the second set of tubes, it gives up heat to the water, some of which
will be evaporated by this addition of energy. Any evaporated cooling water passes through
the floating head and will accumulate in the outlet side of the shell. It then passes through the
open end of the shell where it is mixed with the desuperheated steam.

F
ig. 15.2.2 A tube and bundle type desuperheater

Advantages:

1. Turndown is only limited by the controls that are fitted.


2. This design is capable of producing desuperheated steam to within 5°C of the
saturation temperature.
3. High maximum operating temperatures and pressures, typically around 60 bar and
450°C.
4. Fast response.
Disadvantages:

1. Bulky - because there are now a number of in-line devices available, they have been
largely superseded.
2. Cost.
3. An important concern with this type of desuperheater is the efficiency of the heat
exchange process. The build up of air or scale films on the heat exchange surface can
act as an extremely effective barrier to heat transfer.

Applications:

1. Those applications that experience wide variations in load.

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Direct contact desuperheaters

Water bath type desuperheater


This is the simplest form of direct contact desuperheater. The superheated steam is injected
into a bath of water. This additional heat will cause saturated steam to evaporate from the
surface of the bath. A pressure controller maintains a constant pressure in the vessel, and
hence the temperature and pressure of the saturated steam in the downstream pipe.
Fi
g. 15.2.3 Water bath type desuperheater (schematic)

Since the superheated steam has more energy per unit mass than the saturated steam, more
steam will be evaporated than actually enters the desuperheater. Consequently, the water
level will fall and therefore provision must be made to maintain this level. This usually
requires a pump of similar design to a boiler feedwater pump, as the water must be pumped
against the vessel pressure.

A good non-return valve is required in the superheated steam supply to avoid any water from
the bath being drawn into the superheated steam system should the pressure in the
superheated main drop.

Applications:

1. Simple
2. Steam is produced at saturation temperature.
3. Steam with a dryness fraction of 0.98 can be produced.
4. Turndown is only limited by the controls that are fitted.

Disadvantages:

1. Bulky.
2. Not practical for high temperatures.
Applications:

1. Wide variations in the flowrate.


2. Where no residual superheat can be tolerated.

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Water spray desuperheating


This type of desuperheating represents the vast majority of desuperheating applications. In
water spray desuperheaters, superheated steam is passed through a section of pipe fitted with
one or more spray nozzles. These inject a fine spray of cooling water into the superheated
steam, which causes the water to be converted into steam, reducing the quantity of superheat.

The cooling water may be introduced into the superheated steam in a number of ways;
consequently, there are a number of different types of water spray desuperheater.

Despite this, most water spray desuperheaters are affected by the following factors:

• Particle size - The smaller the water particle size, the greater the ratio of surface area
to mass, and the higher the rates of heat transfer. Since the water is being directly
injected into the moving superheated steam, the smaller the particle size, the shorter
the distance required for heat exchange to take place.

The water is broken into small particles using either a mechanical device (such as a
variable or fixed orifice nozzle) or steam atomising nozzles.
• Turbulence - As the flow within the pipeline becomes more turbulent, the individual
entrained water particles reside longer in the desuperheater, allowing for greater heat
transfer. In addition, turbulence encourages the mixing of the cooling water and the
superheated steam. Increased turbulence results in a shorter distance being required
for complete desuperheating to occur.

Turbulence can be created in two ways:

Pressure drop across the nozzle - Subjecting the cooling water to a higher pressure
drop will increase its velocity and induce greater turbulence.

Velocity - By increasing the overall velocity of the water and steam mixture, the
amount of turbulence is inherently increased. The increase in velocity is usually
achieved by creating a restriction in the steam path, which further generates
turbulence by vortex shedding.

In addition to these high velocities, if poor piping design practices are used, the speed
of the superheated steam could in theory approach Mach 1. At such speeds a number
of problems would occur (including the generation of shock waves). However, this
would be far in excess of the velocities used in good piping design. Typical velocities
of steam entering a desuperheater should be around 40 to 60 m/s.
• Cooling water flowrate - The rate at which cooling water can be added to the
superheated steam is affected by a number of factors, which are related by Equation
4.2.11:

Equation 4.2.11

Where:
qv = Cooling water volumetric flowrate (m3/s)
C = Coefficient of discharge for the nozzle
A = Area of the nozzle (m2)
g = Gravitational constant (9.81 m/s2)
h = Pressure drop over the orifice (m head)

Bearing in mind that C and g are constants, reviewing Equation 4.2.11 shows that only two
factors can be manipulated to alter the cooling water flowrate, qv:

Changing the pressure drop over the orifice (nozzle), h - Expressing flowrate as a function
of pressure drop over the nozzle:

This means that if, for example, flow is increased by a factor of 5, the available pressure must
increase by a factor of 52 = 25. The effect of this relationship is to severely hamper the
turndown ratio.

In addition to affecting the cooling water flowrate, there are two other important
considerations when determining the required cooling water pressure:

1. The cooling water pressure must be greater than the superheated steam pressure at the
point of injection.
2. The greater the pressure drop across the nozzle, the better the atomisation of the
cooling water.

Changing the area of the orifice, A - Expressing flowrate as a function of the area of
the orifice:

This direct relationship means that if, for example, flow is to be increased by a factor of 5, the
available area must also increase by a factor of 5. This change may simply be achieved by an
orifice, which has the ability to change in area (see Figure 15.2.4), or alternatively by altering
the number of orifices passing the coolant.
Fig. 15.2.4 Variable area orifice

1. Thermal sleeves - Careful control of the spray is required to ensure that the water
does not fall out of suspension as this can result in thermal stresses being generated in
the pipeline and cracking may occur. However, in some cases, an inner thermal sleeve
can be used to provide protection from this.

Fig. 15.2.5 A
thermal sleeve inserted in an in-line spray desuperheater

The thermal sleeve also allows the circulation of superheated steam around the annular area
between the sleeve and the inside diameter of the pipe. This provides a hot surface upon
which the injected water can evaporate, as opposed to the walls of the desuperheater, which
are inevitably cooler.

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Water spray type desuperheaters

Single point radial injection spray desuperheaters


The simplest method of injecting cooling water is to introduce a nozzle through the pipe wall.
Fig.
15.2.6 Single point radial injection spray desuperheater

The cooling water particles are sprayed across the flow of the superheated steam. The
quantity of cooling water injected is controlled by varying the position of the valve in the
centre of the nozzle.

Advantages:

1. Simple in operation.
2. Cost effective.
3. Minimum steam pressure drop.

Disadvantages:

1. Low turndown ratio, typically a maximum of 3:1 on both steam and cooling water
flow.
2. Desuperheated steam temperature can only be reduced to 10°C above saturation
temperature.
3. Longer absorption length than the steam atomising type.
4. Most prone to cause erosion damage to the internal pipework. This can be overcome
by the use of a thermal sleeve.
5. Limited pipe sizes.
Applications:

1. Constant steam load.


2. Constant steam temperature.
3. Constant coolant temperature.

All of which mean a relatively constant cooling water requirement.

Multiple point radial injection spray desuperheaters


This is a progression of the single point radial injection spray desuperheater. Cooling water is
sprayed in from a number of orifices around the perimeter of the pipe.

Fi
g. 15.2.7 Multiple radial injection point desuperheater

Advantages:

1. The pressure of the cooling liquid is less than that in the single point version;
therefore, it is not necessary to use a thermal sleeve.
2. The absorption length is shorter compared with that of the single point version due to
better mixing of the water and the superheated steam. The absorption length is still
significantly longer than other types of water spray desuperheater.

Other advantages, disadvantages and applications are similar to those of single point radial
injection spray desuperheaters.

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Axial injection spray desuperheaters


This is also a simple in-line injection spray desuperheater, but the point of injection is moved
to the axis of the pipeline. The cooling water is injected into the steam flow via one or more
atomising nozzles (see Figure 15.2.8). The unit usually employs a thermal sleeve.

Fi
g. 15.2.8 Axial injection spray desuperheater

Axial injection of the cooling water improves the mixing of the water and the superheated
steam by two methods:

1. As the water is injected along the centre of the pipeline, it will be more evenly
distributed throughout the superheated steam.
2. The cooling water delivery pipe that is inserted in the pipeline acts as an obstruction,
creating additional turbulence at the point of water injection due to vortex shedding.

Fig. 15.2.9 Vortex shedding around the


cooling water delivery pipe

A modification of this basic arrangement involves turning the nozzle so that the cooling water
is sprayed upstream, against the steam flow. The high velocity of the superheated steam
reverses the spray water flow pattern and sends it back through a mixing chamber. This
achieves more efficient mixing of the water and steam over a short absorption length.
Fig. 15.2.10 Reverse flow type axial
desuperheater

Advantages:

1. Simple in operation.
2. No moving parts.
3. Cost effective across the entire range of sizes.
4. Minimal steam pressure drop.

Disadvantages:

1. Low turndown ratio, typically a maximum of 3:1 on both steam and cooling water
flow.
2. Desuperheated steam temperature can only be reduced to 10°C above saturation
temperature.
3. Longer absorption length than the steam atomising type, but less than the radial type
desuperheaters.
4. Most prone to cause erosion damage to the internal pipework. This can be overcome
by the use of a thermal sleeve.

Applications:

1. Constant steam load.


2. Constant steam temperature.
3. Constant coolant temperature.

All of which mean a relatively constant cooling water requirement.

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Multiple nozzle axial injection desuperheaters


Rather than a single nozzle, the multiple nozzle axial injection desuperheater provides a
number of nozzles across the flow of superheated steam. This gives good dispersion of the
water droplets. There are three main types of multiple nozzle axial injection desuperheater:

1. Fixed area type - All the nozzles are open when the desuperheater is operating, and
the cooling water is regulated by a spray water control valve.

Fig.15.2.11 A multiple nozzle


desuperheater

2. Variable spray type - The downstream temperature determines the number of


exposed nozzles. Cooling water enters the desuperheater through the water jacket to
the sealing area above the disc (see Figure 15.2.12). When an increase in the
downstream steam temperature is detected by the associated temperature control
system, the actuator moves the stem down, progressively exposing more nozzles.
When the demand for the cooling water changes, the stem and disc arrangement
moves up and down as required. This has the effect of changing the overall orifice
area.
Fig.15.2.12 A variable
area type multiple nozzle desuperheater

3. Spring-assisted type - This is essentially a combination of the two previous types.


Instead of the stem and disc arrangement being controlled by an actuator, the spring-
assisted type contains a spring-loaded flow plug, which moves in response to a change
in the differential pressure between the coolant and the superheated steam. The
moving plug changes the number of open nozzles, thereby adjusting the flow into the
main pipeline. In addition, the cooling water is regulated by a spray water control
valve.

Being able to control both the pressure and flow of the cooling water enables accurate
control over the amount of water injected into the superheated steam. This type does,
however, require a high cooling water pressure.

Advantages:

1. Turndown ratios of up to 8:1 are possible with the fixed area type, up to 9:1 with the
spring assisted type and 12:1 for the variable area type.
2. Better dispersion of the water droplets means that the absorption length is less than
that of single nozzle devices.
3. Minimal steam pressure drop.

Disadvantages:

1. The desuperheated steam temperature can only be reduced to 8°C above saturation
temperature.
2. Longer absorption length than the steam atomising type.
3. Most prone to cause erosion damage to the internal pipework, if a thermal sleeve is
not used.
4. Not suitable for small pipe sizes.
5. Requires high pressure cooling water (particularly true of the spring assisted type).
6. Variable area and spring assisted types can be expensive.

Applications:

1. Applications with a requirement for a higher turndown ratio than that offered by
single nozzle devices, but where the expense of more sophisticated devices is not
justified.
2. Constant steam load.
3. Constant steam temperature.
4. Constant coolant temperature.

All of which require a relatively constant desuperheating load.

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