Thapter 2.

PROCESS ENGINEERING
Weightage of Marks = 10, TeachingHours = 06
Syllabus
2.1. Process Boiler, Steam, Condensate loop in process industry, Steom Distribution System, Steam
Traps, Function of Steam Traps and Type of Steam Traps.
2.2. Introduction of Ultra Supper critical Boiler, Principle,Working, advantages, application.
2.3. Hyperbolic Cooling Towers.
2.4. Waste heat recovery in process industries

About this Chapter

At the end of this chapter, students will be able to:
Apply Heat Engineering in Process Boiler
Understand UltraSupper Critical Boiler (USC)
Understand Hyperbolic Cooling Towers
Waste heat recovery system used in process industries

2.1 INTRODUCTION
Steam:

Steam is a vapour form of water. Steam has been a popular mode of conveying energy since the
industrial revolution. Steam is used for generating power and heating in process industries such as sugar,
paper, fertilizer, refineries, petrochemicals, chemical, food, synthetic fiber and textiles.
Boiler:

It is a closed vessels in which water gets converted into steam with the addition of heat energy which is
generated by combusting fuel (may be solid, liquid and gaseous) in combustion chamber or furnace.
Process Boiler:

The boilers used in process industries for heating purpose are called as process boilers. The pressure
and temperature of the steam generated in these boilers is basically low. Process boilers are capable of
generating saturated steam at apressure of 10 to 15 bar. The saturated steam is then led to the point of
application and the latent heat rejected during the condensation of the saturated steam is used for process
heating.
Sensible Heat of water:

The amount of heat required by 1Kg of water to raise its temperature from freezing temperature up to
the boilingtemperature or saturation temperature is called sensible heat
Sensible heat is called as Liquid enthalpy which is the "Enthalpy (heat energy) in the water when it has
been raised to its boiling point to produce steam, and is measured in kJ/kg, its symbol is hf.
Q = m x Cpw X(Tw - T)
(2.1)
Emerging Trends in Mechanical Engineering 2.2
Process Engineerin,
where, Q = Heat, m = Mass of substance,
Cpw = Specific heat of constant pressure of water
T, = Temperature of water after heating,
T, = Initial
temperature
Latent Heat:
The amount of heat required by water which is at boiling or saturation temperature to
convert it into
vapor form or steam at constant temperature such a heat is called latent heat. When the latent
acquired by the water only phase change willtake place but there is no change in temperature. heatis
Latent heat is also called Enthalpyof Evaporation. When the steam condenses back into water, it give.
up its enthalpy of evaporation, which it had acquired on changing from water to steam. The
evaporation is measured in kJ/kg. enthalpy ot
Its Symbol is htg. In process industries the latent heat aiven out by condensing saturated steam are used
for heating applications.
Saturation Temperature:
The temperature at which water boils, also called as boiling point or saturation temperature increases
as the pressure increases. When water under pressure is heated its saturation temperature rises above 100c
and the usable heat energy in the steam (enthalpy of evaporation) decreases.
The Steam Phase Diagram
The relationship between the enthalpy and the saturation temperatures at various different pressures is
known as a phase diagram.

Formationof Steam

w
Cylinder
W

W Super.
iheated
Piston Dry Steam VSup
Wet : Saturatd | Va
Steam $team
EWater E:Water
t, EWater:
() (i) (iv) (v)
= Saturation temp.
V, =Volume of water
tSuD = Temperature of superheated steam
V, = Volume of dry and saturated steam
Vsuo = Volume of superheated steam

Fig. 2.1: Formation of Steam

 Emerging Trends in Mechanical Engineering 2.3 Process Engineering
Critical Lings of
point Constant
pressure
Liquid
Region
Temperature
Saturated Saturated
liquid line Two phase region vapour line

B
Superheat
region

-he
Fig. 2.2: Steam Phase Diagram
As water is heated from 0°C to its saturation temperature, its condition follows the saturated liquid line
until it has received all of its liquid enthalpy, h, (A - B) this phase of heat is call sensible heat.
Continuously adding heat the temperature remains constant, where the phase changes to saturated
steam and there continues increase in enthalpy, h (B - C).
The condition moves from the saturated liquid line to the saturated vapour line, as the steam/water
mixture increases in dryness, the point is mid-point of B-Cthat means the dryness fraction is 0.5 (50%),
when the point moves toward C side the dryness increases and when it move towards B side the dryness
decreases. When point reaches to saturated vapour line the steam attains 100% dryness.
When it reaches the saturated vapour line, the steam receives all of its enthalpy of evaporation. On
continuously heating after this point, the temperature of the steam willbegin to rise as superheat (C-D).
The region to the left of the saturated liquid ine only water exists, and in the region to the right of the
saturated vapour line only superheated steam exists and the region in between or enclose by saturated
liquid and saturated vapour lines in which a steam/water mixture exists - wet steam.
The point at which the saturated liquid and saturated vapour lines meet known as the critical point. As
the pressure increases towards the critical point the enthalpy of evaporation decreases, until it becomes
zero at the critical point. This suggests that water changes directly into saturated steam at the critical point.
Above the critical point only gas may exist. The gaseous state is the most diffuse state in which the
molecules have an almost unrestricted motion, and the volume increases without limit as the pressure is
reduced.
Condensate loop in process industry:
Steam distribution system
The steam distribution system is the essential link between the steam generator and the steam user.
Whatever the source, an efficient steam distribution system is essential if steam of the right quality and
pressure is to be supplied, in the right quantity, to the steam using equipment. Installation and maintenance
of the steam system are important issues, and must be considered at the design stage.
 Emerging Trends in Mechanical Engineering 2.4 Process Engineering
Space
heating
Steam Steam systen
Pan Pan
Condensate
Process
$9 vessel
Steam Condernsate
Condensate

ueers Make-up
water
Feedtank Condensate
Feedpump

Fig. 2.3: Steam Distribution System

Small
As steam condenses in a process, flow is induced in the supply pipe. Condensate has a very
volume compared to the steam, and this causes a pressure drop, which causes the steam to tiow through
the pipes. The steam generated in the boiler must be conveyed through pipe work to the point where its
heat energy is required. Initially there will be one or more main pipes, or 'steam mains', which carry steam
from the boiler in the general direction of the steam using plant. Smaller branch pipes can then carry the
steam to the individual pieces of equipment. Atypical steam distribution system is shown in Fig. 2.3. It must
be noted that pressure reducing valves (PRV) are used to reduce the pressure of steam as per the
requirement of process device.
The distribution pressure of steam is influenced by a number of factors, but is limited by:
The maximum safe working pressure of the boiler.
The minimum pressure required at the plant.
As steam passes through the distribution pipework, it will lose pressure due to:
Frictional resistance within the pipework.
Condensation within the pipework as heat is transferred to the environment.
Steam Traps
The purpose of installing the steam traps is to obtain fast heating of the product and equipment by
keeping the steam lines and equipment free of condensate, air and non-condensable gases. Asteam trapis
avalve device that discharges condensate and air from the line or piece of equipment without discharging
the steam.
Functions of Steam Traps
The three important functions of steam traps are:
To discharge condensate as soon as it is formed.
Not to allow steam to escape.
To be capable of discharging air and other incondensable gases.
Types of Steam Traps
There are three basic types of steam trap into which all variations fall, all three are classified Dy
International Standard ISO6704:1982.
 Emerging Trends in Mechanical Engineering 2.5 Process Engineering
Thermostatic (operated by changes in fluid temperature)
The temperature of saturated steam is determined by its pressure. In the steam space, steam gives up its
enthalpy of evaporation (heat)., producing condensate at steam temperature. As a result of any further heat
loss, the temperature of the condensate will fall. A thermostatic trap will pass condensate when this lower
temperature is sensed. As steam reaches the trap, the temperature increases and the trap closes.
Mechanical (operated by changes in fluid density)
This range of steam traps operates by sensing the difference in density between steam and condensate.
These steam traps include' ball float traps' and '"inverted bucket traps. In the 'ball float trap', the ball rises in
the presence of condensate, opening avalve which passes the denser condensate. With the 'inverted bucket
trap', the inverted bucket floats when steam reaches the trap and rises to shut the valve. Both are essentially
'mechanical' in their method of operation.
Thermodynamic (operated by changes in fluid dynamics)
Thermodynamic steam traps rely partly on the formation of flash steam from condensate. This group
includes 'thermodynamic', 'disc, impulse' and 'labyrinth' steam traps.
Condensate Discharge
Inverted bucket and thermodynamic disc traps should have intermittent condensate discharge. Float
and thermostatic traps should have a continuous condensate discharge. Thermostatic traps can have either
continuous or intermittent discharge depending upon the load. If inverted bucket traps are used for
extremely smallload, it will have a continuous condensate discharge.
Flash Steam
Flash steam isa name given to the steam formed from hot condensate when the pressure is reduced.
Flash steam is produced when high pressure condensate is discharged to a lower pressure.
This shall not be mistaken for a steam leak through the trap. The users sometimes get confused
between a flash steam and leaking steam. The flash steam and the leaking steam can be approximately
identified as follows:
If steam blows out continuously in a blue stream, it is a leaking steam.
If a steam floats out intermittently in a whitish cloud, it is a flash steam.
2.2 INTRODUCTION TO ULTRA SUPERCRITICALBOILERS
Depending upon the steam pressure boilers are classified as sub-critical, supercritical and
ultra-supercritical boilers. Boilers operating with steanm pressure below 221 bars are called sub-critical
boilers. Supercritical boilers have pressure above 221 bar and superheated temperature upto 593°C.
whereas steam pressure about 225 bar and superheated temperature more than 593°C are usually called
ultra-supercritical boiler. The ultra-supercritical boiler have maximum temperature and pressure range
among all boilers. The power plant efficiency in the range of 38% to 42% for sub-critical, 42% to 469% in
supercritical boiler and 46% to 48% in an ultra-supercritical boiler. It is possible to use high temperature
steam up 620o Cdue to the development of chromium and nickel based super alloy material. The world's
first supercritical boiler Philo power plant of USA 125. MW was commissioned as early as 1957. Large
supercritical unit of 1000 MWcapacity are in operation in Japan and USA since 1970.
Most of the supercritical and ultra-supercritical boiler are operating on Pulverized coal (PC) technology
some boiler also available on circulating fluidized bed combustion(CFBC) technology world largest and first
once through supercritical circulating fluidized bed combustion (CFBC) boiler of 460 MW capacity designed
and executed by forster wheeler in USA Since 2009.ultra-supercritical boiler are in operation in Japan
Germany Denmark and China number of 1000MW ultra-supercritical boiler with steam parameter of 260 bar
600°C pressure and temperature with tendem compounding 4casing, 4f low type turbine are operating in
China.
Emerging Trends in MechanicalEngineering 2.6 Process Engineerin.
Benefit of supercritical and ultra-supercritical (USC) power plant are:
Less fuel consumption,
Highest power plant efficiency,
-650°C
Less CO, emission, Temperature+
Flush Ultra
point, Super-critical
Better availability, Boiler
Flush 593°C
Less NO, SO, and particular emissions, poini Ultra
Large unit size possibility.
Critical
point,
Super-critical
Boller 560'c.
Critical
boiler
1. Sub-critical:
Evaporalure\Superheater
Pressure: 221.1 bar LH. I SH
Temperature: 538/538°C or 538/560°C
E-commiser Enthalpy>
2. Supercritical:
Pressure: 221.1 bar to 260 bar
Fig. 2.4
Temperature: 538/560°C to 566/593°C
3. Ultra-Supercritical (USC)
Pressure: 260 bar

Temperature: 593/593°C to 600/620°C

Table 2.1: Sub-criticalVs. SupercriticalVs. Ultra Supercritical Boilers
Description Unit Subcritical Supercritical Ultra Reduction Reduction
16.7 Mpa 24.1 Mpa Supercritical Sub Vs SC Sub Vs USC
5.38/5.38 566/593 24.1 Mpa
deg. C deg. C 600/600
deg. C
Turbine heat kCal./kWh 1918 1838 1814 80(4.2%) 104(5.5%)
rate

Boiler % 87% 87% 87%

efficiency
Plant heat kCal./kWh 2207 2113 2085 94(4.2%) 121(5.5%)
rate

Coal MMT/Annum 3.676 3.524 3.477 0.152(4.29%) 0.199%.5%)

consumption
Ash MMT/Annum 1.544 1,48 1.46 0.064(4.29%) .084(5.5%)
generation

MMT/Annum 7.278 6.981 6.888 0.39(5.5%)

0.297(4.2%)
SO, MMT/Annum 0.0230 0.0221 0.0218 0.0009(4.2%) 0.0012(5.59%)
Emerging Trends in Mechanical Engineering 2.7 Process Engineering
2.3 HYPERBOLIC COOLING TOWER
Wet Cooling Tower
Natural Draft

Air Outlet

Drift eliminators
Hot Water
Water distribution
Nozzles

-Cooling fil
Air suction
Air suction

Cold water
-Cold water basin
Fig. 2.5
Hyperboloid (sometimes known as hyperbolic) cooling towers have become the design standard for all
natural-draft cooling towers.
It is defined as density difference between the atmospheric air and the hot gas in the chimney.
Purpose of a cooling tower is to reduce the temperature of circulating hot water to reuse this water
again into the boiler, this hot water is coming from the condenser.
The shape is like hyperbolic so it is called hyperbolic cooling tower.
The hyperbolic shape also aids in accelerating the upward convective air flow, improving cooling
efficiency.
Working:
Hot water is coming at the inlet of the tower and pumped-up to the header. The header contains
nozles and sprinklers which is used to spray water, and it will increase the surface area of water, after that
water comes to cooling fillwhere the speed of water is reduced. Because of slow speed and more contact
area of water, it makes a good connection between air and hot water. The air moves from bottom to the
top due to density difference. The process will reduce the temperature of water by evaporation process and
cooled water is collected at the bottom of the cooling tower, and this cooled water is used again in the
boiler.
APPROACH = Cold water temperature - Wet bulb temperature
RANGE = Hot water temperature - Cold water temperature
COOING TOWER EFFICIENCY Range
(Range + Approach) x 100
Effectiveness: This is the ratio between the range and the ideal range (in percentage), ie. difference
between cooling water inlet temperature and ambient wet bulb temperature.
ange
Effectiveness = (Range + Approach)
The higher this ratio, the higher the cooling tower effectivenes.
Emerging Trends in Mechanical Engineering 2.8
Process Engineerlng
List of Commerciality Viable Waste Heat Recovery Devices:
1. Waste heat recovery boilers.
2. Recuperators.
(a) Metallic radiation
recuperators.
(b) Radiative recuperator.
(c) Convective Radiative Recuperator.
(d) Ceramic recuperators.
3. Regenerators.
4. Hot Wheel Exchanger.
5. Thermal Wheel.
6. Economizer.
(a) Shell and tube heat exchanger.
(b) Plate heat exchanger.
7. Heat Pump.
8. Heat Pipe.
9. Thermo-Compressor.
10. Direct contact heat Exchanger.
(a) Hot-Hot Mixing.
(b) Different Phase Mixing.
(c) Hot Cold Mixing.
2.4 WASTE HEAT RECoVERY IN PROCESS INDUSTRIES
In Power generation and process industries continuous produce large amounts of hot waste gases and
then "dumped" into the environment even though it could still be reused for some useful and economic
purpose. These waste gases have been practiced for a long time form Generation of steam or power. The
waste gases temperature can be at high, medium, or low at ~1100, 500, or 300°C, respectively. The gases
meaningful calorific values (CV) are burnt with or without an additional support fuel. Several waste gases
produced at high temperatures or in large volumes that contain considerable heat but no combustible fuel
only need to be cooled (and at times cleaned) before release into the atmosphere.
Waste heat boilers:
The devices that cool the gases and produce steam are generally called waste heat boilers. The
supplementary fuel may or may not be required.
The two types are:
1. Heat recovery steam generators (HRSGs) in power plants.
Gas turbines (GTs) exhaust large amounts of clean, medium hot gases used in boilers, usualy
called HRSGs or turbine exhaust gas (TEG) boilers.
2. Waste heat recovery boilers (WHRBS) in process industries.
In metallurgical, cement, and similar plants, large amounts of dusty hot gases generated ae
cleaned and cooled, steam is produced in boilers generally known as Waste heat recove)
boilers (WHREs) in process industries.
Waste heat recovery boilers (WHRBs) in process industries are bulky and expensive.
The cost of steam and power generated is higher.
 Emerging Trends in Mechanical Engineering 2.9 Process Engineering

To satisfy the condition of a waste heat system the following conditions are met:
1 The cost of the regular fuels is high and hence the high-cost power and steam from waste heat
boilers are acceptable.
2. The process demands its inclusion.
Waste Heat Recovery Boilers (WHRB):
Waste heat boilers are ordinary water tube boilers in which the hot gases from gas turbines pass over a
number of parallel tubes containing water. The water is vaporized in the tubes and collected in the steam
drum from which it is drawn off for use as heating or processing steam.
Because the exhaust gas are usually in the medium temperature range and in order to to conserve
space, a more compact boiler can be produced if the water tubes are finned in order to increase the
effective heat transfer area on the gas side the figure shows a mud drum set off tubes over which the hot
gases make a double pass, and a steam drum which collects team generated above the water surface the
pressure at which the steam isgenerated and the rate of steam production depends on the the temperature
of of waste heat the pressure of a pure vapour inthe presence of it's liquidis a function of the temperature
of the liquid from which it is evaporated.
If the waste heat it in the exhaust gases is insufficient for generating the required amount of process
steam, auxiliary Burners which burn fuel in the waste heat boiler or an after-burner in the exhaust flue gases
are added. waste heat boilers build in capacities from 25 m' almost 30000 m'/min of exhaust gas. Waste
heat boilers are available in a variety of capacitors allowing for gas Intex from 1000 to 1 million ft 3/min.
Water tube boilers that use medium to high temperature exhaust gases to generate steam in case where
the waste heat is not sufficient for producing desire levels of steam auxiliary burners for an afterburner can
be added to attain higher steam output the steam can be used for process heatingor for power generation.
Process
Generator Wasa Steam out Cooled Waste
Gas Out
W
Wsroe
Weart Stack Feedwater In

VFed

Economiízer
Evaporalor
Superheater
Burner
‘Hot Exhaust
|Gas In

Fig. 2.6: Waste Heat Recovery Boilers (WHRB)

Recuperators:
The recuperator is a heat exchange device that takes place between the flue gases and the air through
metallic or ceramic walls. Duct or tubes carry the air for combustion to be pre-heated, the other side
contains the waste heat stream. A recuperator is used for recovering waste heat from flue gases.
Types of Recuperator:
(a) Metallicradiation recuperators.
(b) Radiative recuperator.
Emerging Trends in Mechanical Engineering 2.10
Process Engineerlne
(c) Convective Radiative Recuperator.
(d) Ceramic recuperators.
Gases Air
Inlet air from atmosphere Outlet Outlet

Exhaust gas from Air

process Inlet

Outside ducting Centre tube plate

Preheated air Gases
Tube plate Inlet

(a) Waste Heat Recovery using Recuperator (b) Metallic Radiation Recuperator
Fig. 2.7
Cooled Waste Gas Cooled Heated
Waste Gas Fluid

Hot Air to
hogpes Process

aupauog

uopes
Cold Air Hot Cool
UCaere! Inlet Waste Fluid
Gas

(c) Convective Radiative Recuperator (d) Convective Recuperator

Fig. 2.8
Regenerator
The Regeneration which is preferable for large capacities has been widely used in glass and steel
melting furnaces. Important relations exist between the size of the regenerator, thickness of bric.
conductivity of brick and heat storage ratio of the brick.

Gas

Chimney)

Air
Regererator Gas Air
Regenerator
Fig. 2.9: Regenerator
 Emerging Trends in Mecharical Engineering 211 Prcs ngineering
Hot Wheel Exchanger.
Atherme whee as0 known s a rotary hea erchzrce or rozrya - a etraioy wee. or re
recovery wheel. is atype of energy recovery hezt excharger posiores wthin the Supo'y ac h a s i
streams of an air-handling system or in the ethaus a2ses of an índustial process Anezt whee sagroag
applications in low to medium tenperature waste heat recovery sfstems

ErrasAr

Dreton o.
Rtatior Erras Ar Dicro
Fig. 2.10: Hot Wheel Exchanger
Heat Pipe
The heat pipe is a therml energy absorbing and transferring system. In heat pipe there is no moving
parts and hence it requires minimum maintenance. Aheat pipe can transfer up to100 times more thermal
energy than copper, the best known conductor.
Vaporised fiuid Heat
Cordenses and
in
grves up heat

Vapour

Heat
Metal mesh wick acts Heat evaporates
as return path for liquid working fluid
working fluid
Fig. 2.11: Heat Pipe
Economizer Pressure
gauge Safety valve
Economizers are mechanical devices
intended to reduce energy Water to
Top header
boiler
consumption, or to perform useful
function such as preheating a fluid. The Scrapers
term economizer is used for other
purposes as well. Boiler, power plant,
heating, refrigeration, ventilating, and
Flue gases
H Flue gases
air conditioning In case of boiler system, in out
economizer can be provided to utilize
the flue gas for preheating the boiler
feed water.
For every 22°C reduction in flue gas
Water
temperature through an economiser or Bottom header from
apreheater, there is 1% saving of fuel in feed pump
the boile.
Fig. 2.12: Economiser
Emerging Trends in Mechanical Engineering 2.12
Process Engineerine
Shell and Tube Heat Exchanger:
Ashell and tube heat exchanger is the most common type of heat exchanger in oil refineries
andother
large chemical processes, and is suited for higher-pressure applications. As its name implies this
heat exchanger consists of a shell with a bundle of tubes inside it. The medium containing waste type o
heat
liquid or a vapour which heats another liquid, then the shell and tube heat exchanger must be used siisa
both paths should be sealed to contain the pressures of their respective fluids.
Process Tube Nest
Fluid Out End Head

Geothermal
Fluid In

Geothermal
Fluid Out

Tube Piate
Baffles
Sheil Process
Fluid In

Fig. 2.13: Shell and Tube Heat Exchanger

Plate Heat Exchanger
Flow Pattern in
A plate heat exchanger uses metal plates to transfer heat Series of Plates
between two fluids. This is a major advantage over a conventional Heating
heat exchanger that, the fluids are exposed to much larger surface medium

area because the fluids are spread out over the plates. the plate Product
type heat exchanger, consists of a series of separate parallel plates
forming thin flow passes.Each plate is separated by gaskets and the
hot stream passes parallelly through alternative plates, the liquid
which is to be heated flows in parallel between the hot plates. To
improve heat transfer the plates are corrugated. Fig. 2.14: Plate heat exchanger
Thermocompressor :
The thermocompressor is a device which converts low pressure steam toa very high pressure steam and
reuses it as a medium pressure steam, where high pressure HP steam is accelerated into a high velocity fluid
through a nozzle. The large amount of steam energy is in the form of latent heat and thus thermo
compressing would give a large improvement in waste heat recovery. It is used in evaporators where the
boiling steam is recompressed and used as heating steam.

Motive Discharge
Steam E Steam
H.P. M.P.

Suction Steam L.P.

Fig. 2.15: Thermocompressor

Emerging Trends in Mechanical Engineering 2.13 Process Engineering
Direct Contact Heat Exchanger:
In Direct Contact Heat Exchanger Lowpressure steamis used to preheat the feed water or some other
fuid. Direct Contact Heat Exchanger use in a steam generating station.
Ven

Cold
Water
in

L.P.

Hot

Fig. 2.16: Direct Contact Condenser

Multiple Choice Questions
1. Latent heat of steam at lower pressure is lower
(a) True (b) False
2. The heat which is required to change the phase from water at 100°C to saturated steam is
called
(a) Latent Heat (b) Sensible Heat (c) Super Heat (d) Specific Heat
3. Ideal trap for steam mains is ..
(a) Thermodynamic (b) float (c) inverted bucket (d) bimetallic
4. The best quality of steam for industrial process heating is ......
(a) Dry saturated (b) Super-heated (c) Wet Steam (d) High pressure steam
5. Cooling tower effectiveness is the ratio of ....
(a) Range/(Range + Approach) (b) Range/Approach
(c) Approach/(Range + Approach) (d) Approach/Range
6. Cooling tower reduces the water temperature close to
(a) Dry bulb temperature (b) Dew point temperature
(c) Ambient wet bulb temperature (d) None of the above
7. Which type of cooling towers with maximum heat transfer between air to water is
(a) Natural draft (b) Mechanical draft (c) Both (a) and (b) (d) None of the above
8. LG ratio in a cooling tower is the ratio of
(a) Length and girth (b) Length and temperature gradient
(c) Water flow rate and their mass flow rate (d) Air mass flowrate and water flow rate
9. Generally which Type of the steam use in process industries
(a) Dry saturated (b) Super-heated (c) Wet Steam (d) High pressure steam
Emerging Trends in Mechanical Engineering 2.14 Process Engineering
10. Steam Temperature of ultra-supercritical boiler (USC) in °C (d) 330
(a) 520 (b) 620 (c) S60
11. What is the working pressure of ultra-supercritical boiler in bar?
(d) None of the above
(a) More than 260 bar (b) Less than 260 bar (c) Both (a) and (b)
12. What does WHRB stands for?
(a) Waste heat recovery boiler. (b) World heat recovery boiler.
(c) Waste harvest recovery boiler. (d) All of the above.
13. What is the efficiency of ultra-supercritical boiler?
(a) 38 to 42% (b) 42 to 46% (c) 46 to 48% (d) None of the above
14. Which of the following are not waste heat recovery device?
(a) Direct contact heat exchanger. (b) Economizer.
(c) Radiator. (d) Thermo compressor.
15. Which of the following is not the type of recuperator?
(a) Metallic radiation (b) Radiative (c) Ceramic (d) Shell and tube type
16. Major advantage of waste heat recovery in industry is
(a) Reduction in pollution. (b) Increase in efficiency.
(c) Both (a) and (b). (d) None of the above.
17. Identify the Process Bto C in the Fig. 2.15.
Critical point
Lines of
Constant
Sub-saturated pressure
Temperature
water D
S a t u r a t e d

w a l e r

Super-head
streanm

Fig. 2.17
(a) Sensible heat (b) Latent heat (c) Both (a) and (b) (d) None of the above
18. Recuperator is used mainly as waste heat recovery system in a
(a) Boiler (b) Compressor
(c) Billet reheating furnace (d) None of the above
19. Heat recovery equipment will be the most effective when the temperature of flue gas is
(a) 250°C (b) 200°C (C) 400°C (d) 280°C
20. Air preheater is not used as waste heat recovery system in a
(a) Boiler (b) Billet reheating furnace
(c) Compressor (d) Heat treatment furnace
Answers
1 2 4 6 9 10
Question No. 7

Answer (b) (a) (a) (a) (a) (c) (b) (c) (a) (b)
Question No. 11 12 13 14 15 16 18 19 20
17
(a) (a) (c) (c)
Answer (c) (d) (c) (b) (a)