A constructal theory framework for optimizing HRSG design: Enhancing thermal performance and cost-effectiveness
Year: 2025
Type: article
Abstract: This study uses Constructal Theory alongside genetic algorithms to develop a comprehensive optimization framework for selecting Heat Recovery Steam Generator (HRSG) Type in combined cycle power plants. Constructal Theory enables the design of HRSG systems that balance thermodynamic efficiency and capital costs within a fixed volume, addressing space constraints and optimal geometric configurations in industrial applications. The framework applies single- and multi-objective optimization approaches across three HRSG Types connected to five distinct gas turbine models. For each HRSG Type, the optimization considers critical geometric parameters directly influencing thermal efficiency by optimizing surface area, temperature gradients, and gas flow paths within the volume constraint. The results identify the optimal HRSG Type for each turbine: single-pressure for smaller turbines, dual-pressure for mid-sized, and triple-pressure for high-capacity turbines, where each type minimizes exergy destruction and capital costs within the specified volume. Compared to conventional designs, the optimized configurations yield a 5-10% increase in steam production and a 1.5 MW reduction in exergy destruction. These findings underscore the utility of Constructal Theory in determining the optimal HRSG Type and precise geometric design for various gas turbine specifications, resulting in substantial improvements in energy recovery and cost efficiency.
Source: Results in Engineering
Authors: Morteza Mehrgoo, Majid Amidpour
Language: German
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,940
OpenAlex ID: W4411399215