Performance degradation analysis of a medium pressure superheater due to tube deactivation

Steam is essential in petrochemical industries for the transportation of thermal energy and usage some reforming process. Superheaters are heat exchangers that convert saturated steam to dry by utilizing waste from flue gas stream. Medium pressure superheaters prone tube deterioration due service at elevated temperatures erosion presence liquid phase steam, leading plugging after failure. This reduces overall surface heating area superheater. Relations between practice dynamics important engineers identify responses superheater operation planning, this issue has not been extensively explored academically. article analyses performance reduction based on operational data a generation line. The objective find relations effect states both streams, as well its impact exchange. operating conditions two separate years, before (year 2014) 2017) plugging, were compared through first law analysis. average inlet 248 °C 250 °C, flow rates 70 90 ton/hour. analysis indicated 0.3 0.8 % increase required every plugged compensate surface. At 3 area, exchanger effectiveness decreases an 11 also leads lower temperature output approximately 6% design temperature. These results would assist analyse changes economics whole plant decide feasibility replacing existing with new ones. Also, another significant finding be considered current increasing rate does offset loss plugging.