Superheated Steam: Block 2 Steam Engineering Principles and Heat Transfer
Superheated Steam: Block 2 Steam Engineering Principles and Heat Transfer
3
SC-GCM-07 CM Issue 2 © Copyright 2005 Spirax-Sarco Limited
Module 2.3
Superheated Steam
Superheated Steam
If the saturated steam produced in a boiler is exposed to a surface with a higher temperature, its
temperature will increase above the evaporating temperature.
The steam is then described as superheated by the number of temperature degrees through which
it has been heated above saturation temperature.
Superheat cannot be imparted to the steam whilst it is still in the presence of water, as any additional
heat simply evaporates more water. The saturated steam must be passed through an additional
heat exchanger. This may be a second heat exchange stage in the boiler, or a separate superheater
unit. The primary heating medium may be either the hot flue gas from the boiler, or may be
separately fired.
Superheated steam has its applications in, for Steam in
Turbine blade
example, turbines where the steam is directed
by nozzles onto a rotor. This causes the rotor to
turn. The energy to make this happen can only Force
have come from the steam, so logically the steam
has less energy after it has gone through the
turbine rotor. If the steam was at saturation
temperature, this loss of energy would cause Steam out
some of the steam to condense. Fig. 2.3.1 Steam and force on a turbine blade
Turbines have a number of stages; the exhaust steam from the first rotor will be directed to a second
rotor on the same shaft. This means that saturated steam would get wetter and wetter as it went
through the successive stages. Not only would this promote waterhammer, but the water particles
would cause severe erosion within the turbine. The solution is to supply the turbine with superheated
steam at the inlet, and use the energy in the superheated portion to drive the rotor until the
temperature/pressure conditions are close to saturation; and then exhaust the steam.
Another very important reason for using superheated steam in turbines is to improve thermal efficiency.
The thermodynamic efficiency of a heat engine such as a turbine, may be determined using one
of two theories:
o The Carnot cycle, where the change in temperature of the steam between the inlet and outlet
is compared to the inlet temperature.
o The Rankine cycle, where the change in heat energy of the steam between the inlet and outlet
is compared to the total energy taken from the steam.
Example 2.3.1
A turbine is supplied with superheated steam at 90 bar a /450°C.
The exhaust is at 0.06 bar a (partial vacuum) and 10% wet.
Saturated temperature = 36.2°C.
Note: The values used for the temperature and energy content in the following examples are from
steam tables.
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Example 2.3.2
How much more heat does superheated steam with a temperature of 400°C and a pressure of
1.013 bar a (0 bar g) have than saturated steam at the same pressure?
hg for saturated steam at 1.013 bar a = 2 676 kJ /kg (from saturated steam tables)
hg for steam at 1.013 bar a and 400°C = 3 278 kJ /kg (from superheated steam tables)
Enthalpy in the superheat = 3 278 kJ /kg - 2 676 kJ /kg
Enthalpy in the superheat = 602 kJ /kg
This may sound a useful increase in energy, but in fact it will actually make life more difficult for
the engineer who wants to use steam for heating purposes.
From the energy in the superheat shown, the specific heat capacity can be determined by dividing
this value by the temperature difference between saturation temperature (100°C) and the
superheated steam temperature (400°C):
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However, unlike the specific heat capacity of water, the specific heat capacity for superheated
steam varies considerably with pressure and temperature and cannot be taken as a constant.
The value of 2.0 kJ /kg °C given above is therefore only the mean specific heat capacity over the
specified temperature range for that pressure.
There is no direct relationship between temperature, pressure and the specific heat capacity of
superheated steam. There is, however, a general trend towards an increase in specific heat capacity
with increasing pressure at low degrees of superheat, but this is not always the case.
Typical value range: 2.0 kJ /kg °C at 125°C and 1.013 bar a (0 bar g)
3.5 kJ /kg °C at 400°C and 120 bar a.
Can superheated steam be used in process heat exchangers and other heating processes?
Although not the ideal medium for transferring heat, superheated steam is sometimes used for
process heating in many steam plants around the world, especially in the HPIs (Hydrocarbon
Processing Industries) which produce oils and petrochemicals. This is more likely to be because
superheated steam is already available on site for power generation, being the preferred energy
source for turbines, rather than because it has any advantage over saturated steam for heating
purposes. To be clear on this point, in most cases, saturated steam should be used for heat
transfer processes, even if it means desuperheating the steam to do so. HPIs often desuperheat
steam to within about ten degrees of superheat. This small degree of superheat is removed readily
in the first part of the heating surface. Greater amounts of superheat are more difficult, and often
uneconomic to deal with and (for heating purposes) are best avoided.
There are quite a few reasons why superheated steam is not as suitable for process heating as
saturated steam:
Superheated steam has to cool to saturation temperature before it can condense to release its
latent heat (enthalpy of evaporation). The amount of heat given up by the superheated steam as
it cools to saturation temperature is relatively small in comparison to its enthalpy of evaporation.
If the steam has only a few degrees of superheat, this small amount of heat is quickly given up
before it condenses. However, if the steam has a large degree of superheat, it may take a relatively
long time to cool, during which time the steam is releasing very little energy.
Unlike saturated steam, the temperature of superheated steam is not uniform. Superheated steam
has to cool to give up heat, whilst saturated steam changes phase. This means that temperature
gradients over the heat transfer surface may occur with superheated steam.
In a heat exchanger, use of superheated steam can lead to the formation of a dry wall boiling
zone, close to the tube sheet. This dry wall area can quickly become scaled or fouled, and the
resulting high temperature of the tube wall may cause tube failure.
This clearly shows that in heat transfer applications, steam with a large degree of superheat is of
little use because it:
o Gives up little heat until it has cooled to saturation temperature.
o Creates temperature gradients over the heat transfer surface as it cools to saturation temperature.
o Provides lower rates of heat transfer whilst the steam is superheated.
o Requires larger heat transfer areas.
So, superheated steam is not as effective as saturated steam for heat transfer applications. This
may seem strange, considering that the rate of heat transfer across a heating surface is directly
proportional to the temperature difference across it. If superheated steam has a higher temperature
than saturated steam at the same pressure, surely superheated steam should be able to impart
more heat? The answer to this is no. This will now be looked at in more detail.
It is true that the temperature difference will have an effect on the rate of heat transfer across the
heat transfer surface, as clearly shown by Equation 2.5.3.
Where:
Q = Heat transferred per unit time (W)
U = Overall thermal transmittance (heat transfer coefficient) (W/m2 °C)
A = Heat transfer area (m2)
DT = Temperature difference between primary and secondary fluid (°C)
Equation 2.5.3 also shows that heat transfer will depend on the overall heat transfer coefficient
U, and the heat transfer area A.
For any single application, the heat transfer area might be fixed. However, the same cannot be
said of the U value; and this is the major difference between saturated and superheated steam.
The overall U value for superheated steam will vary throughout the process, but will always be
much lower than that for saturated steam. It is difficult to predict U values for superheated
steam, as these will depend upon many factors, but generally, the higher the degree of superheat,
the lower the U value.
Typically, for a horizontal steam coil surrounded with water, U values might be as low as 50
to 100 W/m2 °C for superheated steam but 1 200 W/m2 °C for saturated steam, as depicted
in Figure 2.3.2.
For steam to oil applications, the U values might be considerably less, perhaps as low
as 20 W/m2 °C for superheated steam and 150 W/m2 °C for saturated steam.
In a shell and tube heat exchanger, 100 W/m2 °C for superheated steam and 500 W/m2 °C for
saturated steam can be expected. These figures are typical; actual figures will vary due to other
design and operational considerations.
Superheated
steam IN
50 W/m2 °C
Saturated
steam IN
Steam coil surrounded in water
1200 W/m2 °C
Superheated steam OUT
Steam coil surrounded in water
Steam trap
Condensate OUT
Figure 2.3.2 Typical U values for superheated and saturated steam coils in water
Although the temperature of superheated steam is always higher than saturated steam at the
same pressure, its ability to transfer heat is therefore much lower. The overall effect is that
superheated steam is much less effective at transferring heat than saturated steam at the same
pressure. The next Section Fouling gives more detail.
Not only is superheated steam less effective at transferring heat, it is very difficult to quantify
using Equation 2.5.3, Q = U A DT, as the temperature of the steam will fall as it gives up its heat
while passing along the heating surface.
Predicting the size of heat transfer surfaces utilising superheated steam is difficult and complex.
In practice, the basic data needed to perform such calculations is either not known or empirically
obtained, putting their reliability and accuracy in doubt.
Clearly, as superheated steam is less effective at transferring heat than saturated steam, then any
heating area using superheated steam would have to be larger than a saturated steam coil operating
at the same pressure to deliver the same heat flowrate.
If there is no choice but to use superheated steam, it is not possible to maintain steam in its
superheated state throughout the heating coil or heat exchanger, since as it gives up some of its
heat content to the secondary fluid, it cools towards saturation temperature. The amount of heat
above saturation is quite small compared with the large amount available as condensation occurs.
The steam should reach saturation relatively soon in the process; this allows the steam to condense
to produce higher heat transfer rates and result in a higher overall U value for the whole coil, see
Figure 2.3.3.
To help to enable this, superheated steam used for heat transfer purposes should not hold more
than about 10°C of superheat.
Superheated steam IN
Steam coil surrounded in water 1 200 W/m2 °C
Steam trap
Overall U value typically 90% of the saturated value
Condensate OUT
Figure 2.3.3 Less superheat allows the steam to condense in the major part of the coil thus increasing the
overall U value approaching that of saturated steam.
If this is so, it is relatively easy and practical to design a heat exchanger or a coil with a heating
surface area based upon saturated steam at the same pressure, by adding on a certain amount of
surface area to allow for the superheat. Using this guideline, the first part of a coil will be used
purely to reduce the temperature of superheated steam to its saturation point. The rest of the coil
will then be able to take advantage of the higher heat transfer ability of the saturated steam. The
effect is that the overall U value may not be much less than if saturated steam were supplied to
the coil.
From practical experience, if the extra heating area needed for superheated steam is 1%
per 2°C of superheat, the coil (or heat exchanger) will be large enough. This seems to work up
to 10°C of superheat. It is not recommended that superheated steam above 10°C of superheat
be used for heating purposes due to the probable disproportionate and uneconomic size of the
heating surface, the propensity for fouling by dirt, and the possibility of product spoilage by the
high and uneven superheat temperatures.
Fouling
Fouling is caused by deposits building up on the heat transfer surface adding a resistance to
heat flow. Many process liquids can deposit sludge or scale on heating surfaces, and will do so
at a faster rate at higher temperatures. Further, superheated steam is a dry gas. Heat flowing
from the steam to the metal wall must pass through the static films adhering to the wall, which
resist heat flow.
By contrast, the condensation of saturated steam causes the movement of steam towards the
wall, and the release of large quantities of latent heat right at the condensing surface. The
combination of these factors means that the overall heat transfer rates are much lower where
superheated steam is present, even though the temperature difference between the steam and
the secondary fluid is higher.
Example 2.3.3 Sizing a tube bundle for superheated steam
Superheated steam at 3 bar g with 10°C of superheat (154°C) is to be used as the primary heat
source for a shell and tube process heat exchanger with a heating load of 250 kW, heating an oil
based fluid from 80°C to 120°C (making the arithmetic mean secondary temperature (DTAM)
100°C). Estimate the area of primary steam coil required.
(Arithmetic mean temperature differences are used to keep this calculation simple; in practice,
logarithmic mean temperatures would be used for greater accuracy. Please refer to Module 2.5
Heat Transfer for details on arithmetic and logarithmic mean temperature differences).
First, consider the coil if it were heated by saturated steam at 3 bar g (144°C).
The U value for saturated steam heating oil via a new carbon steel coil is taken to be 500 W/m2 °C.
For supply steam below 30 bar g in the dry saturated state, any drop in pressure will produce
superheated steam after throttling. The degree of superheat will depend on the amount of pressure
reduction.
For supply steam above 30 bar g in the dry saturated state, the throttled steam might be
superheated, dry saturated, or even wet, depending on the amount of pressure drop.
For example, dry saturated steam at 60 bar g would have to be reduced to approximately
10.5 bar g to produce dry saturated steam. Any less of a pressure drop will produce wet
steam, while any greater pressure drop would produce superheated steam.
Equally, the state of the supply steam at any pressure will influence the state of the throttled
steam. For example, wet steam at a pressure of 10 bar g and 0.95 dryness fraction would need to
be reduced to 0.135 bar g to produce dry saturated steam. Any less of a pressure drop would
produce wet steam while any greater pressure drop would superheat the throttled steam.
Example 2.3.4 Increasing the dryness of wet steam with a control valve
Steam with a dryness fraction (χ) of 0.95 is reduced from 6 bar g to 1 bar g, using a pressure
reducing valve.
Determine the steam conditions after the pressure reducing valve.
This quantity of heat energy is retained by the steam as the pressure is reduced to 1 bar g.
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1 bar g, then the steam is not superheated and still retains a proportion of moisture in its content.
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Since the total enthalpy after the pressure reducing valve is less than the total enthalpy of steam at
1 bar g, the steam is still wet.
10 bar 1 bar
180°C
Pressure
reducing valve
136°C
2 741.7 kJ /kg
The degree of superheat can be determined either by using superheated steam tables, or by using
a Mollier chart.
Figure 2.3.5 shows a simplified, small scale version of the Mollier chart. The Mollier chart displays
many different relationships between enthalpy, entropy, temperature, pressure and dryness fraction.
It may appear to be quite complicated, due to the number of lines:
o Constant enthalpy lines (horizontal).
o Constant entropy lines (vertical).
o The steam saturation curve across the centre of the chart divides it into a superheated steam
region, and a wet steam region. At any point above the saturation curve the steam is superheated,
and at any point below the saturation curve the steam is wet. The saturation curve itself represents
the condition of dry saturated steam at various pressures.
o Constant pressure lines in both regions.
o Constant temperature lines in the superheat region.
o Constant dryness fraction (χ) lines in the wet region.
A perfect expansion, for example within a steam turbine or a steam engine, is a constant entropy
process, and can be represented on the chart by moving vertically downwards from a point
representing the initial condition to a point representing the final condition.
A perfect throttling process, for example across a pressure reducing valve, is a constant enthalpy
process. It can be represented on the chart by moving horizontally from left to right, from a point
representing the initial condition to a point representing the final condition.
Both these processes involve a reduction in pressure, but the difference lies in the way in which
this is achieved.
The two examples shown in Figure 2.3.6 illustrate the advantage of using the chart to analyse
steam processes; they provide a pictorial representation of such processes. However, steam
processes can also be numerically represented by the values provided in the superheated steam
tables.
Enthalpy
Pressure drop P1 P2
h2 P2
Entropy s1 Entropy s2
Fig. 2.3.6 Examples of expansion and throttling
400 bar 200 bar 100 bar 50 bar 20 bar 10 bar 5 bar 2 bar
3 800 650°C
600°C
1 bar
3 600 550°C
500°C
3 400 450°C 0.5 bar
400°C
Specific enthalpy (kJ /kg)
Since the entropy of dry saturated steam at 0.04 bar a (8.473 k J /kg°C) is greater than the
entropy of the superheated steam at 50 bar a /300°C (6.212 k J / kg°C), it follows that some of
the dry saturated steam must have condensed to maintain the constant entropy.
As the entropy remains constant, at the final condition:
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These answers correspond closely with the results obtained using the Mollier chart. The small
difference in value between the two sets of results is to be expected, considering the inaccuracies
involved in reading off a chart such as this.
Questions
4. If steam with a dryness fraction of 0.97 is reduced from 7 bar g to 2 bar g using a
pressure reducing valve, at the final condition it has:
a| A temperature of 170.5°C and a dryness fraction of 0.97 ¨
b| A temperature of 164°C and a dryness fraction of 1 ¨
c| A temperature of 133.7°C and a dryness fraction of 0.99 ¨
d| A temperature of 149.9°C and a dryness fraction of 0.98 ¨
Answers
1: a, 2: b, 3: d, 4: c, 5: b, 6: b