9.1 Introduction
9.2 Types of steam nozzles
9.3 Flow of steam through nozzle
9.4 Discharge through nozzle and critical pressure ratio
9.5 Effect of friction and nozzle efficiency
9.6 Supersaturated flow
9.7 Relation between area, velocity and pressure in nozzle flow
9.8 Characteristics of converging–diverging nozzle
9.9 Steam injector
9.10 Questions
Steam nozzle is an essential device used to generate high kinetic energy. This energy is used for different purposes, namely in injectors to pump feed water into boilers, to maintain vacuum in condensers and also in turbines to run rotors. In steam turbines, the nozzle plays an important role by converting enthalpy of steam into kinetic energy. This chapter deals with steam nozzles and steam injectors. The basic governing equation for nozzles is discussed along with the condition for maximum discharge. The concept of supersaturated flow is also discussed in greater detail.
High-pressure, high-temperature steam from the boiler entering the nozzle expands to low-pressure, low-temperature steam gaining kinetic energy. This high-velocity jet of steam is used to run the turbine. As steam expands in the nozzle its velocity and specific volume both will increase. The dryness fraction will also change due to condensation of steam. As the mass flow rate through the nozzle is constant at any given cross section, the cross section of the nozzle varies according to velocity, specific volume and dryness fraction.
Depending on the cross section of the nozzle, steam nozzles are classified as follows:
1. Convergent nozzle
If the cross section of the nozzle decreases continuously from the entrance to exit, the nozzle is known as convergent nozzle. A convergent nozzle is shown in Figure 9.1(a).
Fig. 9.1 Types of Nozzles
2. Divergent nozzle
If the cross section of the nozzle increases from entrance to exit, such a nozzle is called as divergent nozzle. Figure 9.1(b) shows a divergent nozzle.
3. Convergent divergent nozzle
If the cross section of the nozzle first decreases and then increases, such a nozzle is called as convergent divergent nozzle. The divergent portion of the nozzle increases the pressure ratio beyond the critical value. The area of minimum cross section at which the convergent section ends and divergent section begins is known as throat of the nozzle.
Area of application: It may be noted that in a typical turbine application, converging or subsonic nozzles are generally used. In particular, two available types of nozzles are reamed or foiled type.
Reamed or round nozzles: These nozzles are used in high-pressure impulse stages of steam turbines. These nozzles come with low cost and are characterized by better adaptability to standardization with sharp convergent part and a rounded entrance. However, they possess lower efficiency and underutilize the area of flow annulus. The lengths of the nozzles are often large, the divergence angle being 12°–15°.
Foil nozzles: These nozzles are characterized by aerofoil section with sharp rounded edges and short rounded exit, enabling a better issuing jet. They are costly to manufacture but have higher efficiency. They are used in large steam turbines.
Consider the flow of steam through a convergent nozzle between sections 1 and 2 as shown in Figure 9.2.
Fig. 9.2 Flow Through a Nozzle
Let
h1, h2 = Enthalpy/kg of steam at sections 1 and 2, respectively, kJ/kg
V1, V2 = Velocity of steam at sections 1 and 2, respectively, m/s
w = Work done/kg of steam
q = Heat transferred/kg of steam
Applying steady flow energy equation at sections 1 and 2, we have
(1)
For nozzles, expansion is assumed as isentropic.
Hence, w = 0 and q = 0. This means nozzle is neither a work-absorbing nor a work-generating device.
Equation (1) is now modified to
∴
∴ (2)
The above equation gives exit velocity of steam through the nozzle.
But usually the velocity of steam entering the nozzle is negligible compared with exit velocity.
Hence, ignoring V1 in the above Equation (2), we have
(3)
=
where h1 and h2 are in kJ/kg.
Equation (3) gives the general expression for the exit velocity of steam from the nozzle irrespective of its shape.
Note: Expansion through the nozzle is neither free expansion nor throttling. This is evident from Equation (2). When steam expands through the nozzle, the loss in enthalpy is gained in the form of kinetic energy.
Exit velocity through the nozzle if the expansion is polytropic can be determined as follows:
Let us assume that expansion follows the law pv n = constant, where n = polytropic index
Work done during the flow process, if the expansion is polytropic, is given by
W = (4)
For a nozzle, this work is equal to work done during expansion, which in turn is equal to change in kinetic energy.
∴ = (5)
Ignoring the velocity of steam at entry, Equation (5) modifies to
= (6)
According to polytropic law
or = (7)
Substituting (7) in (6)
=
=
V2 = (8)
Nozzles should always be designed for maximum discharge. Discharge through the nozzle is determined by applying continuity equation.
Let m = Mass flow rate of steam through the nozzle, kg/s
A2 = Cross-section area at the nozzle exit, m2
V2 = Velocity at the nozzle exit, m/s
v2 = Specific volume of steam at nozzle exit, m3/kg
Mass flow rate or discharge through the nozzle is given by
m = (1)
If expansion is polytropic, then exit velocity
V2 =
Substituting rp = pressure ratio = , we have
V2 = (2)
Substituting (2) in (1), we have
m = (3)
But
∴ = =(4)
Substituting (4) in (3)
m =
m = (5)
(i) Optimum pressure ratio or critical pressure ratio
The above equation gives the discharge of steam through a convergent nozzle. It can be observed that discharge through the nozzle mainly depends on the pressure ratio for a given value of n. Thus, for maximum discharge through the nozzle
= 0
or
∴
or =
=
Or
= = rpc(6)
This equation gives the optimum pressure ratio for maximum discharge. It is also known as critical pressure ratio.
Note:
For saturated steam
n = 1.135
∴ rp = = 0.58
For superheated steam
n = 1.3
∴ rp = = 0.546
(ii) Maximum discharge
The maximum mass flow rate from the nozzle occurs at critical pressure ratio.
Substituting Equation (6) in Equation (5), we have
(m)max =
=
=
=
(m)max =
(m)max = (7)
(iii) Maximum velocity
Maximum velocity through the nozzle for maximum discharge can be determined as follows:
Maximum velocity
V2 =
(V2)max =
=
(V2)max = (8)
Figure 9.3 shows the variation of mass flow, rate, steam velocity and specific volume with back pressure for a convergent–divergent nozzle.
Fig. 9.3 Variation of m, V and v with Respect to Back Pressure
When steam expands in the nozzle, steam pressure drops on account of the following reasons:
Due to friction the exit velocity of steam reduces, and both dryness fraction and specific volume increase as evident from Figure 9.4.
Fig. 9.4 Effect of Friction During Flow Through a Nozzle
In Figure 9.4, line 1–2–3 shows isentropic expansion process through a nozzle without friction. But due to friction expansion follows as shown in line 1–2–3′. In case of a convergent–divergent nozzle, maximum friction loss occurs between the throat and exit. Thus
Isentropic enthalpy drop = h1 − h3
Actual enthalpy drop due to friction = h1 − h3′
It is evident that (h1 − h3′) < h1 − h3, which means that there is reduction in enthalpy drop under the influence of friction. Hence, there will be subsequent reduction in exit velocity of steam.
Further, due to friction, the final state of steam is corresponding to point 3′ instead of point 3. But, dryness fraction of steam at 3′ is higher than dryness fraction of steam at 3. Thus, under the influence of friction steam becomes more wet.
Similarly, the specific volume of steam at point 3′ is higher compared with specific volume of steam at 3. Hence, specific volume of steam also increases due to friction.
We can summarize the effect of friction as follows:
Due to friction efficiency of the nozzle is reduced. Nozzle efficiency is given by
ηn =
ηn =
Exit velocity of steam from the nozzle can be modified to
V2 =
where (Δh)i = Isentropic enthalpy drop.
Consider the isentropic expansion of superheated steam in a nozzle from pressure p1 to pressure pb as shown in Figure 9.5 by the line 1–2–3. Under normal condition, condensation of steam must begin at point 2 (vapour phase changes to liquid phase below the saturation curve). But due to the high velocity of steam passing through the nozzle at sonic or supersonic speed, time available for condensation at point 2 is only a fraction of a second (about 0.001 s). Because of this, steam expands further in its vapour phase beyond the saturation curve corresponding to pressure p3 and point 2′ by an amount 2–2′. Thus, steam remains dry even along the line passing through point 2′. This line, which is a limit to the supersaturated state, is known as Wilson line.
Fig. 9.5 Metastable Flow
The vapour between pressures p2 and p3 is said to be supersaturated or super cooled. This is because between points 2 and 2′ corresponding to pressures p2 and p3, respectively, the temperature of vapour is lesser than the corresponding saturation temperature. The difference between these temperatures is known as degree of undercooling and the flow is known as supersaturated flow or metastable flow.
After reaching the Wilson line corresponding to point 2′, partial condensation begins at constant enthalpy along the line 2′–2″. Due to partial condensation of steam, heat is released which further raises the steam temperature to saturation temperature. Further, steam expands isentropically to back pressure along 2″–3′.
For supersaturated flow, the following relations are used for calculation purpose:
V2 =
v2 =
T2 =
Consider flow through a nozzle as shown in Figure 9.6. Let us further consider two sections 1–1 and 2–2 over a small distance δx. Assuming steady, isentropic and uniform flow across any cross section, we have
Fig. 9.6 Variation of Area, Velocity and Volume in a Nozzle
At section 1–1, m =
At section 2–2, m =
where δA, δV and δv are small increments in area, velocity and specific volume between the two sections, respectively.
Using continuity equation,
m = =
On simplifying
= 0
or between the limits
= 0(1)
For an isentropic flow
pvγ = constant = C
∴ lnp + γ lnv = lnC(2)
Differentiating Equation (2) and dividing throughout by pv
= 0
or =
Applying steady flow energy equation between the two sections, we have
δq =
For a nozzle δq = 0 and δw = 0
∴ = 0
But dh = Tds + vdp = vdp (for isentropic flow)
Substituting in the above equation
= −vdp
or VdV = −vdp
or = −
From Equation (1)
=
=
= (3)
where C = = Sonic velocity
M = = Mach number
1. Accelerated flow
For accelerated flow dp is negative in Equation (3), which means pressure decreases along the flow direction (Figure 9.7).
Fig. 9.7 Accelerated Flow (Nozzle)
2. Decelerated flow (diffuser)
For decelerated flow dp is positive in Equation (3), which means pressure increases along the flow direction (Figure 9.8).
Fig. 9.8 Decelerated Flow (Diffuser)
It may be noted that Equation (3) may also be reduced to the following form:
(4)
Note:
Fig. 9.9 Arrangement of Nozzles and Diffusers
Consider a converging–diverging nozzle (De Laval nozzle) as shown in Figure 9.10.
Fig. 9.10 Converging–Diverging Nozzle
Let subscript 0 represent stagnation condition and let us assume that the stagnation enthalpy and pressure at the inlet are known. The pressure at the nozzle exit is pE, back pressure is pB and critical pressure is p*.
Before making the analysis, let us see how pressure distribution occurs in a converging nozzle as shown in Figure 9.11.
Fig. 9.11 Pressure Distribution in a Convergent Nozzle
When the back pressure is varied by operating the valve, the mass flow rate and the exit plane pressure pB/p0 also varies as shown in Figure 9.12.
Fig. 9.12 Variation of Mass Flow Rate and Exit Pressure versus Back Pressure in a Convergent Nozzle
Let us now consider a convergent–divergent nozzle to understand the pressure distribution and the phenomenon of shock as shown in Figure 9.13.
Fig. 9.13 Pressure Distribution in a Convergent– Divergent Nozzle
In case of a convergent–divergent nozzle
The flow is not isentropic between pressures corresponding to curves 3 and 4 in the diverging section. This is due to the phenomenon known as shock where the flow that starts accelerating downstream of the throat suddenly decelerates at a certain section through a nearly normal surface of discontinuity. At supersonic speeds, shocks occur and subsequently flow becomes subsonic; after that the rest of the duct acts like a diffuser. By gradually lowering the exit pressure pE, the position of shock moves down the nozzle and finally disappears at the exit end, when pE reaches a value corresponding to point 4.
Note: When M = 1 at the throat, the discharge is maximum and the nozzle is said to be choked. At this point, the nozzle is incapable of allowing more discharge even if the exhaust pressure is reduced further. Hence, the discharge corresponding to this condition is also known as critical discharge.
A steam injector is a device used to supply feed water at high pressure to the boiler. It works similar to a steam nozzle. Figure 9.14 shows the working of a steam injector. High-pressure steam from the boiler passes through a convergent nozzle. The high-velocity steam coming from the convergent nozzle mixes with the feed water coming from the feed tank in the combined nozzle. The kinetic energy of the mixture is converted into pressure energy in the divergent portion of the combined nozzle. High-pressure water then enters the water nozzle from where it is delivered to the boiler at boiler pressure. Water, which overflows during starting, is collected in an overflow chamber and then discharged to the drain.
Fig. 9.14 Steam Injector
Example 9.1
Find the velocity of steam issuing from a nozzle in which the steam has been expanded in an initial condition of 10.3 bar absolute dry to a pressure of 0.686 bar (i) neglecting friction and (ii) considering frictional loss as 10 per cent of the heat drop.
Solution: From Mollier chart
Heat drop = 456 kJ/kg = (h1 − h2)
Velocity V2 =
V2 =
= 954.96 m/s
ηnozzle = 90%
∴ V2 =
=
= 905.95 m/s.
∴ Diameter of nozzle mouth
d =
d = 3.34 cm.
Example 9.2
Steam at a pressure of 6.85 bar and 0.9 dry expands through a nozzle having a throat area of 4.65 cm2. The back pressure is 1.03 bar. Determine (i) the mass of steam flowing per minute; (ii) the diameter of the mouth of nozzle for maximum discharge; and (iii) the final velocity of the steam.
Solution: Since the steam is saturated, for the maximum discharge, theoretical pressure at the throat of nozzle will be
p2 = 0.58p1
= 0.58 × 6.85
= 3.97 bar
From Mollier chart, the heat drop from the inlet of nozzle to the nozzle throat is
h1 = h2 = 92.95 kJ
Dryness fraction
x2 = 0.872
∴ Velocity of steam at throat
V2 =
V2 = 431 m/s
From steam tables, the specific volume of steam at nozzle throat is
V2 = 0.463 m3/kg
= 0.496 kg/s.
h1 = h3 = 297 kJ
x3 = 0.83
From steam tables, the specific volume of steam is
v3 = 1.64 m3/kg
Velocity of steam at the nozzle mouth is
V3 = = 771 m/s
m =
A3 =
A3 = 8.757 cm2.
Example 9.3
Dry saturated steam enters a convergent nozzle at a pressure of 10 bar with a velocity of 90 m/s. The exit pressure is 5 bar and steam leaves the nozzle at a velocity of 435 m/s. The friction is 8 kJ/kg of steam flow. Determine
Solution: Neglecting losses
(1)
at 10 bar h1 = 2776.2 kJ/kg v1 = 0.1943 m3/kg
at 5 bar hw2 = 640.1 kJ/kg = 2107.4 kJ/kg
From (1)
h2 = 2685.64 kJ/kg
isentropic enthalpy drop = h1 − h2
= 2776.2 − 2685.64
= 90.56 kJ/kg
Actual enthalpy drop, h1 − h2 = (90.56 − 8)
= 82.56 kJ/kg
Velocity coefficient =
=
=
= 0.95.
h1 − h2′ = 82.56
h2′ = (2776.2 − 82.56)
= 2693.64
But, h2′ =
= 640.1 + 2107.4
640.1 + x2 2107.4 = 2693.64
x2′ = 0.97.
A2 = 487.6 mm2
Example 9.4
Steam at 15 bar and 300°C expands in a nozzle to a pressure of 1 bar. If the efficiency of the nozzle is 80 per cent, calculate the mass of steam discharged when the exit area is 0.18 × 10−3 m2.
Solution:
Initial pressure p1 = 15 bar
Final pressure p2 = 1 bar
Exit area A2 = 0.18 × 10−3 m2
Nozzle efficiency = 0.80%
Friction factor = 0.80.
From Mollier chart
h1 = 3037 kJ/kg
h2 = 2515 kJ/kg
x2′ = 0.93.
From steam tables vs2 = 1.6937 m3/kg
Exit velocity v2 =
=
= 914 m/s.
Mass of steam discharged,
m =
=
= 0.105 kg/s.
It can be concluded that
The enthalpy drop used for reheating the steam by friction in the divergent part is 10 per cent of the overall isentropic drop.
Take index of expansion = 1.13.