DESC:FIELD
The present disclosure relates to the field of a steam generation system. More specifically, the present disclosure relates to a steam generation system integrated with a heat and condensate recovery unit.
DEFINITIONS
As used in the present disclosure, the following term is generally intended to have the meaning as set forth below, except to the extent that the context in which they are used to indicate otherwise.
Dryness fraction - Dryness fraction refers to the ratio of weight of dry steam present in a known quantity of wet steam to the total weight of the wet steam. The dryness fraction is used to specify the quality of steam. The value of dryness fraction ranges from 0 to 1.
BACKGROUND
The background information hereinbelow relates to the present disclosure but is not necessarily prior art.
Helical coil once through steam generator is a popular device for steam generation due to its lower cost, compact design and inherent safety. Helical coil once through steam generator does not require drum and it has very low water holdup. Low water holdup makes it intrinsically safe design. Conventionally, heat is recovered from the flue gases via direct heat transfer between flue gases and feed water. As direct heat transfer takes place between flue gases and water, gas side heat transfer coefficient is very low, thereby leading to a lower heat transfer rate. In order to increase the heat transfer rate, the heat transfer area needs to be increased. The higher heat transfer area also means higher water holdup of a heat recovery unit or an economizer. If this economizer is placed after the feed water pump, it increases water holdup of the pressurised feed water and compromises the safety of the boiler. This problem is solved by placing heat recovery unit before feed water pump. This helps to reduce pressurised feed water holdup capacity and improve the safety of the boiler. But it constrains the use of hot feed water generated from the condensation of process steam. As heat recovery unit is placed before the feed water pump and the feed water pump cannot accept feed water at a temperature more than the temperature specified by pump suppliers. This limits the use of condensate recovery and a significant amount of heat is lost. Another limitation of the conventional heat recovery unit is corrosion of equipments/components caused by condensation of the acidic gases present in the flue gases. Most of the residual fuel oil has higher sulphur content, which produces sulphur dioxide and sulphur trioxide after combustion. Sulphur dioxide and sulphur trioxide react with water vapour and produce sulphurous and sulphuric acid. If the temperature of the metal wall surface participating in heat transfer is below the dew point temperature of these acids, condensation of these acids take place resulting in the corrosion of the metal wall surfaces. In a conventional feed water heater, the metal wall temperature is approximately equal to the temperature of feed water due to higher heat transfer coefficient of feed water. The condensation of the acidic gases leads to corrosion of the metal walls/surfaces.
Further, dryness fraction of the once through helical coil steam generator is restricted to a certain level. Higher dryness fraction of the helical coil once through steam generator can lead to a dry out and overheating of the coil. So, the helical coil once through steam generator having lower dryness fraction reduces the overall efficiency of the process. Further, higher quantity of steam is required for the process/end application thereby leading to higher condensate loss and lower process efficiency. This problem is partially solved by using moisture separator before the process/ end application. As dryness fraction of the helical coil once through boiler is very less, conventional moisture separators are only able to achieve moderate dryness fraction. This dryness fraction is still very less than the conventional drum type boiler. Moreover, another limitation comes due to significantly higher quantity of collected moisture causing loss of water and heat. This separated moisture cannot be used as feed water due to higher concentration of total dissolved solids (TDS) and the inherent limitation of using hot feed water due to the reciprocating pump.
There is, therefore, felt a necessity to develop a steam generation system that mitigates the drawbacks mentioned hereinabove.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a helical coil once through steam generation system.
Another object of the present disclosure is to provide a helical coil once through steam generation system that is integrated with a heat and condensate recovery unit.
Still another object of the present invention is to provide a helical coil once through steam generation system that will achieve higher dryness fraction.
Still another object of the present invention is to provide a steam generation system that will reduce water holdup.
Yet another object of the present disclosure is to provide a steam generation system that eliminates low end corrosion.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a steam generation system. The steam generation system comprises a heat recovery unit, a steam generator, a moisture separator, a flash pipe, a heat exchanger and a feed water tank. The heat recovery unit is configured to receive feed water form a feed water pump and flu gas from a steam generator. The heat recovery unit is used to preheat feed water. The steam generator is configured to receive feed water from the heat recovery unit and to convert feed water into steam. The moisture separator is configured to receive steam from the steam generator, and to separate and collect moisture from the steam. The moisture separator further delivers generated dry steam to a process utilization. The flash pipe is configured to receive moisture collected in the moisture separator and converts moisture into steam using flashing operation. The heat exchanger is configured to receive a portion of flash steam form the flash pipe and to pre-heat makeup water. The feed water tank is configured to receive and store steam form the flash pipe, acondensate from the process utilization and the makeup water from the heat exchanger. The feed water tank is further provides feed water to the feed water pump.
In an embodiment, the steam generator is selected from a group consisting of helical coil steam generator, single coil reverse flame boiler and two coil helical boiler.
In another embodiment, the steam generator consists of a burner for combustion of fuel, a helical coil having an inlet and an outlet for circulating water therethrough, and a jacket encompassing said helical coil.
In yet another embodiment, the heat recovery unit consists of a plurality of vertical tubes, a serpentine tube and a shell. The plurality of vertical tubes is configured to allow flue gases received from the steam generator to pass through it. The serpentine tube is configured to allow feed water received from the feed water pump to pass through it. The shell encompasses the plurality of vertical tubes and serpentine tube. The shell is filled with a secondary fluid medium for heat transfer from flue gas to feed water.
In yet another embodiment, the secondary fluid medium is selected from a group consisting of water and organic fluids.
In yet another embodiment, the moisture separator consists of a steam inlet pipe, a steam outlet pipe and a main pipe. The steam inlet pipe is positioned at the operational lower end of the moisture separator. The steam inlet pipe is configured to allow steam received form the steam generator into a cyclone separator. The steam outlet pipe is positioned at the operation top end of the moisture separator and is fluidly connected to the cyclone separator. The steam outlet pipe is surrounded by a demister pad for moisture separation from steam received from the cyclone separator. The main pipe encompasses the steam inlet pipe, the cyclone separator and the steam outlet pipe.
In yet another embodiment, the steam inlet pipe is provided with plurality of tangentially placed holes. The holes are configured to allow tangentially exit of steam received at the steam inlet pipe.
In yet another embodiment, the moisture separator is provided with an air vent at an operative top section of the main pipe and a drain pipe with a steam trap at an operative bottom portion/section of the main pipe.
In yet another embodiment, the drain pipe is configured to collect and remove moisture from the moisture separator.
In yet another embodiment, the steam generation system consists of a steam trap positioned between the moisture separator and the flash pipe. The steam trap withhold steam exiting the moisture separator.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a sectional view of a once through helical coil steam generator system, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a sectional view of a heat recovery unit using a secondary heat transfer medium, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a schematic view of a two stage moisture separator unit, in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a block diagram of the once through helical coil steam generator/boiler that is integrated with the heat and condensate recovery unit, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a line graph depicting the percentage fuel saving in accordance with an embodiment of the present disclosure;
Figure 6 illustrates a line graph depicting the system efficiency in accordance with an embodiment of the present disclosure; and
Figure 7 illustrates a pie chart depicting process output vs heat input of a conventional system.
Figure 8 illustrates a pie chart depicting process output vs heat input in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
Reference Numeral References
100 Once through helical coil steam generator
102 Burner
104 Jacket
106 Helical coil
200 Heat recovery unit using secondary heat transfer medium
202 Vertical tube for flue gas cooling
204 Shell
206 Secondary medium/ fluid
208 Serpentine tube feed water heater
300 Two stage moisture separator
302 Steam inlet pipe
304 Steam outlet pipe
306 Cyclone separator
308 Demister
310 Drain
312 Air vent
400 Schematic of heat recovery loop of the once through helical coil steam generator
402 Feed water pump
404 Helical coil steam generator
406 Steam to the process utilization
408 Moisture separator
410 Steam trap
412 Flash pipe
414 Feed water tank
416 Condensate from the process/used steam
418 Heat exchanger
420 Make up water
422 Drain
426 Steam trap
428 Flash tank

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Normally, in a once through helical coil steam generator (also referred as a boiler), an economizer is placed before a feed water pump. This helps to reduce steam generator water holdup and safe operation of the steam generator. Cold feed water receives heat from the hot gases to produce hot feed water. This hot feed water is further pumped to the steam generator. The helical coil steam generator generally utilizes reciprocating pump to pump the hot feed water. The inlet temperature of the pump is restricted for the safe operation of the pump. This provides a constraint on the use of the hot feed water, as feed water cannot be heated at higher temperature for the safe operation of the pump. Further, condensate recovery is not used in the conventional boilers which results in a significant loss of energy.
The present disclosure envisages a steam generation system with reference to Figure 1 to Figure 4. Particularly, the present disclosure envisages a steam generation system integrated with a heat and condensate recovery unit.
The steam generation system 400 comprises a steam generator/boiler 100, 404, a heat recovery unit 200, a moisture separator 300, 408, steam trap 410, a flash pipe 412, a feed water tank 414 and a heat exchanger 418.
Process flow of the once through helical coil steam generator/boiler integrated with the heat and condensate recovery unit is illustrated in Figure 4. Firstly, feed water is fed to the heat recovery unit 200 (shown in figure 2) through the feed water pump 402. The feed water gets heated in the heat recovery unit 200 as it passes through the helical coils of the once through helical coil steam generator 100, 404 and gets converted into a steam. Moisture present in the steam is removed by using the moisture separator 300, 408 to increase the dryness fraction of steam. The dry steam is sent for end use/process utilization 406. A process steam trap 426 receives utilized steam from the process utilization for separation of moisture from utilized steam. Further the moisture from the process steam trap 426 is sent to process a flash tank 428 for flashing operation. The low pressure flashed condensate is then sent to feed water tank 414 for storage through a condensate return means 416.
Moisture collected from the moisture separator 300, 408 is flashed in the flash pipe 412 by the process of pressure reduction. The condensate generated in the flash pipe 412 is fed to the feed water tank 414 for storage. Further, the feed water tank 414 receives makeup water 420 through the heat exchanger 418. The water collected in the feed water tank is fed to the heat recovery unit 200 which is subsequently fed to the steam generator/boiler 100, 404.
In an embodiment, the steam generator 100, 404 is selected from a group consisting of once through helical coil steam generator, single coil reverse flame boiler or two coil helical boiler. In an exemplary embodiment, the steam generator is a once through helical coil steam generator. Other suitable steam generator can also be used.
The helical coil steam generator 100 comprises a burner 102 for combustion of a fuel, a helical coil 106 for circulating water therethrough, and a jacket 104 for covering the helical coil 106.
The flue gases generated at the burner 102 heat the helical coil and the water passing through the coil gets converted into steam.
The heat recovery unit 200 comprises vertical tubes 202, a shell 204, a secondary fluid medium 206, and a serpentine tube 208.
The flue gases leaving from the once through helical coil steam generator passes through the vertical tubes 202.
Heat energy of the flue gases leaving from the steam generator 100 is indirectly transferred to the feed water using the secondary fluid or medium 206 present in the shell 204.
In an embodiment, the secondary fluid medium can be water or organic fluid. In an exemplary embodiment, the secondary fluid medium is water. Other suitable secondary fluid medium can also be used.
In this heat recovery unit 200, the secondary fluid medium 206 is filled in the shell 204 to a predetermined height. The secondary fluid medium 206 filled in the shell 204 acts as a heat transfer medium. The secondary fluid medium 206 indirectly receives heat from flue gases and transfers heat to the feed water which is flowing through the serpentine tube 208. The vertical tubes 202 are placed in the shell 204 for the passage of the flue gases. The flue gases passing through the vertical tubes 202 indirectly transfer heat to the secondary fluid medium 206 which is present in the shell 204. The serpentine tube 208 is placed in the shell 204 for the passage of feed water and receiving heat from the secondary fluid medium 206. Flue gases indirectly transfers heat to the secondary medium 206 through the vertical tube 202. The secondary medium 206 rejects heat to the feed water flowing through the serpentine tube 208. As the feed water present in the serpentine tube 208 gets heated, only holdup in the serpentine tube 208 play a role for a startup time and safety of the boiler/heat generator. The required heat transfer area of the serpentine tube 208 is less, as the overall heat transfer coefficient for the heat exchange between the secondary fluid medium 206 and the feed water is higher due to heat exchange between two liquid. The temperature of the secondary fluid medium 206 is higher than the temperature of the feed water. This helps to reduce the possibility of condensation of the acidic gases thereby reducing the corrosion. The temperature of the secondary fluid medium 206 can be intended above the dew point temperature by selecting appropriate area of the vertical tubes 202 and the serpentine tube 208. Further, the temperature of the secondary fluid medium 206 can be controlled by bypassing the feed water from the serpentine tube 208.
Steam obtained from the once through helical coil steam generator 100 has low dryness fraction. Therefore, in order to remove the moisture from the steam to increase the dryness fraction, the present disclosure provides a two stage moisture separator 300 as shown in figure 3.
The two-stage moisture separator 300 comprises a cyclone separator 306, a demister 308, a steam inlet pipe 302, and a steam outlet pipe 304. Steam obtained from the once through helical coil steam generator 100 enters through the inlet pipe 302 from the bottom and exit from the multiple holes tangentially placed over the inlet pipe 302. The inlet pipe 302 is closed at the end and steam tangentially exits from the multiple holes placed over the inlet pipe 302. High velocity steam moves in cycloidal path and heavier particles/ moisture is separated at the inner surface of the main pipe due to a centrifugal action. The steam outlet pipe 304 is placed at the top section of the main pipe. The steam outlet pipe 304 is surrounded by the thick demister pad 308. The steam exiting from the inlet pipe 302 goes through the demister pad 308, moisture separation takes place due to impact separation and dry steam enters to the outlet pipe 304 through the rectangular slots. A sufficient length has been provided between the inlet pipe 302 and the outlet pipe 304 to provide sufficient residence time for cyclonic separation before entering to the demister pad 308 for impact separation. An air vent 312 is provided at the top section of the main pipe. A drain pipe 310 with a steam trap is provided at the bottom for the removal of the separated moisture.
In the present system, the cyclone separator 306 is used as first stage separator to remove bigger droplets and finer droplets are removed by the demister pad 308. First stage moisture separator 306 reduces moisture concentration at the inlet of demister pad 308 and helps to eliminate the possibility of re-entrainment and loss of efficiency. Maximum pressure drops in moisture separator of approx. 2 kg/cm2 can be obtained.
A significant amount of moisture is collected through the drain pipe 310 of the moisture separator 300. Higher amount of moisture is collected due to the presence of the higher quantity of moisture in steam of the once through helical coil steam generator 100 and higher separation efficiency of the moisture separator 300. The collected moisture has higher concentration of total dissolved solids TDS. So, due to higher concentration of TDS, the collected moisture cannot be reused as a boiler/steam generator feed water.
In conventional system, separated moisture is discarded or thrown away. Therefore, a substantial amount of heat energy is lost thereby reducing the overall system efficiency. This problem is resolved by introducing a flash pipe 412 at the outlet of the steam trap 410 as shown in figure 4.
Drain water/moisture enters the flash pipe 412 through the steam trap 410. A sufficient amount of water is flashed into steam by reducing the pressure of the flash pipe 412. This is possible because of higher makeup water availability in the case of the once through helical coil steam generator. The generated steam from the flash pipe 412 is sent to a feed water tank 414. Further, the feed water tank 414 receives a condensate/used steam from the process 416. Furthermore, the feed water tank 414 also receives makeup water 420 through heat exchanger 418. The makeup water 420 is required due to flash steam loss at the outlet of the process heat exchanger 418 and loss of drain water 422. The condensate/used steam from the process 416, flashed steam, and makeup water 420 received in the feed tank 414 is sent to the boiler/steam generator 404 through a feed water pump 402. In another embodiment, the steam generation and the heat recovery and condensate recovery can take place in a closed loop.
Experimental Analysis
Below table showing Temperature, Pressure and Dryness fraction of the steam at different stages of the present system

Feed water/Steam Transfer from Feed water /Steam transfer to Mass (Kg/h) Pressure (kg/cm2) Temperature (Deg.c) Dryness Fraction
Feed Water Pump (402) Heat recovery unit (200) 680 - 98 0
Heat recovery unit (200) Steam generator (404) 680 - 126 0
Steam generator (404) Moisture separator (408) 680 9 179 0.8
Moisture separator (408)
Flash pipe (412) 119.2 9 179 0
Process Steam Trap (426) 561 9 179 0.97
Process Steam Trap (426) Process Flash tank (428) 561 9 179 0
Process Flash tank (428) Feed water Tank (414) 475.7 0 99 0
Flash pipe (412)
Heat Exchanger (418) 103.5 0.5 111 0
Feed water Tank (414) 15.8 0.5 111 1
Heat Exchanger (418) Condensate discharge line (422) 103.5 - 74 0
Makeup water (420) Heat Exchanger (418) 188.9 - 30 0
Heat Exchanger (418) Feed water Tank (414) 188.9 - 50 -
Table 1
The below table provides working parameters of the present system compared to conventional system
Present system Conventional system
Capacity 600 Kg/Hr 600 Kg/Hr
Efficiency 89 % 89 %
Output 324000 Kcal ?hr 324000 Kcal ?hr
CV 9650 Kcal/Kg 9650 Kcal/Kg
Fuel qty 37.7248646446 Kg/Hr 37.7248646446 Kg/Hr
Water temp. 98.2381884818 DegC 30 DegC
Steam press 9 Kg/cm2 9 Kg/cm2
Water enthalpy 181.2600483042 Kcal/Kg 181.2600483042 Kcal/Kg
Steam enthalpy 663.0382304687 Kcal/Kg 663.0382304687 Kcal/Kg
Steam dryness 0.8 0.8
Net enthalpy 566.6825940358 Kcal/Kg 566.6825940358 Kcal/Kg
Water qty 691.6509113111 Kg/Hr 603.7087910072 Kg/Hr
Final steam dryness 0.975 0.975
Pure Steam qty 553.3207290488 Kg/Hr 482.9670328058 Kg/Hr
Net steam qty 567.5084400501 Kg/Hr 495.3508028777 Kg/Hr
Extra steam generated 70.3536962431
% Saving 14.57%

Table 2
Referring to Table 1 shows, the net steam generated in the present system is 14.57% greater than the net seam generated in the conventional system.
Referring to Figure 5 discloses a line chart depicting the percentage fuel savings in conventional system without moisture separator unit and the present system with moisture separator unit.
Referring to Figure 6 discloses a line chart depicting the system efficiency in conventional system without moisture separator unit and the present system with moisture separator unit.
Referring to Figure 7 and Figure 8 illustrates a pie chart depicting process output vs heat input of a conventional system and the present disclosure respectively.
In the present system the process loss is reduced to 16% compared to 25% in the conventional system without the moisture separator and the process output is increased to 72% form 63%.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of a steam generation system that:
• generates steam with higher dryness fraction in the range of 96- 98.5 % against the current 80 % without moisture separator;
• has lower water holdup and safe operation;
• almost 80 % reduction in water holdup is achieved;
• has higher process efficiency; and
• is subjected to minimum low-end corrosion.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A steam generation system (400) comprising,
a feed water tank (414) configured to store feed water;
a feedwater pump (402) configured to receive feed water from said feed water tank (414) and pressurize said feed water to obtain pressurized water;
a steam generator unit (404) downstream of said feedwater pump (402) configured to convert said pressurized water into a moist steam;
a moisture separator unit (408) positioned downstream of said steam generator unit (404) and configured to receive said moist steam and separate moisture to obtain a dry steam and a condensate;
a flash pipe (412) positioned downstream of said moisture separator unit (408) for flashing said condensate to generate a secondary steam and secondary condensate; and
a heat exchanger unit (418) positioned downstream of said flash pipe (412) and configured to receive said secondary condensate for pre-heating makeup water (420),
wherein said feed water tank (414) is further configured to receive said secondary steam from said flash pipe (412), a condensate generated during process utilization (406), and said makeup water (420) from the heat exchanger (418) respectively.
2. The steam generation system (400) as claimed in claim 1, wherein the steam generator unit (404) comprises:
a heat recovery unit (200); and
a steam generator (100);

wherein said heat recovery unit (200) is configured to receive pressurized feed water from said feed water pump (402) and flue gas from said steam generator unit (404) for preheating said pressurized water and deliver said preheated water to said steam generator (100);
wherein said steam generator (100) is configured to generate a moist steam by heating said preheated water using flue gas.
3. The steam generation system (400) as claimed in claim 2, wherein the steam generator (100) is selected from a group consisting of once through helical coil steam generator, single coil reverse flame boiler and two coil helical boiler.
4. The steam generation system (400) as claimed in claim 2, wherein the steam generator (100) consists,
a burner (102) for combustion of fuel;
a helical coil (106) having an inlet and an outlet for circulating said preheated water therethrough; and
a jacket (104) encompassing the helical coil (106).
5. The steam generation system (400) as claimed in claim 2, wherein the heat recovery unit (200) consists,
a serpentine tube (208) configured to receive said pressurized water from the feed water pump (402) and circulate therethrough to obtain a preheated water;
a plurality of vertical tubes (202) placed around the serpentine tube (208) and configured to allow flue gases received from the steam generator (100) to pass through it; and
a shell (204) encompassing the plurality of vertical tubes (202) and the serpentine tube (208),
wherein said shell (204) is filled with a secondary fluid medium (206) for transfer of heat from flue gas to pressurized water.
6. The steam generation system (400) as claimed in claim 5, wherein the secondary fluid medium (206) is selected from a group consisting of water and organic fluids.
7. The steam generation system (400) as claimed in claim 1, wherein the moisture separator unit (408) is configured to receive said moist steam generated from the steam generator (404) and to deliver generated dry steam to process utilization (406).
8. The steam generation system (400) as claimed in claim 1, wherein the moisture separator unit (408) contains a two stage moisture separator (300), said two stage moisture separator (300) having:
a steam inlet pipe (302) positioned at an operational lower end of the moisture separator (300), the steam inlet pipe (302) configured to allow steam received form the steam generator (100) into a cyclone separator (306);
a steam outlet pipe (304) positioned at an operational top end of the moisture separator (300) and fluidly connected to the cyclone separator (306), the steam outlet pipe (304) surrounded by a demister pad (308) for separation of moisture from steam received from the cyclone separator (306); and
a main pipe encompassing the steam inlet pipe (302), the cyclone separator (306) and the steam outlet pipe (304).
9. The steam generation system (400) as claimed in claim 8, wherein proximal end of the steam inlet pipe (302) is provided with plurality of tangentially placed holes, the holes configured to allow tangentially exit of steam received at distal end of the steam inlet pipe (302).
10. The steam generation system (400) as claimed in claim 8, wherein the moisture separator (300) is provided with an air vent (312) at an operative top section of the main pipe and a drain pipe (310) with a steam trap at an operative bottom portion/section of the main pipe.
11. The steam generation system (400) as claimed in claim 10, wherein the drain pipe (310) is configured to collect and remove moisture from the moisture separator (300).
12. The steam generation system (400) as claimed in claim 1, wherein the steam generation system (400) consists of a steam trap (410) positioned between the moisture separator unit (408) and the flash pipe (412) for withholding steam exiting moisture separator unit (408).
13. A method for steam generation system (400), said method comprising the steps of:
• pumping feed water to a steam generation unit (404);
• generating steam in said steam generator (404) to obtain a moist steam;
• separating moisture from said moist steam using a moisture separator unit (408) to obtain dry steam and a first condensate.
• flashing said first condensate in a flash pipe (412) to obtain steam and secondary condensate;
• transferring said secondary condensate to a heat exchanger unit (418) to preheat makeup water;
• receiving condensate generated during process utilization (406), remaining portion of the flashed steam from the flash pipe (412) and the pre heated makeup water from the heat exchanger unit (418) respectively in the feed water tank for storage.

Dated this 25th day of March, 2022

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI