Energy Systems Analysis-Heat Transfer PDF

Technishe Univesitait Eindhoven
Faculty of Mechanical Engineering

Sustainable Energy Technology

Energy Conversion

Case B-Design of Rankine Cycle

Author: Pavel Jungman
Date: 10.11.2012
Year: 2012/2013
Group: Without Group

Pavel Jungman Page 2

Technical Report

You are commissioned to design a 5 MWelectric combined heat and power plant at
the site of a saw mill. The waste heat is used as process heat at a temperature of
50C (for the drying chambers). The lower heating value of the wood chips is 10
MJkg-1 and the air requirement 3.8 kg/kgfuel. For the steam turbine a Siemens SST-200
single casing, modular package is selected. The specifications are:
- Power output up to 10 MW
- Inlet steam pressure up to 520C
1. Rankine cycle
In this section the process parameters of the Rankine cycle are determined. In Figure
1.the process flow chart is given. As can be seen in Figure 1. beside the very basic
components of the steam cycle a steam drum is used in the boiler section to separate
the steam from the water so only water flows though the evaporator. Thereby the
heat transfer is improved and the velocities are regulated in the boiler. To make sure
that in every part of the boiler the temperature difference is as high as possible and
thereby the heat transfer area as small
as possible, the steam/water and the
flue gases flow in reverse direction
through the boiler parts. The following
paragraph presents the calculation of
the basic Rankine cycle parameters and
the assumptions made.

Figure 1. Process flow chart


Figure 2. Temperature-Entropy diagram
Table 1. Process parameters
State Pressure[kPa] Temperature[C] Enthalpy[kJ/kg]
1 12,35 10 209,330
2 5000 10 214,34
3 5000 520 3480,42
4 12,35 50 2254,7
4s 12,35 50 2561,13

3-4 Turbine
At this calculation of the Rankine cycle will start at the turbine. The procces will be
calculated for chosen parameters and in chapter 4 we will try to optimize it. All
properties of the cycle are derived from steam tables and put into the Table 1.
Process parameters.
- The tubine efficiency 75-77%
-
) ( )
(1-1)
)
( ) ( )

(1-2)
) ( )

(1-3)


(1-4)
4-1 Condenser
In the next step an assumption has to be made regarding the state at the outlet of the
turbine. For the basic calculation of Rankine cycle we estimate only the heat which
we have to take out because of condensation of saturated steam.
) ( ) (1-5)

(1-6)
( )
( )

(1-7)
( )

(1-8)
1-2 Pump
The power of the turbine has to be 5 MW plus the energy needs of the pumps and
fans, which will be neglected in the first step but added in an iterative process after
the calculation of the pressure losses in the process and the pumps energy needs. In
this section is not caculate with pressure losses. The calculation with losses and real
power is estimated at chapter 3. Pump selection.
)

(1-9)

(1-10)

2-3 Boiler
In this part of our Rankine cycle is the water heated and the water is revising to
steam. In this part is calculated only needed heat which is use for the steam
generation.
) ( )

(1-11)
()

(1-12)

Efficiency Rankine Cycle
This efficiency is estimated without any losses in boiler section and condenser. That
means, real efficiency is lower than this one.

|

(1-13)

Efficiency of Rankine cycle is 28 % without optimalization.
Table 2. Results of basic Rankine cycle
Turbine Condenser Pump Boiler
Efficiency=0,75
=12791,2kW
=-27,263kW
=
-32660,8kJ/kg
=919,29kJ/kg x=0,987
=214,34kJ/kg
=-17763kW
=303,43 kJ/kg
=7,98kJ/kg.K
=209,33kJ/kg
=2561,13kJ/kg
=0,0018kJ/kg.K

=0,29

2.Heat Exchangers

Superheater:
) ( )

Evaporator:

Economiser:
) ( )

Flame
temperature

( )

(2-1)

Flue gas mass flow

)
(2-2)
Figure 3. Progress of temperatures in boiler section

( )

Heat combustion
( )

(2-3)

The system efficiency including boiler losses

|

(2-4)

The Superheater Section
Temperature after superheating

(2-5)
Flue Gasses at 1543C (1800K)

(2-6)

(2-7)

(2-8)
Superheated steam at 520C

(2-6)

(2-7)


(2-8)
staggered steal

thickness tube

(2-9)

(2-10)

(2-11)

(2-12)

) (
)
(
( ) ( )
( )
( )

(2-13)

(2-14)

Evaporator section

(2-15)

) (
)
(
( ) ( )
( )
( )

(2-16)

(2-17)

Economizer section
Flue gas properties are evaluated at a temperature of 200C



) (
)
(
( ) ( )
( )
( )

(2-16)

(2-17)

Number of tubes
The results are simile for Economiser and Evaporator section. Number of tube
is 2.

(2-18)

The total lenght of pipes is 3052,5 m. The total heat transfer area is
Number of tubes is 2 for Economiser and Evaporator section. Total
Number of tube is 10 for superheater section.
Condensor
In the next step an assumption has to be made regarding the state at the outlet of the
turbine. A value for the temperature T4 can be derived from the given parameters.
The drying chamber needs to have a temperature of 50 C for drying the timber and
the waste wood, respectively the fuel. A fair assumption for the minimal temperature
difference in a heat exchanger is 10 C.

Cooling water

Outlet cooling water

The Capacity of Condenser


Water heat capacity

Density of cooling water

(2-19)

(2-20)

(2-21)

(2-23)
(
)(
) ( (
)
(
)(
)( ()
)
(2-24)

(2-25)
) (
)
(
( ) ( )
( )
( )

(2-26)

(2-27)

(2-28)

Table 3. Boiler, Condenser parametres
Section Economizer Evaporator Super heater Condenser
U[W/m
2
K] 100 82 72,46 2338,87
Logarithmic
temperature[C]
177,5 552,2 1000,87 25,5
Number of
tubes[-]
2 2 10 32
Length of
tubes[m]
1641,5 1120 291 1219,5
Lenght of
section[m]
2,40 1,634 0,424 -


Figure 4. Boiler Lay-out
3.Pump Selection
For the design of the pumps the pressure losses in the economiser, evaporator and
condenser have to be calculated. The pressure loss in the pipes in the rest of the
system is assumed to be negligible in comparison to the boiler losses. Also height
differences are neglected. The pressure loss in the superheater does not have to be
substituted by a pump as the pressure will rise in the steam drum due to the steam
generation, guaranteeing the steam flow through the superheater.
The value from tables and diagrams
Epsilon value
Ratio

Fiction factor
Diameter of tubes

Turbine loss

Economiser
Lenght of tubes
Velocity

Density of medium

(3-1)

Evaporator
Lenght of tubes
Velocity

Density of medium

(3-2)

Superheater
Lenght of tubes
Velocity

Density of medium

(3-3)

Main Loss+Power Pump

+

(3-4)

(3-5)

Condenser:
Lenght of tubes
Velocity

Density of medium

(3-6)

(3-7)


Figure 5. Pump selection
From the Fig. 5. We can see, that we will choice Centrifugal impeller design.
With characteristic speed 2000 rpm. And with the efficiency around 70%.

4. Optimization
First optimization was used at chapter 1 Rankine cycle when we found the best
parameters due to Microsoft Excel. As we can see in Table 4. Original Properties
before optimization.
Table 4. Original Properties before optimization
State Pressure[kPa] Temperature[C] Enthalpy[kJ/kg]
1 70 90 376,97
2 11000 90 376,97
3 11000 520 3414,92
4 70 90 2344,20

At the chapter 1 was first time performed Optimization and the optimized parameters
were used in following chapters. Comparison between optimized and un-optimized
parametres is showed in Table 5.
Table 5. Comparison of optimized and un-optimized parameters
Optimized Parameters Un-optimized Parameters

=0,29 =0,26
=-17763kW
=-18846kW
=-27,263kW
=-68,395kW
=12791,2kW
=13915,3kW
At table 5. We can observe how negligible is good choice of incoming parameters
and how big impact parameters have to efficiency. Also the impact is on factors like
how much fuel we will consume. Also parameter Q
boiler
plays main role in design of
the boiler. That means how many tubes (length) we will use which depend on how
big losses we can get.
Next possibility of optimization is occur in boiler section on stack temperature. The
boiler efficiency is a linear function of Tstack. The total heat transfer area shows a high
negative slope at low stack temperature and a less negative slope at higher stack
temperatures. As it can be seen in Figure 6. that the largest reduction of heat transfer
area and the lowest efficiency loss can be obtained at a stack temperature of
Tstack=160 C (Point of maximal vertical distance of the curves). The reduction of heat
transfer area and the boiler coefficient is shown below. It can be seen that the stack
temperature optimisation mainly reduced the economiser heat transfer area and the
others slightly. By optimising the stack temperature we will achieve of 9% save of
cost investment of tubes by the same efficiency of Rakine cycle.
Table 6. Impact of stack temperature on transfer area and efficiency of boiler
Tstack Aboiler boiler
100 537,03 0,88
120 402,54 0,87
140 343,64 0,86
160 306,67 0,85
180 280,21 0,83
200 259,87 0,82
220 243,53 0,81
240 229,98 0,8
260 218,5 0,79
280 208,6 0,78
300 199,92 0,76



Figure 6. Graph of Impact of stack temperature on transfer area and efficiency of boiler
Table 7. Impact of stack temperature to safe of pipe system
Section Superheater Evaporator Economiser
T[C] 1546 1252 553
Tlog[C] 1005 568 205,6
Lenght before[m] 291 1120 1641,5
Lenght after[m] 291 1088 1413,2
Safe of pipes [%] 0 2,86 14
Safe of all pipes[%] 9

0,76
0,78
0,8
0,82
0,84
0,86
0,88
200
250
300
350
400
450
500
0 50 100 150 200 250 300 350
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Stack Temperature [C]
Aboiler
boiler

References

[1] SST-200 - Siemens 2012, http://www.energy.siemens.com/hq/de/stromerzeugung/dampfturbinen/sst-200.htm,
accessed 8 November 2012.

[2] G. Schembecker, Skript zur Vorlesung Anlagen- und Prozesstechnik 2010.

[3] E. van Kemenade, Energy Conversion: 4P570 lecture notes 2012.

[4] Steam Turbine Efficiency - Turbines Info, http://www.turbinesinfo.com/steam-turbine-efficiency/, accessed 8
November 2012.

[5] U. S. Environmental Protection Agency, Biomass Combined Heat and Power Catalogue of Technologies
2008.

[6] Babcock & Wilcox, PCH-565 - B&W's Open-Bottom Bubbling Fluidized-Bed Technology Designed for
Biomass Firing 2010.

[7] T. Nussbaumer, Energy Fuels 2003 17 (6), 1510. DOI: 10.1021/ef030031q.

[8] Online - Berechnung - Stickstoff - N2 2012, http://www.peacesoftware.de/einigewerte/stickstoff.html,
accessed 9 November 2012.

[9] J. Howard, Introduction to kiln drying: Straight forward answers to 24 important questions 2012.

[10] Water - Thermal Properties 2012, http://www.engineeringtoolbox.com/water-thermal-properties-
d_162.html, accessed 9 November 2012.

[11] Peace software 2012, http://www.peacesoftware.de/, accessed 9 November 2012.

[12] LOWARA, TDB - TDV Series: VERTICAL MULTISTAGE ELECTRIC PUMPS 2011,
http://www.lowara.co.uk/lowdata/doc/EN/tdbtdv-td-en.pdf, accessed 10 November 2012.

[13] Cost assessment of selected decentralised CHP applications based on biomass combustion and biomass
gasification (Eds: I. Obernberger, G. Thek) 2008.

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