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Assessment and modelling of the waste heat availability from gas turbine based
CHP systems for ORC systems
Abstract. This paper presents the findings of modelling of Interest in capturing low-grade (low temperature) heat
waste heat availability from a Combined Heat and Power (CHP) has grown dramatically in past decades [1]. Important
system with a rated electrical output of 4.35 MW and steam alternatives have been proposed to generate electricity
production of 8,165 kg/hr at 16 barg. The model has been from low temperature heat sources such as solar thermal
developed using HYSYS DynamicsTM. The amount of waste heat power, industrial waste heat, engine exhaust gases and
available from the CHP system is dependent on the ambient air, domestic boilers [1]-[2]. The potential for utilising waste
steam production, and gas turbine power output. A Pitot traverse heat from industrial applications is particularly promising
measurement across the duct was undertaken to determine the
actual amount of waste heat available from the CHP system. The
[3] because of the large amount of waste heat. Statistical
measurements were conducted in accordance to BS EN investigations indicate that low-grade waste heat account
15259:2007 standards. The simulation results of waste heat for 50% or more of the total heat generated in industry
availability have been compared to experimental data at various [4].
CHP power outputs. The HYSYS DynamicsTM model waste heat
calculation was shown to be 5.3% lower than experimental waste Using conventional methods such as steam rankine cycle
heat measurements. An analysis of the waste heat availability by to recover energy from low-grade heat is economically
both modelling and experiment was done which shows that the infeasible [5]-[6]. However, the Organic Rankine Cycle
CHP system waste heat available between 3.82 MW and (ORC) system [1],[6],[4],[7] uses a high molecular
5.09 MW. Recovering this low grade heat from the CHP system
using Clean CycleTM 125 ORC systems generates between
working fluid which boils at a lower temperature than
217 kW and 344 kW of electricity, respectively. Increases of water and is thus more efficient than water with low
2.3% in electrical efficiency of the CHP system are predicted. grade waste heat. Working fluids used in the ORC system
have been studied, such as R-113 [8]-[11], R-245fa
Key words [5],[12],[13], R-245ca [9]-[11], Toluene [7],[11] and
Ammonia [10],[14].
waste heat recovery; gas turbine; modelling; Hysys; CHP; A typical ORC system basically comprises a pump, a
ORC turbine, an evaporator and a condenser. The working
fluid is vaporised by a heat source in the evaporator. The
1. Introduction superheated vapour of the working fluid expands in the
turbine to generate electricity and is then condensed. The
condensed working fluid is finally sent via a pump into
Air
Inlet
Turbine Generator
Condenser Fig. 2. Simplified process flow diagram of CHP systems based
on gas turbine in simple-cycle (Brayton cycle) mode integrated
with waste heat steam boiler.
Evaporator Economiser Table I. Summary of different combined cycles integrated with
gas turbine.
Combined Gas turbine model New
Pump
cycle/Technology overall
Fig. 1. Process flow diagram of ORC system integrated with an efficiency
economiser. Gas to gas 1.4 MW Heron [22] 39-43%
recuperation 21 MW Rolls-Royce [23] 42%
This paper focuses on low-grade heat recovery from gas cycle
Brayton-rankine W501G
turbine based systems. Most of the modern gas turbines
cycle Siemens/Westinghouse [24] 58%
available in the market offer efficiencies up to 42% [17]. GT24 and GT26 ABB-
One important disadvantage of a gas turbine is that it does Alstom[24] 58.5%
not perform well in part-load operation [17]-[19]. For General Electric 60%
instance, at 50% load, a gas turbine achieves around 75% Brayton-brayton Allison 571 K [17] 43.2%
of the full-load efficiency, and at 30% this drops to 50% of cycle LM2500 General Electric
the nominal efficiency [17]. Technology has combined Brayton-Stirling RB211 Rolls Royce 47.7%
with gas turbines to boost the overall efficiency to more cycle
than 50% [20]-[21]. Most of the technologies utilise the Chemical LM5000PC General Electric 45%
high-grade heat exhaust from the gas turbine. Table I recuperation
cycle
summarises these different technologies. The low-grade
Cheng cycle M1A-13CC KAWASAKI
heat exhausted from combined cycle can be further
Heavy Industries 33.7%
utilised. For instance, the temperature of exhaust gas 501-KII Allison Engine 39.9%
leaving Brayton-Brayton cycle is between 200C and Company
250C [17]. LM5000 General Electric 43.8%
3 6 9
2 5 8
1.26 m
Tapping
Point
1 4 7
Fig. 3. HYSYS Process Flow Diagram for CHP systems
The amount of waste heat available from the CHP system 360
320
280
The viability of recovering waste heat using ORC systems 260
Ambient Temperature = -5oC
Ambient Temperature = 0oC
is dependent on the amount of waste heat and the 240
Ambient Temperature = 5oC
Ambient Temperature = 10oC
temperature of the heat source. The amount of waste heat Ambient Temperature = 15oC
Ambient Temperature = 20oC
220
available and power generation from the CHP system was Ambient Temperature = 25oC
200
calculated based on an exit exhaust gas temperature of 50 55 60 65 70 75 80 85 90 95 100
125C and ORC system efficiency of 12.75%. The amount Steam production capacity, %
of waste heat available from the CHP system varies Fig. 6(a). Influence of steam production on the exhaust gas
between 1.70 MW and 2.70 MW (see figure 10(a)). temperature at various ambient temperatures.
Transforming this waste heat using ORC systems (Clean
CycleTM 125) could generate between 217 kW and 344 kW
7500
6500
6000
19
5500
Exhaust gas flowrate, kg/s
18.5 5000
Ambient Temperature = -5oC
Ambient Temperature = 0oC
4500
18 Ambient Temperature = 5oC
Ambient Temperature = 10oC
4000 Ambient Temperature = 15oC
Ambient Temperature = 20oC
17.5 Ambient Temperature = 25oC
3500
50 55 60 65 70 75 80 85 90 95 100
17 Steam production capacity, %
18.35
Exhaust gas temperature, oC
515
510
550 18.3
500 505
Exhaust gas temperature, oC
450 18.25
500
400
495
350 18.2
490
300 Exhaust gas temperature
Exhaust gas flowrate
250 485 18.15
2 2.5 3 3.5 4 4.5 5
200
Exhaust gas temperature from Gas turbine power output, MW
gas turbine
150 Exhaust gas temperature from
waste heat boiler Fig. 7(a). Exhaust gas conditions from the gas turbine at various
100
gas turbine output.
-10 -5 0 5 10 15 20 25 30
Ambient temperature, oC
5000 240
Fig. 5(b). The effect of ambient air temperature on the exhaust 4900
235
gas temperature from gas turbine and waste heat boiler. 4800
4700
230
Exhaust gas temperature, oC
Waste heat availability, kW
4600
4500 225
4400
220
4300
4200
215
4100
4000 210
3900
205
3800
Waste heat availability
3700
200
3600 Exhaust gas temperature
3500 195
2 2.5 3 3.5 4 4.5 5
Gas turbine power output, MW
Fig. 7(b). Exhaust gas conditions from the waste heat boiler and
energy available at various gas turbine output.
250
30
190
25 200
180
20
150
170 15
100
10
160 50
Exhaust gas temperature
5
Exhaust gas flowrate
150 0 0
0 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12
Measurement point Month
Fig. 8(a). Temperature and flow profiles across the duct of Fig. 10(b). Projection of electricity generation using ORC
exhaust gas for CHP output of 2.3 MW systems, Clean CycleTM 125.
250 50
4. Discussion
45
240
40
The simulation results show the amount of waste heat is
Exhaust gas temperature, oC
Fig. 9. Analysis of waste heat availability exhausted from the the simulation is based on clean performance of a
CHP systems from 2007-2009.
CHP system whilst the actual CHP is less efficient
3000
and creates more waste heat due to fouling in the
2007
2008
waste heat boiler.
2009
2500
the actual gas turbine efficiency is less than the
Available waste heat input, kW
1000
The amount of waste heat from the CHP system between
2007 and 2009 varies between 3.82 MW and 5.09 MW.
500 Only 44.5% of the waste heat can be recovered using the
Clean CycleTM 125 ORC systems. This is due to the
0
1 2 3 4 5 6 7 8 9 10 11 12
evaporation temperature of the R-245fa used in the ORC
Month systems. Recovering the waste heat from the CHP system
Fig. 10(a). Availability of waste heat to be utilised using Clean could generate between 217 kW and 344 kW gross
CycleTM. electricity. The proposed waste heat recovery systems