I??Process??

Overview

The??process??is??a??power??generation??facility??particularly??a??steam??power??plant
??The??power??plant??is??designed??through??the??implementation??of??a??Rankine??cy
cle??A??Rankine??cycle??is??an??idealized??thermodynamic??cycle??of??a??constant??pr
essure??heat??engine??that??converts??part??of??heat??into??mechanical??work??In??this
??process??the??heat??is??supplied??externally??to??a??closed??loop??which??uses??wat
er??as??the??working??fluid??This??fluid??undergoes??phase??change??from??a??liquid??
to??vapor??phase??and??vice??versa?? Nuclear??Power??Net??
??????It??is??desired??to??have??an??efficiency??of?? ??February??and??the??turbine
??should??generate?? ??MW??of??power??The??cycle??consists??of??fourunit??operation
s??namely????the??turbine??the??cooler??the??pump??and??the??heater??They??are??en
closed??into??a??loop??which??uses??and??produces??both??heat??and??mechanical??w
ork??The??cooler??and??heater??produce??and??consumes??heat??respectively??while??t
he??turbine??and??the??pump??produce??and??consumes??work??The??steam??power??
plant??has??been??used??for??decades??to??generate??power??in??the??form??of??electr
icity?? Forbes??Martial??
????

For??the??cooler??part??of??the??Rankine??cycle??it??is??desired??to??heat??up??the??
water??supplied??at???? ??°C??with??a??temperature??of??approach??of??????°C??For
??this??to??be??possible??the??implementation??of??both??a??cooler??and??a??condense
r??is??made??The??cooler??is??the??one??responsible??for??the??sensible??cooling?? n
o??phase??change????while??the??condenser??for??the??condensation?? phase??change
????The??steam??is??first??brought??down??to??the??saturation??temperature??before??e
ntering??the??condenser??at??constant??temperature??From??the??Rankine??cycle??the??
mass??flowrate??of??the??steam??is??
????????kgs??and??its??inlet??temperature??and??pressure??are?? ????????°C??and??

??kPa??gauge??The??saturation??temperature??is??determined??to??be??
??
??°C??The??condensation??then??proceeds??at??constant??temperature??of??
??
??°C??

For??the??heater??part??of??the??Rankine??cycle??it??is??desired??to??power??the??stea
m??plant??through??incineration??of??municipal??solid??waste????The??waste??is??first??
burnt??in??a??furnace??where??the??product??gas??is??called??the??flue??gas??The??flu
e??gas??then??enters??the??absorption??towers??which??are??implemented??for??the??re
moval??of??SOx??and??NOx??Gas??Absorber??is??a??masstransfer??process??in??which
??a??vapor??solute??in??a??gas??mixture??is??absorbed??by??means??of??a??liquid??in
??which??the??solute??is??more??or??less??soluble?? Geankoplis?? ??????????The??re
leased??gas??then??enters??the??fixed??bed??adsorber??to??remove??the??organic??com
pounds??from??the??flue??gas??such??as??dioxins??Adsorption??processes??one??or??m
ore??components??of??a??gas??or??liquid??stream??which??are??adsorbed??on??the??su
rface??of??a??solid??adsorbent??In??commercial??processes??adsorbents??are??usually??
fixed??bed??When??the??bed??is??already??saturated??the??flow??is??stopped??and??th
e??bed??is??regenerated??thermally??or??by??other??methods??so??desorption??occurs??
Geankoplis?? ??????????Two??gas??absorbers??were??designed??One??for??SOx??an
d??one??for??NOx??because??they??have??different??solvents??that??aid??in??their??rem
oval??The??solvent??for??SOx??is??water??while??for??NOx??is??H O ??SOx??NOx??a
nd??dioxins??are??all??harmful??gases??for??the??atmosphere??which??is??why??they??s
hould??be??removed??from??the??flue??gas??More??applications??for??adsorption??proce
sses??include??various??fermentation??products??from??fermenter??effluents??and??remov
al??of??colored??impurities??from??organics?? Geankoplis?? ????????

II??Process??Description

The??power??plant??utilizes??water??in??vapor??and??liquid??phase??as??process??strea
m??to??transform??heat??energy??into??work????
??????kghr??of??subcooled??liquid??water??initially??at????
??°C??and??
??kPa??gauge??is??pressurized??to????

??kPa??gauge??using??a??pump???? ??MW??of??heat??is??then??supplied??at??the??fu
rnace??to??the??process??stream??bringing??its??temperature??to????

??°C??This??superheated??highpressure??steam??is??fed??to??the??turbines??to??produc
e??work??amounting??to?? ??MW??The??energy??loss??in??the??steam??brought??it??d
own??to??a??temperature??and??pressure??of?? ????????°C??and??
??kPa??gauge??The??resulting??steam??is??then??fed??to??a??twophase??heat??exchan
ger?? coolercondenser????cooling??it??to??a??subcooled??liquid??water??at????
??°C??and??
??kPa??gauge??using??a??cooling??water??supplied??at???? ??°C??The??resulting??sub
cooled??process??liquid??is??then??ready??to??be??compressed??again??by??the??pump
??hence??completing??the??Rankine??cycle

The???? ??MW??of??energy??supplied??at??the??furnace??to??the??process??stream??c
ame??from??the??incineration??of??
??????kgs??of??municipal??solid??wastes??with??average??calorific??value??of????MJkg
??It??is??assumed??that??the??incineration??process??produced??flue??gases??at??the??f
urnace??exit??at??a??temperature??of??????????°C??This??was??obtained??from??energ
y??balance??while??assuming??a??heat??capacity??value??equal??to??that??of??Carbon
??dioxide??The??flue??gas??was??treated??to??a??series??of??absorbers??to??capture??
pollutants??such??as??SOx??NOx??and??Dioxins??before??releasing??it??to??the??atmos
phere??The??SOx??and??NOx??were??both??treated??using??a??gas??absorber??with??
water??and??hydrogen??peroxide?? H O ????respectively??as??solvents??Dioxins??were
??absorbed??using??a??fixedbed??absorber??composed??of??activated??carbon??The??ab
sorber??geometries??were??designed??according??to??the??allowable??pollutant??exit??co
ncentration??as??mentioned??by??Johnke??et??al??

III??Process??Flow??Diagram
To??follow??

IV??Heat??and??Material??Balance

Table?? ??Heat??and??Material??Balance??Sheet??of??the??Rankine??Cycle
Stream??Number??Subcooled_ ??Subcooled_ ??Steam_ ??Steam_
Mass??Flowrate??[kghr]????
????????
????????
????????
????
Molar??Flowrate??[kmolhr]?? ???????? ???????? ???????? ??????
Temperature??[oC]????
??????
????????
?? ??????
Pressure??[kPag]??
????
????
??

Enthalpy??[kJhr]??????????e
????????????e
????????????e
????????????e
??
Composition??wtFebruary??molFebruary??wtFebruary??molFebruary??wtFebruary??mol
February??wtFebruary??molFebruary
???? ?? ?? ?? ?? ?? ?? ??
Liquid??Fraction??Subcooled_ ??Subcooled_ ??Steam_ ??Steam_
Mass??Flowrate??[kghr]????
????????
??????
??

Molar??Flowrate??[kmolhr]?? ???????? ????????

??

Density??[kgm??]???????? ??????????
??

Heat??Capacity??[kJkgK]???? ???????? ?? ??
??

Viscosity??[cP]??
??????
??
????????
??

Thermal??Conductivity??[WmK]??
??????????
??????????
??

Surface??Tension??[dynecm]?????? ???????? ??
??

Bubble??Pressure??[kPaa]????????
Composition??wtFebruary??molFebruary??wtFebruary??molFebruary??wtFebruary??mol
February??wtFebruary??molFebruary
???? ?? ?? ?? ??
??
??
??

Vapor??Fraction??Subcooled_ ??Subcooled_ ??Steam_ ??Steam_

Mass??Flowrate??[kghr]??
??
????
????????
????
Molar??Flowrate??[kmolhr]??
??
?? ???????? ??????
Density??[kgm??]??
??
??
????????
??e

Heat??Capacity??[kJkgK]??
??
?? ???????? ??????
Viscosity??[cP]??
??
????
??e
?? ??????e

Thermal??Conductivity??[WmK]??
??
??

????????????e

Dew??Pressure?? kPaa??????????
Composition??wtFebruary??molFebruary??wtFebruary??molFebruary??wtFebruary??mol
February??wtFebruary??molFebruary
????
??
??
??
?? ?? ?? ??

V??Equipment??Design
??
A??CoolerCondenser??Heat??Exchanger

a??Equipment??Description
The??equipment??is??responsible??for??cooling??down??the??process??stream??from??a
??superheated??steam??at?? ????????°C??to????
??°C??subcooled??liquid??water

b??Design??Narrative
Design??procedures??were??performed??using??both??MSexcel??and??HTRI??Energy??ba
lance??and??initial??calculations??of??geometry??were??performed??using??an??excel??ca
lculation??sheet??The??twophase??heat??exchanger??was??treated??as??a??coolerconden
sercooler??in??series??with??additive??geometry??and??duties??Since??it??utilizes??a??co
untercurrent??configuration??mass??and??energy??parameters??of??the??cooling??streams
??are??specified??according??to??the??specified??approach??temperature??of??????°C??T
he??resulting??temperature??profile??is??given??in??figure??A ??Kern??method??was??us
ed??to??estimate??heat??transfer??coefficient??of??the??heat??exchanger??for??a??given
??geometry
 Figure A1. Temperature profile through the Cooler-Condenser system for the hot (process
stream) and cold (cooling water) streams

The main parameters manipulated in the design process include the shell inside diameter, the
tube length, tube outside diameter, and tube passes. The hot and cold fluid properties also
played a big role in the design process since physical properties such as heat capacity, thermal,
conductivity, and density for each stream were obtained from these data. It is executed through
interpolation of values.

The decisions made were primarily based on heuristics. The percent overdesign should not
exceed 10% and pressure drops should not exceed 60 kPa.

The resulting geometry was then used as a starting point to design using HTRI. The geometric
parameters including, bundle diameter and shell inner diameter was adjusted to achieve an
acceptable overdesign (close to 10%) and allowable pressure drop. Both design procedures
resulted to comparable and consistent results.

c. Equipment Specification Sheet

B. Heat Exchanger (Flue gas cooler)
a. Equipment Description
This equipment is responsible for bringing the temperature of the flue gas at 98.9 °C
down to the temperature specified at the absorber inlet (40 °C).

b. Design Narrative
This design involves a simple heat exchanger. Specifications are of default type since
there are no specific details. The design is optimized in order to have a heat exchanger with
plausible and acceptable specifications. The only main goal of this design is sensible cooling of
the flue gas from 98.9 °C to 40 °C for the designed isothermal gas absorber to be used which
operating temperature is at 40 °C.

c. Equipment Specification Sheet

C. SOx Gas Absorber

a. Equipment Description
The equipment is responsible for absorbing SOx pollutant included in the flue gas using water
as solvent.

b. Design Narrative
Mass and Energy balance were performed based on assumed inlet flue gas composition based
on Johnke, et. al and allowable pollutant concentration based on the Decision Makers’ Guide to
Municipal Waste Incineration (1999). The HOG*NOG method was implemented as the design
procedure with mass transfer relations used according to the two-film theory assuming diffusion
through a stationary component (DTSC) behavior. Equilibrium behavior between the solvent
and SOx was established based on the example given in class. On the other hand, the
operating line was established using mass balance relations on a solute-free basis.

NOG was calculated from both the established operating and equilibrium line. The design
equation was solved using numerical integration (trapezoidal method) with 150 steps. HOG was
solved assuming the properties of the intalox packing material.

c. Equipment Specification Sheet

D. NOx Gas Absorber

a. Equipment Description
The equipment is responsible for absorbing NOx pollutant included in the flue gas using H2O2
as solvent.

b. Design Narrative
Mass and Energy balance were performed based on assumed inlet flue gas composition based
on Johnke, et. al and allowable pollutant concentration based on the Decision Makers’ Guide to
Municipal Waste Incineration (1999). The HOG*NOG method was implemented as the design
procedure with mass transfer relations used according to the two-film theory assuming diffusion
through a stationary component (DTSC) behavior. Equilibrium behavior between the solvent
and NOx was established based on Raoult’s law with slope obtained from the Antoine equation.
On the other hand, the operating line was established using mass balance relations on a solute-
free basis.

NOG was calculated from both the established operating and equilibrium line. The design
equation was solved using numerical integration (trapezoidal method) with 150 steps. HOG was
solved assuming the properties of the intalox packing material.

c. Equipment Specification Sheet

E. Fixed bed Adsorber

a. Equipment Description
This equipment is desired to remove the organic compounds from the flue gas such as
dioxins. Dioxins are removed with chlorobenzene constituent over activated carbon.

b. Design Narrative
For the breakthrough curve, the group extracted the data from literature (Guo, Y. 2016).
The data is for the dioxin adsorption in activated carbon. Lab-scale reactor dimensions from the
paper were scaled-up to accommodate desired volumetric flow rate (see Equipment
Specification Sheet). The HOG*NOG method was then used to determine the length of unused
bed given the geometries.

c. Equipment Specification Sheet

VI. References

Decision Makers’ Guide to Municipal Waste Incineration. (1999). Washington, D.C.

20433, U.S.A.: Library of Congress Cataloging-in-Publication Data.
 Fundamental Applications of Steam. (2017, April). From Forbes Martial:
https://www.forbesmarshall.com/fm_micro/news_room.aspx?Id=boilers&nid=155

Geankoplis, C. (1993). Transport Processes and Separation Process Principles. United

States: Prentice Hall.

Johnke, B. (n.d.). Emissions from Waste Incineration. Good Practice Guidance and
Uncertainty Management in National Greenhouse Gas Inventories.

Nuclear Power. (2017). From Rankine Cycle - Steam Turbine Cycle: http://www.nuclear-
power.net/nuclear-engineering/thermodynamics/thermodynamic-cycles/rankine-cycle-
steam-turbine-cycle/

Guo, Y., Li, Y., Zhu, T., Wang, J. & Ye, M. Modeling of dioxin adsorption on activated carbon.
Chem. Eng. J. 283, 1210–1215 (2016).