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Abstract
Efficiency enhancement in a low grade fuel fired power plant is one of the challenging
tasks for researchers. In a low grade fuel fired power plant even a fraction of a percentage
improvement in efficiency implies a huge savings in annual fuel costs. Mainly, the poor
vapor quality of steam in the last stages of an LP turbine and energy loss in the condenser
deteriorates the Rankine steam cycle performance. Reducing the amount of energy loss in
the condenser and minimizing two-phase fluid operation in last stages of the LP turbine can
substantially improve the cycle efficiency. The objective is to reduce the energy losses and
to enhance the system performance. In this work a direct-fired 82.2 MWfuel biomass fueled
condensing power Rankine cycle is considered for performance improvement. Energy and
exergy analysis are performed for the proposed Rankine-Kalina combined cycle (RKC).
The RKC cycle produces higher power output and is more efficient than a Rankine steam
cycle.
Keywords: Rankine-Kalina combined cycle, low grade fuel, biomass.
1. Introduction
loss. The pressure in the condenser determines
The efficiency of the Rankine cycle can be
the quantity of latent heat that is to be removed
improved by varying cycle parameters such as
for the vapor to become condensed. The steam
turbine inlet pressure, inlet temperature, reheat
condenser cooling section weakens under partial
pressure, reheat temperature, extraction pressure
load conditions and the resultant increase in
and the condenser pressure with respect to the
vapor tends to overload the vent system at the
optimum value. The last few stages of an LP
same time as the vent system capacity is reduced
turbine usually operate in the two-phase region
at lower condenser pressures.
and they are subjected to blade corrosion
problems. Mainly, blade erosion occurs due to Dejfors et al. (1997) investigated
sudden impingement of moisture droplets at the thermodynamic advantages of utilizing
leading edge of the blades. The energy loss due ammonia-water mixtures in small direct-fired
to moisture reduces the power output and thus, biomass fueled cogeneration plants. In the
plant profitability (Dooley, 2001). Specific conventional condensing power application, the
volume of the steam is gradually increasing as cycle utilizing ammonia water reaches higher
the steam expands in the steam turbine. The power generation than the conventional Rankine
substantial increase in specific volume in the LP steam cycle. Modifications in the cycle
turbine leads to careful design of LP turbine configuration with respect to less energy and
stages and exhaust part. Appropriate selection of exergy loss may lead to further improvement in
blade material, and exhaust hood area are of power output of ammonia water cycle. Kalina
paramount importance in design. (Li et al., cycle shows better performance at different load
1985). The energy loss due to moisture and condition. During partial load, the performance
energy loss in the condenser are unavoidable of Rankine cycle further reduces due to variation
losses in steam electric power plants. These of steam quality at the turbine exhaust. It leads to
losses are even larger during off-design higher energy loss and reduction of LP turbine
conditions (Li et al., 1985). When compared to internal efficiency. In Kalina cycle, the quality of
the other cycle components, the condenser in turbine exhaust is always superior, adjusting the
steam power cycle is subjected to higher energy composition will maintain proper quality of
steam at the exit, and it reduces the component
*
Author to whom correspondence should be Int. J. of Thermodynamics, Vol. 11 (No. 3) 133
addressed. r_sm4@yahoo.co.in
irreversibility, hence more power output. Kalina 2. Proposed cycle configuration and its
proposed a novel bottoming cycle for use in integrated approach
combined cycle system using an ammonia-water
The literature often suggested that
mixture as a working fluid. The multi component
combining two or more thermal cycles within a
working fluid with variable boiling and
single power plant is more beneficial than
condensing temperature provides less exergy loss
operating in a single cycle alone. Two different
in the evaporator and condenser. Due to that, the
Kalina cycle configurations like distillation
Kalina cycle is more efficient than the Rankine
condensation subsystem (Marston, 1990) and
cycle especially when working with finite heat
modified Kalina cycle system for geothermal
sources (Dejfors et al. 1997; Mlcak, 1996).
resources-KCS 34 (Mlcak et al,2002) are
Using ammonia-water mixture throughout the
analyzed for better performance match with the
cycle is another way to improve the performance
topping cycle (Rankine cycle). Figure 1 depicts
of the cycle.
the proposed configuration of RKC cycle. RKC
The results of Dejfors et al. (1997) proved cycle represents the two-fluid cycles, where two
the same. Normally, using ammonia-water cycles amalgamated in series.
mixture at more than (400 °C) is not advisable,
because at higher temperature NH3 becomes
unstable which leads to nitride corrosion.
4
3 14
SH1
Tur-1 Tur-2
APH3 2
15
7 10
EVA1
1 22
SEP
EVA2
APH2 23
5
21 HTR
ECO P2
Valve 2
24 MIX
13 20 25 16
APH1 LTR
PH
Air 6
8 19
Flue gas P3
18 17
valve1
12 Condenser
OFH
P1 9
11 2c 1c
In all cases, the intention is to increase the the steam from the superheater (3) is partially
cycle efficiency over that of a single cycle. A expanded in the turbine and exhaust from the
combined cycle with a different working turbine (4) is sent to the bottoming cycle
medium is more interesting because the (Kalina) for further processing. In the open feed
advantages can complement one another. The water heater, the saturated liquid from the
topping cycle identified in Figure 1 is part of an preheater (9) is mixed with the saturated liquid
82.2 MW biomass fueled condensing power from the evaporator (6). The resultant mixture is
Rankine cycle. In the topping cycle (Rankine) heated by bleed steam from the turbine (10). In
134 Int. J. of Thermodynamics, Vol.11 (No. 3)
bottoming cycle, the working fluid is in liquid Figure 2 shows a T- s diagram for the RKC
phase before entering the evaporator (21). After cycle. The state of the working fluid is identified
the evaporator (22), the ammonia-water mixture by the same numbers as those of the schematic
splits into two streams (14, 23). The vapor (14) diagram in Figure.1. In the separator the
from the separator is expanded through the ammonia water mixture is separated into liquid
turbine. The liquid (23) gives off its heat to the and vapor with different fractions of ammonia
incoming saturated liquid from the condenser, represented by thin lines (14-23 and 14-22) as
further throttled to the turbine exit pressure and shown in Figure. 2.
finally it is mixed with stream (15) from the For the present case, efficiency of the cycle
turbine exit. is considered as the objective function to
3. Strategy of optimization optimize. The efficiency of RKC cycle depends
on the following parameters:
The first step in optimization is to
1. Bleed steam extraction pressure (Topping
transform the physical situation into a
cycle).
mathematical model, by identifying the number
2. Fraction of ammonia-water mixture at
and type of variables, objective function and the
separator inlet
constraints imposed on the system.
3. Turbine inlet pressure (Bottoming cycle).
600
550 3
500
450
400 2
7
Temperature , [ C ]
350
1
300
250
14
200 13
8
12 9
6 11
150
23 5 4
22
100
10
21
50 25 16
24 1920 2c
17 15
18 1c
0
-25 0 25 50 75 100 125 150 175 200 225 250 275
Total Entropy (m*s), [kW/ k]
Q3 Q (1 − η 1 )(1 − η 2 ) e 0 ch , NH 3 e 0 ch , H 2O
η = 1− = 1− 1 E ch = yi + (1 − y i ) (12)
Q1 Q1 M NH 3 M H 2 0
or
Where, e 0 ch, NH 3 and e 0 ch, H 2O are chemical
η =η1 + η 2 − η1 ×η 2 (6) exergies of Ammonia and water. The standard
chemical exergy of ammonia and water are taken
The cycle efficiency of topping and from Ahrendts (1980). The chemical exergy term
bottoming cycle can be written in terms of cycle vanishes during irreversibility calculation.
parameters indicated in Figure 1 as given below,
The second law efficiency, ε, for the net
power production is written as,
(m3×h3) −(m7 ×h7) −(m10 ×h10) −(m4 ×h4)−Wp1 −Wp2
η1= (7)
m3×(h3 −h13) Total exergyout in product
ε= (13)
W p1 = m12 (h12 − h11 ) &W p 2 = m5 (h6 − h5 ) Exergy in
(8)
9. Results and discussion
Where WP1 and WP2 are the pump work Analyses were performed at different steam
turbine outlet conditions and ammonia mass
m14 (h14 − h15 ) − WP3 fractions at the separator inlet.
η2 = (9) It is found that efficiency is best at a steam
m21 × (h22 − h21 )
turbine exit pressure and temperature of 3 bar
and 133.5 °C and the cycle configuration
W p3 = m18 (h1 9 − h18 ) (10) corresponding with the optimum parameter is
depicted in TABLE I.
Where Wp3 is the pump work corresponding to In bottoming cycle ammonia, mass fraction
the bottoming cycle. at the inlet to the evaporator and the turbine inlet
pressure varied continuously to obtain the
8. Exergy analysis of the cycle maximum power output. Optimum fraction of
Exergy is the maximum theoretical useful ammonia water mixture was found to be 0.89.
work (or maximum reversible work) obtained as Further increases in fraction of ammonia-
a system interacts with an equilibrium state. water mixture leads to a) decrease in mass flow
Exergy analysis provides accurate information of rate of ammonia water mixture at the inlet
the actual inefficiency in the system and the true separator inlet, b) decrease in mass flow rate of
location of these inefficiencies. ammonia liquid at the inlet to the HTR, and c)
Exergy method shows the designer how the decrease in work output. The variation of mass
performance of the system departs from the ideal flow rate at different fractions of ammonia-water
limit, to what extent each component contributes mixture are shown in Figure. 4. Reducing the
to this departure, and what can be done to design fraction of ammonia water mixture from the
a better less irreversible system (Rosen, 1999). optimum value leads to increase in mass flow
For all exergy analysis calculations, the rate of ammonia-water mixture at the separator
reference temperature is taken to be 15 °C, and inlet. Though mass flow rate increases, the plant
the reference pressure is 1.01325 bar. The total output does not show much variation. The reason
exergy of a system becomes the summation of is increasing mass flow rate increased the
physical exergy and chemical exergy. The quantity of work required for the pump which
alleviates the benefit.
Figure 4. Variation of mass flow rate for −0.2499(x O 2 /x C )[1 + 0.7884(x H2 /x C )] (15)
different fractions of ammonia-water mixture.
β 2 = (1 − 0.3035)( x O2 /x C ) (16)
The net power output of RKC cycle is 1.4
MW more than the power output of the The heat of vaporization, hvap, is 2.44 kJ/kg
condensing Rankine steam cycle configuration and), ech,H2O=64 kJ/kg.
reported by Dejfors et. al (1997). The first law
The exergy destructions are graphically
efficiency of RKC cycle is 1.43% more than
represented by the exergy flow diagram in
condensing Rankine steam cycle. RKC cycle is
Figure.5.
Seperator
0.0347MW
0.149 MW Heat transfer loss
(0.1414%) (4.517 MW,4.26%) 2.0359 MW
15.72 MW
Net
Poweroutput
17.761 MW 19.74 MW
20.113MW 21.739MW
(18.62%)
36.05 % 0.02 MW
Valve 2 1.47 MW(0.016%) loss in turbine
Mix loss
0.033 MW 0.041MW HTR loss (2.3 MW,2.22%)
0.031 (0.038%) 0.20 MW Exhaust loss
Mix loss% 46.56 %
(8.9MW,8.48%)
0.020 MW (0.188 %)
10.53MW Heat transfer loss FWH PUMP 2
(0.0188 %) (9.935%) (20.1,19.0 %) 65.56 % 2.150 MW
(2.030 %)
Air preheater 63.53 %
LTR loss (2.562 MW,2.42 %)
0.273 MW 65.95 %
Radiation Loss
(0.257 %) Pump(3) loss ( 1.199 MW,1.13%) 67.08 %
0.069 MW
(0.065%) Combustion Loss
Cond loss (34.89MW,32.92%)
100 %
0.317 MW
(0.299%)
105.98 MW
295
condensing Rankine cycle reported by Dejfors
and Svedberg (1999). The thermal exergy flow 290
diagram in Fig. 5 shows not only exergy losses
but also the splitting of exergy streams and 285
recirculation of exergy. Temperature- Enthalpy
rate difference diagram is an important tool for 280
-50 100 250 400 550 700 850 1000
heat exchanger analysis.
Figure 6 shows the temperature profile of Enthalpy (kJ/kg)
heat exchange process taking place in the
Figure 6. dT vs dh diagram for the condenser.
Int. J. of Thermodynamics, Vol. 11 (No. 3) 139
46.785 MW, which is 1.441 MW more than the encouragement. The work was performed using
RKC cycle. The exergy loss in the condenser is the computer facilities of Indian Institute of
0.299 % and is 7 % less than condensing Technology Delhi.
Rankine steam cycle. It confirms that RKC cycle
has less energy as well as exergy loss in the Nomenclature
condenser. Second law efficiency of RKC cycle E Exergy flow rate [kW]
is around 27.22 % and is 2.0 % more than the e Specific exergy [kJ/kg]
condensing Rankine cycle configuration adopted h Enthalpy [kJ/kg]
for this study. s Entropy [kJ/kg K]
10. Conclusions W1 Net power output topping cycle [kW]
W2 Net power output bottoming cycle [kW]
The current study explored the possibility Q1 Heat added in topping cycle [kW]
of integrating two different cycles for the sake of Q2 Heat added in bottoming cycle [kW]
better performance. The overall energy and Q3 Heat rejected from the bottoming cycle [kW]
exergy analysis were performed to find out the p Pressure [bar]
thermodynamic performance of proposed RKC t Temperature [°C]
cycle. The author proposed a new approach for m Mass flow rate [kg/sec]
reducing energy loss due to moisture in the X Quality of steam at the turbine exhaust
turbine exhaust and losses in the condenser of n Number of cycle
Rankine steam cycle power plant. The energy y Ammonia mass fraction in the solution
and exergy results shows that proposed Rankine- M Molecular weight
Kalina combined cycle is more efficient than
Rankine steam cycle operating on a condensing Subscripts
mode.
ph Physical exergy
In the topping cycle all the parameters that ch Chemical exergy
we used for this analysis pertain to one of the
direct-fired 82.2 MWfuel biomass fueled Rankine Greeks
cycle power plants in Sweden. Addition of
Ammonia-Water cycle as a bottoming cycle to η1 Topping cycle efficiency
the real direct-fired biomass plant provides the η2 Bottoming cycle efficiency
following benefits.
1. The condenser pressure in Rankine steam Abbreviation
cycle always operates under vacuum, whereas in RKC Rankine- Kalina combined cycle
RKC cycle condenser pressure is more than LTR Low temperature recuperater
atmospheric pressure. Due to that an air removal HTR High temperature recuperater
system and dearation are not required for RKC FWH Feed water heater
cycle. In RKC, cycle condenser pressure depends
on cooling water inlet temperature unlike References
Rankine cycle power plant in which it depends
on cooling water outlet temperature. Energy loss Ahrendts, J., 1980, “Reference states”, Energy,
in the condenser is less when compared to Vol. 5, pp. 667–677.
energy loss in the Rankine cycle. Bauer, W. F., 1958, “The Monte Carlo Method”,
2. Since the specific volume of steam at the Journal of the Society for Industrial and Applied
turbine exhaust of RKC cycle is lower than that Mathematics, Vol. 6(4), pp.438-451.
of the Rankine cycle, the turbine system and Dejfors, C., Thorin, E., Svedberg., 1997,
exhaust is very small. “Ammonia-Water Power cycle for Direct Fired
The cost of electricity for RKC cycle may Cogeneration applications”, Energy conversion
be substantially lower only if the cost associated and management, Vol. 39, pp.16-18.
with the additional components in the RKC are Dejfors, C., and Svedberg G., 1999, “Second law
not excessive compared to that for a condensing Analysis of Ammonia-water Power Cycle for
Rankine steam cycle. Direct Fired Cogeneration Applications”,
International Journal of Applied
Acknowledgement Thermodynamics, Vol. 2, pp.125-131.
The author would like to thank Dr.Mark Dooley, B., 2001, “Low Pressure Steam Turbine
Mirolli, Recurrent Engineering, Dr. Martson, Performance”, EPRI report, Strategic science
Villanova University, Dr. Eva Thorin, andTechnology,http://amptest.epri.com/targetSS
Department of Public Technology, Mälardalen TContent.asp?program=224919&value=01T023
University, for their valuable suggestions and 037&objid=266782.