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Venue : 04-02-02
Definition:
Steam is formed when water is heated over its boiling point at specific pressure.
(419 kJ of energy needed to convert 1 kg water into steam at 1 atm)
• Vacuum ejectors
• Flare atomization
Atomizer schematic
Dr. Shuhaimi Mahadzir
Steam Network
Steam normally distributed at several pressure levels (LS, MS, HS, HHS).
Letdown valves control the steam header pressure (with BFW injection for de-
superheating)
Cogeneration Network
Boiler Designs
Lancashire boiler
Horizontal, Stationary,
Fire tube, Internally fired,
Low Pressure
Stirling boiler
Vertical, Stationary,
Water tube,
Externally fired,
Low pressure
Steam Traps
Need steam traps to allow condensate (water) to pass out but prevent steam
from leaving the system
Free
moving
Disc
Question:
What is the problem
Metal disc of having condensate
(liquid) in steam line?
Furnace/Boiler Efficiency
Qprocess
hboiler =
Qfuel
CP (TTFT – Tstack)
=
CP (TTFT – To)
(TTFT – Tstack)
=
(TTFT – To)
Liquid hydrocarbon fuel is fed with air into a burner and generates 150 kW of heat for a
steam boiler. Boiler feed water (BFW) at a flow rate of 130 kg/h and temperature 150 oC is
supplied to the boiler, which generates steam at 40 bar,450 oC.
Determine the efficiency of the boiler.
Solution :
A fuel gas comprising pure methane is burned with 15% excess air inside a furnace. Both
fuel and air is at 25oC and 1 atm. The air is wet having a relative humidity of 60%.
Determine the efficiency of the furnace if the stack temperature is 100 oC.
Solution :
Find the composition of fuel and air inlet into the furnace:
At 25oC (298K), saturated water vapor pressure = 0.002832 MPa = 0.032 bar
Partial pressure of H2O in air, p’H2O = 0.6×0.032 bar = 0.019 bar.
Composition of H2O in wet air at 1 atm, yH2O = 0.019/1.01325 = 0.019 mol H2O/mol air
Solving for m = 0.019 × 11.16 kmol = 0.21 kmol H2O in wet air.
Both the fuel and wet air enter the burner at 25oC so that DHinlet = 0.
DHoC = -889,000 kJ/kmol.
1 kmol CO2
2.21 kmol H2O
The outlet composition (combustion product) is:
0.30 kmol O2
8.65 kmol N2
1st Guess Toutlet = TFT = 2000oC
Dhoutlet = {[1×54.85] + [2.21×43.67] + [0.3×35.27] + [8.65×33.47]} × [TFT – 25]
= 451.5 × [TFT – 25]
h =
96.2%
Gas Turbines
A heat engine that gives propulsive power to generate electricity in a power plant
or power to an aircraft.
6
5
3
1 2
Gas Turbines
COMPONENTS/PROCESSES:
DENERGY
1
INLET: 0 – 2 2 V0 2
COMPRESSOR: 2 – 3
4 COMBUSTOR: 3 – 4 DhCOMPRESSOR
COMPRESSOR
TURBINE: 4 – 5 qADDED
3 MAX AVAIL
OUTPUT POWER: 5 – AMB
DhCOMPRESSOR*
5
DhEXPANSION
2
T
Open Cycle
W=∆H
Taking air as ideal gas with constant Cp
W = ∆ H = CpDT
Open Cycle
2’
4’
REAL PROCESS
For a simple cycle (e.g. Bryanton Cycle, air only), thermal efficiency:
hth =
Wnet Qin – Qout Cp (T4 – T1)
= = 1-
Qin Qin Cp (T3 – T2) …………Equation (1)
A simple gas turbine cycle operates with a pressure ratio P 2/P1 = 10:1. The temperature
of the air entering the compressor is 30oC and the maximum permissible temperature in
the turbine is 760oC. Calculate the efficiency of the simple gas turbine cycle for g = 1.4.
Solution :
1 (g – 1)/g
hT = 1 -
r
(0.4/1.4)
1
=1- = 0.482 or 48.2%
10
Suppose both the compressor and turbine in the previous example operate adiabatically
Solution :
Thermal efficiency of the power plant 2’
2
Workturbine - Workcompressor
hth =
Heat Input
1
Calculate compressor work,
For Isentropic compression, T2/T1 = (P2/P1)(g-1)/g
T2 = 303(10)(0.4/1.4) = 585 K
= 22.9%
The thermal efficiency of a real cycle is much lower than the ideal cycle (~48%)
Steam Turbines
A steam turbine utilize high velocity steam flows through a fixed nozzles to
cause motion of blades that in-turns rotate a shaft. In a typical power plant, the
shaft is connected to a dynamic system that generates electricity.
• Condensing
Steam Turbine
• Back-pressure
Steam Turbine
• Extraction
Steam Turbine
Steam Turbines
Steam Turbines
Heating
(Phase Change,
Steam Generation, P1 > P 2
Superheating)
Isentropic Expansion
Pumping
(Shaft Work,
Heating
Power Generation)
Condensation
(Phase Change)
Steam Turbines
P1 > P 2
Actual Expansion
(nonisentropic)
(Shaft Work,
Power Generation)
Condensation
(Phase Change)
Steam Turbines
Real Process ∆H H1 – H 2
his = = =
Ideal Process ∆ H’ H1 – H 2’
Steam Turbines
N.B.:
x = dry fraction
sf = entropy of saturated liquid
sg = entropy of saturated vapor
Dr. Shuhaimi Mahadzir
Example:
A steam turbine operates with inlet steam at 7 bar, 320oC and is expanded to 1 atm.
If the isentropic efficiency is 75%, determine the shaft work generated by 1 kg steam.
Solution :
A steam cycle consists of a turbine with a rated capacity of 24 MW, which operates with
inlet steam at 86 bar, 500oC and is exhausted to 0.1 bar.
If the efficiency of the turbine is 75%, determine:
a) the state of the exhaust steam (isentropic),
b) the flow rate of the steam, and
c) the thermal efficiency if the turbine
Solution :
From steam table (by interpolation),
H186 bar, 500C = 3392 kJ/kg
For isentropic expansion
S186 bar, 500C = 6.6868 kJ/kg-K
= H1 – H2 @ DS = 0
From steam table, At 0.1 bar = 10.1325 kPa,
Steam enthalpy at 86 bar, 500oC; S20.1 bar = 6.6868 kJ/kg-K (Isentropic)
Superheated Steam at T = 500oC
S20.1 bar = 8.1461 kJ/kg-K (saturated vapor
Pressure 8 MPa 8.6 MPa 9 MPa
from steam table)
h (kJ/kg) 3399.5 3387.4
S20.1 bar < S0.1 bar, saturated(7.3541),
S (kJ/kgK) 6.7266 6.6603
which means the state of exhaust steam is
saturated. Dr. Shuhaimi Mahadzir
(solution Contd.)
Solving for flow rate of steam gives msteam = 37.4 kg/s or 134.6 t/h steam flowrate
Steam Balance
To determine the requirement for boiler feed water (BFW) and fresh water make-up
Find power generated by extraction of 40 bar, 4400C steam to 10.5 bar steam and
the flow rate of steam from 40 bar, 4400C header to 2 bar header in turbine T1.
40 bar, 440oC to 10.5 bar DHis = 350 kJ/kg (from steam table)
W2 = 1.7 MW
Do a steam balance on the given network below to determine flow rates m 1 to m7.
Utility
Boilers
Process Blowdown 5%
P = 40 bar Blowdown 5% m1
5 t/h
T = 350oC
h = 3094 kJ/kg 15 t/h
Process
Process m2
P = 4 bar 10 t/h Blowdown 5%
T = 150oC
h = 2753 kJ/kg 20 t/h
m3 Vent 5% Process
m4
Deaerator 2683 kJ/kg
m5
T = 105oC
h = 439 kJ/kg m6 m7
Treated Water Condensate Return 70%
T = 25oC T = 80oC
h = 105 kJ/kg h = 336 kJ/kg
m6 = m5 – m7 – 0.95m3
105m6 + 336m7 = 439m5 – 2618.8m3
Utility
Boilers
Process Blowdown 5%
P = 40 bar Blowdown 5%
5 t/h 23 t/h
T = 350oC
h = 3094 kJ/kg 15 t/h
Process 13 t/h
Process
P = 4 bar 10 t/h Blowdown 5%
T = 150oC
h = 2753 kJ/kg 3 t/h Vent 20 t/h
0.15 t/h Process
Deaerator
24.2 + 5.3 + 10.5 = 40.0 t/h