Combined cycle with detailed calculation of Cp in the HRSG

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Shannon Randall
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1 Combined cycle with detailed calculation of Cp in the HRSG A large, light-oil fired gas turbine with an electrical power output of 171 MW is integrated with a steam cycle, forming a combined cycle. Some gas turbine data: Electrical efficiency 36.1% Exhaust gas flow 445 kg/s Exhaust gas temperature 601ºC Heating Value Light Oil 42.3 MJ/kg The steam cycle has a single pressure HRSG, without supplementary firing. The stack temperature has been measured to 138ºC. Disregard approach temperature in the economizer outlet, i.e. assume that the temperature out from the economizer equals the drum temperature. The pressure at the steam turbine inlet is 40 bar and the temperature 550 ºC. The isentropic efficiency of the turbine is 0.88%. The mechanical and electrical efficiency of the steam turbine are each Consider a steam cycle with a feedwater tank at 0.2 bar, which obtains steam from the steam turbine at the same pressure. Feedwater from this preheater is fed directly to the HRSG via a feedwater pump placed after the preheater. The pressure in the condenser is 0.05 bar. a) Sketch the layout of the plant b) Calculate the pinch point temperature difference To obtain full score you have to determine Cp for the exhaust gas (i.e. not assume a value) c) Calculate the steam turbine power output d) Calculate the combined cycle efficiency

2 SOLUTION a) Power plant layout Gas Turbine Cycle Air Fuel Heat Recovery Steam Generator g4 g3 g1 s1 s1 s2 1 Steam Cycle 6 x b) Pinch point temperature Pinch point temperature is Δt pp = t g3 t S where t s = (saturation 40 bar) = ºC and t g3 is obtained from a heat balance over the superheater and the evaporator: m gt c pg (t g1 t g3 ) = m st (h 1 h S1 ) [A]

3 But as both t g3 and the steam flow are unknown we have to find a way first to determine the steam flow. As we have been given the stack temperature, a similar heat balance considering this will give us the steam flow: m gt c pg (t g1 t g4 ) = m st (h 1 h 6 ) [B] h 6 =(neglect pumpwork) = h 5 = sat 0.2 bar = kj/kg h 1 = 40 bar and 550ºC = 3560 kj/kg t g1 and m gt are given for the turbine. But we have to estimate c pg, which is dependent both on the temperature and on the composition of the exhaust. The c p chart we have available, considers average temperature of flue gases from light oil firing with a certain gas content, thus we have to determine both the gas content and the average temperature. Average temperature is t ave = (t g1 + t g4 )/2 = ( )/2 ºC = 370ºC The gas content can be obtained from the gas turbine data given. We know that for light oil, the gas content is obtained from: x = ( ) 1+ We thus have to find, which is defined as = Here we need to find both the flow and the flow! We know that m & gt = 445 kg / s = + = gt Furthermore Q& FUEL = LHV = QFUEL LHV But as we have both the power output and the efficiency of the gas turbine we get the power as: P Q& GTel 171 = = MW = MW η GT Now the flow can be determined:

4 QFUEL = = kg / s = 11.2kg / s LHV 42.3 The flow becomes = gt = kg / s = 433.8kg / s The specific consumption: = 11.2 = = Finally the gas content can be determined: x = ( ) = = With x = 0.39 and t ave = 370ºC, we find c p for equation [B] as c pgb = 1.10 kj/kgk Equation B is now solved for the steam mass flow: mgt c pg (t g1 - t g4 ) ( ) st = & = = 68.5kg / s h h Before solving equation [A] for the gas temperature t g3 we need to find a new c pg : Assume tg3 to 260 ºC (which is 10ºC more than the water saturation temperature in the drum) then t ave2 = ( )/2ºC= 430 ºC and with x = 0.39 we find that c pga = kj/kgk. h s1 = saturated 40 bar = kj/kg Equation A gives us tg3 as: t st ( h1 hs 1) 68.5 ( ) = t1 = 601 = c g 3 gt pg We made a very good guess, so we do not have to iterate Cp. C Δt pp = tg3 ts = = 9.8 ºC c) Steam turbine power output

5 The steam power output is: P ST = [m ST (h s1 -h x ) + (m st - m x ) (h x - h 2 )] η M η G We need to find h x, h 2 and m x. The expansion line through the turbine in a h-s diagram is determined by the inlet and the outlet, that is h 1 and h 2. The steam extraction enthalpy is found on this expansion line on the given pressure 0.2 bar. Via a heat balance on the feedwater tank we find the steam flow in x. The enthalpy in turbine inlet is found in the intersection of 550ºC and 40 bar lines. The isentropic enthalpy in the turbine inlet is found by drawing a straight vertical line until intersected with the condenser pressure = pressure in the turbine outlet. Thus h 2S = 2210 kj/kg The real enthalpy of turbine outlet is found through the definition of the isentropic enthalpy of expansion: h2 = h1 ηis h1 h2s = ( h 2 = 2370 kj/kg ( ) ) 550 deg C h1 h2s x 40 bar h2 0,2 bar 0,05 bar Introduce the value of h 2 into the h-s diagram and connect h 1 and h 2 with a straight line to create the expansion line. The steam extraction in x is now found in the intersection between the extraction pressure, 0.2 bar and the expansion line: h X = 2540 kj/kg The steam flow in x is found through a heat balance on the feedwater tank. Energy in = Energy out x m x h x + (m st m x ) h 4 = m st h 5 h 4 h 3 (neglect pumpwork) = sat liq 0.05 bar = kj/kg h 5 = sat liq 0.2 bar = kj/kg 5 4 Rearranging the equation and solving for m x we obtain: ( h5 h4 ) ( ) x = st = 68.5 kg / s ( h h ) ( ) m x = 3.24 kg/s X 4 We are now able to calculate the turbine power output as: P STel = [68.5 ( ) + ( ) ( )] kw

6 P STel = kw d) The combined cycle efficiency Finally the combined cycle efficiency is PGT + PST η CC = = = Q& η CC = 52.5%

2. The data at inlet and exit of the turbine, running under steady flow, is given below.

2. The data at inlet and exit of the turbine, running under steady flow, is given below. 3 rd week quiz 1. Identify the correct path of fluid flow in a steam power plant. a) Steam turbine-pump-boiler-condenser. b) Economizer- evaporator- superheater. c) Pump-turbine-condenser-evaporator. d)