Seminar Report

On
Energy Conservation in a Steam
combined cycle Power Plant

Hoozefa J. Shaikh
08BME040
Guide
Prof. R N Patel

Mechanical Engineering Department

Institute of Technology
Nirma University of Science and Technology
Ahmedabad 382 481

Certificate
This is to certify that Mr. Shaikh Hoozefa J, Roll No 08BME040, of B. Tech. Sem. VI has
successfully completed the report of seminar on Energy Conservation in a Steam combined
cycle power plant.
Date: 23/4/2011
Guide: Prof R N Patel

Head of the Department: Prof V R Iyer

Contents
Acknowledgements
Abstract
List of Figures / Diagrams
List of Tables
Nomenclature

Page No.
I
II
III
IV
VI

Chapter 1 Introduction to Combined Cycle power plant

1.1 Combine cycle power plant (CCPP)
1.2 Basic Layout of CCPP
1.3 Working Principle of a CCPP
1.4 Thermodynamic Cycles Involved in a CCPP
1.4.1 Toppling Cycle
1.4.2 Bottoming Cycle
Chapter 2 Methods of energy Conservation of Combined Cycle Power Plant
2.1 Various Methods for Energy Conservation

8-9

10

Chapter 3 Performance Improvement of Combined Cycle Power Plant Based

11-14
on the Optimization of the Bottom Cycle and Heat Recuperation
3.1 Influence of HRSG inlet temperature on the efficiency of steam bottoming cycle
3.2 Gas to Gas Recuperation
3.3 Conclusion
Chapter 4 Effect of Inlet Air Cooling in Gas turbine
4.1 Effect on inlet air temperature
4.1.1 Case study for determining effect of inlet air cooling in GT
4.2 Result
4.2.1 Power Output and Efficiency
4.2.2 Specific Fuel Consumption
4.2.3 Energy of Exhaust Gas
4.3 Conclusion
Chapter 5 Comparison of various types of Cooling Method for inlet air Cooling
5.1 Case Study comparing various cooling technique for inlet air cooling
5.2 Various techniques considered
5.2.1 Evaporative coolers
5.2.2 Heat absorption chillers
5.2.3Mechanical chillers
5.2.4 Heat absorption chillers with ice storage

15-18

19-23

5.3 Economic Result

5.4 Conclusion
References

24

Acknowledgement
I wish to express my sincere gratitude to Prof. V R Iyer, HOD of Mechanical engineering
department of Institute of Technology, Nirma University for providing me an opportunity to do
my seminar work on Energy Conversation of a steam combined cycle power plant. I sincerely
thank to my seminar guide, Prof. R N Patel, Mechanical Engineering Department of Institute of
Technology, Nirma University for guidance and encouragement in carrying out this seminar
work. I also wish to express my gratitude to seminar instructor Prof B A Shah, who rendered his
help during the period of my seminar work. Last but not least I wish to avail myself of this
opportunity, express a sense of gratitude and love to my friends and my beloved parents for their
manual support, strength, help and for everything.

Hoozefa J Shaikh

Abstract

It is of great interest to investigate the efficiency improvement of CCPP plant. A combined cycle
with three-pressure reheat heat recovery steam generator (HRSG) is selected for study in this
paper.The optimization of the HRSG operating parameters is performed. The influence of HRSG
inlet gas temperature on the steam bottoming cycle efficiency is discussed. The result shows that
increasing the HRSG inlet temperature has less improvement to steam cycle efficiency when it is
over 590C. Partial gas to gas recuperation in the topping cycle is studied. Joining HRSG
optimization with the use of gas to gas heat recuperation, the combined plant efficiency can rise
up to 59.05% at base load. In addition, the part load performance of the GTCC power plant gets
much better. The efficiency is increased by 2.11% at 75% load and by 4.17% at 50% load.
Also, Despite their high efficiency, GT performance strongly depends on ambient air
temperature. It is well known the negative effect of this parameter on GT efficiency and power
output. In a CC, the high temperature and relative humidity of the ambient air also influence the
cooling tower behaviour, causing higher pressure in the condenser, and consequently reducing the
steam turbine cycle efficiency.
A proper solution to minimise this negative effect is to reduce GT inlet air
temperature by means of an air cooling system. Nevertheless, although the effect of different
cooling systems on GT operation has been widely analysed.

List of Figures / Diagrams

Fig. No.
1.1
1.2
1.3
3.1
3.2
3.3
3.4
4.1
4.2
4.3
4.4
5.1

5.2
5.3

Title
Basic Layout Of CCPP
P-V Diagram of Brayton Cycle
T-S Diagram of Rankine Cycle
Steam bottoming cycle efficiency as a function of HRSG Inlet Temp
Steam turbine exergy efficiency and HRSG Exergy loss v/s
HRSG inlet Temp
Gas Turbine with Partial Gas to Gas recuperation
HRSG inlet Temperature after recuperation v/s efficiency at
75% and 50% load
Power Output Temperature v/s Inlet air temperature
Efficiency variation v/s Inlet air Temperature
Specific fuel consumption v/s Inlet air temperature
Energy of exhaust gas v/s Inlet air temperature
CCPP power output performance over a year with and without
Evaporative cooler.
CCPP power output performance over a year with and without
Heat absorption Chiller
CCPP power output performance over a year with and without
Mechanical Chillers.

Page No.
8
9
9
11
12
13
14
16
16
17
18
19

20
21

List of Tables
Table No.
5.1

Title
Cooling systems investments depending on the selected technology

Page No.
23

Nomenclature
CCPP = Combined Cycle Power Plant
HRSG = Heat Recovery Steam Generator
T = Temperature
S= Entropy

Chapter 1
Introduction to Combined Cycle power plant
1.1 Combine cycle power plant (CCPP)
In electric power generation a combined cycle is an assembly of heat engines that work in tandem
off the same source of heat, converting it into mechanical energy, which in turn usually drives
electrical generators. The principle is that the exhaust of one heat engine is used as the heat
source for another, thus extracting more useful energy from the heat, increasing the system's
overall efficiency

1.2 Basic Layout of CCPP

Fig 1.1 Basic Layout of CCPP

1.3 Working Principle of a CCPP

In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant, a gas
turbine generator generates electricity and heat in the exhaust is used to make steam, which in
turn drives a steam turbine to generate additional electricity. This last step enhances the efficiency
of electricity generation.

1.4 Thermodynamic Cycles Involved in a CCPP

1.4.1 Toppling Cycle
The thermodynamic cycle associated with Gas Turbine Generator is referred to as Toppling cycle.
Brayton cycle is the most commonly used cycle in Gas turbine.

Fig 1.2 P-V Diagram of Brayton Cycle

1.4.2 Bottoming Cycle
The thermodynamic cycle involved in Steam turbine generator is known as Bottoming cycle
Rankine cycle is the most common cycle in Steam Turbine Generator.

Fig 1.3 T-S Diagram of Rankine Cycle

Chapter 2
Methods of energy Conservation of
Combined Cycle Power Plant
2.1 Various Methods for Energy Conservation are
1. Optimization of Bottoming Cycle
2.

Partial Gas to Gas Heat Recuperation In Gas Turbine(GT)

3.

Inlet Air Cooling Methods using

a. Evaporative Coolers
b. Mechanical Chillers
c. Heat Absorption Chillers
d. Heat Absorption Chillers using Ice Storage

10

Chapter 3
Performance Improvement of Combined CyclePower Plant Based on the
Optimization of the Bottom Cycle and Heat Recuperation

3.1 Influence of HRSG inlet temperature on the efficiency of steam bottoming

cycle
For a given HRSG configuration, the efficiency of the steam bottoming cycle is the function of
inlet gas temperature of HRSG. From Fig. 3.1 it appears that there is an upper limit value for the
inlet temperature of the exhaust gas to HRSG.
The increase in HRSG inlet temperature over a value of 590 C will lead to a less increase in the
efficiency of steam bottoming cycle.

Fig 3.1 Steam bottoming cycle efficiency as a function of HRSG Inlet Temp

11

Fig 3.2 Steam turbine exergy efficiency and HRSG Exergy loss v/s HRSG inlet Temp
This can also be confirmed by the analysis of the exergy losses rate in HRSG and turbine exergy
efficiency, as shown in Fig. 4. By the temperature of 620, the exergy losses rate in HRSG will
be minimal.
Hence, we conclude that efficiency of HRSG increases with increase in inlet air temperature, but
above 590 C due to increase in exergy loss rate it is not advisable to raise the temperature further.

12

3.2 Gas to Gas Recuperation

IF TEMPERATURE IS ABOVE 590 C, efficiency improvement is done using
Gas to Gas Recuperation
The gas turbine exhaust gas temperature reaches 615C at base load and even higher than 640C
under 75% load. To increase the efficiency of the combined cycle plant, heating the compressed
air through partial gas to gas recuperation heat exchanger is done.

Fig 3.3 Gas Turbine with Partial Gas to Gas recuperation

The compressed air from compressor is divided into two streams: one directly to combustion
chamber and the other to the exchanger and then to combustion chamber,
Partial gas to gas recuperation does not decrease the steam bottoming cycle efficiency, but can
save the fuel consumption in Brayton cycle and increase the topping cycle efficiency.

13

Fig 3.4 HRSG inlet Temperature after recuperation v/s efficiency at 75% and 50% load
The combined cycle will operate at the best point when the gas to gas recuperation temperature is
regulated at the point of 620C at 75% load. The combined cycle plant efficiency is as high as
57.13%,
At the load of 50%, the best efficiency of the combined cycle plant is 54.25%, 4.17% more than
that of original value.

3.3 Conclusion
Hence, we conclude that increasing inlet HRSG temperature would lead to increase in efficiency
of bottoming cycle, but if temperature of GT outlet temperature is above 590C,
Partial gas to gas Recuperation in the toppling cycle will help in increasing the efficiency.

14

Chapter 4
Effect of Inlet Air Cooling in Gas turbine
4.1 Effect on inlet air temperature
The power output and efficiency of a gas turbine plant depends among on the temperature of
inlet air. The efficiency and power output of a gas turbine during hot condition is less than power
output during cold condition.
Cooling the inlet air of gas turbine, decreases the temperature which increases the air density,
hence increasing the mass flow rate.
Ability to cool the inlet air will facilitate the production of consistent gas turbine power output
throughout the year, irrespective of the changes in ambient temperature. Also cooling the inlet air
increases the mass flow of air into the gas turbine and at the exhaust outlet. The increased exhaust
mass flow increases steam production in the heat recovery steam generator downstream of the
gas turbine due to higher energy availability in the exhaust gas. For the same power output,
decreasing the inlet air has the effect of decreasing the fuel consumption.
4.1.1 Case study for determining effect of inlet air cooling in GT
The data used for the analysis is obtained from the manufacturer data sheet of TAURUS 60 gas
turbine model. TAURUS 60 is a simple gas turbine, the nominal performance at ISO condition
(15oC and 60% RH), power output is 5670 KW, heat rate 11425 KJ/KW.hr, exhaust temperature
783 K and natural gas fuel flow, no inlet and exhaust losses and no accessory losses.

15

4.2 Result
4.2.1 Power Output and Efficiency
The power output and efficiency of the cycle were calculated for various ambient air
temperatures, for relative humidity of 60% and 100%, and the results of the analysis are
presented in Fig.4.1 and Fig4.2 respectively. A rise in the ambient temperature by 1oC result
0.75% drop from gas turbine rated capacity.

Fig 4.1 Power Output Temperature v/s Inlet air temperature

Fig4.2 Efficiency variation v/s Inlet air Temperature

16

4.2.2 Specific Fuel Consumption

The specific fuel consumption (SFC) of gas turbine decrease when the ambient temperature
decreases, Fig.4.3 shows that at low ambient temperature of 24oC decreases to ISO standard
condition, the specific fuel consumption drop by 1.8% and at high ambient temperature of 35oC
decreases to ISO standard condition the specific fuel consumption drop by a 4.7%.

Fig 4.3 Specific fuel consumption v/s Inlet air temperature

17

4.2.3 Energy of Exhaust Gas

By reducing the intake air temperature, the flow rate of the exhaust gas will correspondingly
increase. Fig.4.4 shows at the low ambient temperature of 24oC decreases to ISO standard
condition, the energy of exhaust gases increases by about 3.55% and at the high ambient
temperature of 35oC decreases to ISO standard condition, the energy of exhaust gases increases
by about 8.3%.

Fig 4.4 Energy of exhaust gas v/s Inlet air temperature

4.3 Conclusion
The performance of gas turbine can be successfully improved by decreasing the temperature of
inlet air. Reducing the temperature from ambient condition to ISO standard condition could help
to increase the power output between 6.3% to 13.65%.

18

Chapter 5
Comparison of various types of Cooling Method
For inlet air Cooling
5.1 Case Study comparing various cooling technique for inlet air cooling
A three-level steam pressure combined cycle has been chosen for analysis. It is based
on a 260 MW Industrial GT and a 140 MW steam turbine.

5.2 Various techniques considered

5.2.1 Evaporative coolers:
Evaporative systems cool the inlet air by pulverising water into the air stream. The water
evaporation causes the air temperature to decrease.
Locations of low humidity climate are suitable to use this cooling technology.
Two considerations must be taken into account.
a) The maximum relative humidity that it is possible to reach with an evaporative system is
hardly over 90%.
b) The difference between wet and dry bulb temperatures in the outer section of the evaporative
system is recommended not to be under 1C.

Fig5.1 CCPP power output performance over a year with and without Evaporative cooler.
It can be inferred from figure 5.1, using an evaporative cooling system, a better
Improvement is reached in summer months than in winter ones. In addition, in the central hours
of summer days the improvement is still higher than the average result

19

5.2.2 Heat absorption chillers:

These systems are one of the best options for CCPP, due to the possibility of working with a lowpressure steam extraction. That extraction is condensed and returns to the steam cycle via
desgasificator. The required steam mass flow rate is taken to avoid unnecessary power loses in
the bottoming cycle. The absorption chiller selected uses the CC cooling tower to refrigerate both
absorber and evaporator. As a consequence, steam cycle performance is slightly deteriorated due
to the losses in steam mass flow and the increase of the condenser pressure.

Fig.5.2 CCPP power output performance over a year with and without Heat absorption Chiller
Results using a heat absorption chiller are shown in figure 5.2.
A 20 MW cooling power heat-absorption LiBr system has been selected for the study.
It allows to reach the maximum recommended cooling of the inlet air stream (7C) during 88% of
the period.

20

5.2.3Mechanical chillers:
Since the chiller compressor needs electricity to work, the power output improvement is partially
reduced with mechanical cooling systems. However, the temperature reduction could be as high
as desired. Mechanical chiller results are similar to those obtained with an absorption chiller.

Fig 5.3 CCPP power output performance over a year with and without Mechanical
Chillers.

5.2.4 Heat absorption chiller with ice storage.:

When the differences between peak and no-peak demand prices are high, the use of ice storage is
advisable. This system allows to storage cool energy, i.e. when electricity prices are low, and to
use the storage energy to reduce air temperature when electricity prices increase. In places with
small variation of electricity prices, this option is not economically competitive.
Although an important temperature reduction could be achieved during some period, the
month average power output improvements are worse as compared to other chillers. During part
of the day, the cooling system is off but a power consumption exists to generate and storage ice.
This system could work some hours a day in critical months (summer), but the same ice tank
capacity allows to work more hours (sometimes all day) in winter months.
Normally, the selected hours to work are those with higher electricity prices, and the energy
storage is made along the whole day.

21

5.3 Economic Result

90% CC availability per year is considered and values of equipment prices derived from the
economic study are shown in table

Table 5.1 Cooling systems investments depending on the selected technology

22

5.4 Conclusion
In evaporative cooling, the inlet air is cooled to near the ambient wet bulb temperature. In
Refrigerated cooling, the inlet air is cooled to below the dew point temperature. Since larger
temperature reductions are possible with refrigerated cooling, capacity enhancements are
correspondingly higher compared to evaporative cooling.
The main advantage of evaporative cooling is simple design and low initial cost. The payback is
quicker for evaporative cooling even though the capacity increment is limited by ambient wet
bulb temperature.
Since electricity power generates higher incomes per kilowatt, the maximum temperature
reduction is the recommended goal. A cooling system with the same technology but with higher
chilling power always produces higher cash flows. Therefore, sizing must be made in order to
reach the minimal air temperature that is technologically allowable in the GT inlet duct (5-7C).
Combining technical and economic results, evaporative coolers generally have a good economic
behaviour, due to their low cost. Their main disadvantage is that it is impossible to fix the inlet
temperature below a point (dew temperature) which depends on the weather conditions (site
climate). Their payback periods are less of a year when the climate is favourable and near a year
with adverse humidity.
Mechanical coolers have lower cash flow as compared to heat absorption ones
With the former, a slightly lower power output improvement and a slightly fuel decrement is
obtained in comparison with the latter.
Both effects make the mechanical chillers cash flow to decrease.
Hence, it is advisable to use evaporative coolers only if climate are favourable, else mechanical
type or heat absorption type chillers are to be used depending on the requirement of the plant.

23

References

www.wikipedia.org
2. Wenguo XIANG, Yingying CHEN Journal of Thermal Science Vol.16, No.1 8489
3. Waiel Kamal Elsaied, Zainal AmbriBin Abdul Karim, Effect of Inlet air cooling, University of
Technology, Petronas, Bandar Seri Iskandar, 31750 Tronoh, Perak, Malaysia
4. Raquel Gareta, Luis M. Romeo,Antonia Gil, The Effect of Inlet air Cooling System in CC
performance, CIRCE (Centre of Research for Power Plants Efficiency). University of Zaragoza
1.

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