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Received March 11, 2013; revised April 9, 2013; accepted April 28, 2013
Copyright 2013 Satoru Okamoto. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
ABSTRACT
A ceramic gas turbine can save energy because of its high thermal efficiency at high turbine inlet temperatures. This
paper deals with the thermodynamic and economic aspects of a ceramic gas turbine cogeneration system. Here cogene-
ration means the simultaneous production of electrical energy and useful thermal energy from the same facility. The
thermodynamic performance of a ceramic gas turbine cycle is assessed using a computer model. This model is used in
parametric studies of performance under partial loads and at various inlet air temperatures. The computed performance
is compared to the measured performance of a conventional gas turbine cycle. Then, an economic evaluation of a ce-
ramic gas turbine cogeneration system is investigated. Energy savings provided by this system are estimated on the ba-
sis of the distributions of heat/power ratios. The computed economic evaluation is compared to the actual economic
performance of a conventional system in which boilers produce the required thermal energy and electricity is purchased
from a utility.
Keywords: Energy; Exergy; Energy-Saving; Economical Evaluation; Ceramic Gas Turbine; Cogeneration Plant
Table 1. Performance of a ceramic gas turbine (CGT302) Water in (20C) Saturated steam (1MPa)
[1,2]. Boiler
Eu(Qu)
Waste gas
Characteristics Units Data P11=101.3 LWp Exhaust gas
Ee(Qe)
T11=170
Maximum power output kW 300 G11=0.874 P10=104.4
T10=390
Heat-exchange P3=810.4 P4=794.2
Gas turbine type G10=0.874
twin-shaft T3=296 T4=717
G3=0.885 G4=0.858
Thermal efficiency % 42
ical energy Wnet and thermal energy or process heat than the quality of the energy content in low-pressure
Qu . A parameter used to assess the thermodynamic per- saturated steam. The exergy factor of fuel input is close
formance of such a system is the fuel-utilization effi- to unity for most fuels because the chemical energy in
ciency, which is simply the ratio of overall energy in the fuel is essentially overall exergy [5]. Thus, the second-
useful products, Wnet and Qu , to the energy of input law efficiency is not very sensitive to the exergy factor of
fuel Qo , the fuel used in cogeneration systems.
Wnet Qu For a typical cogeneration system with process heat in
q . (1) the form of saturated steam, u is in the range 0.25 -
Qo
0.4, and R ph is usually less than unity. Thus, e is
Another parameter commonly used to assess the ther- significantly less than q , and an evaluation of thermo-
dynamic performance of a cogeneration system is the dynamic performance of a cogeneration system based on
power-to-heat ratio R ph , the first-law efficiency alone could be misleading [5].
Wnet
R ph . (2) 2.3. Results and Discussion
Qu
The thermodynamic performance of a ceramic gas tur-
In these parameters, power and process heat are treated
bine cogeneration system was studied. Pertinent data are
equally. This reflects the first law of thermodynamics,
shown in Table l [1,2]. With this information, only a
which is concerned with the quantity and not the quality
procedure for calculating the quantity and quality of
of energy. Thus, the fuel-utilization efficiency is also
process heat produced is required. Then, the fuel-uti-
known as the first-law efficiency. However, according to
lization efficiency, power-to-heat ratio, and second-law
the second law of thermodynamics, electric power is sig-
efficiency can be calculated.
nificantly more valuable than process heat. Exergy, the
Overall thermal efficiency and net specific work were
central concept in a second-law analysis, is always con-
calculated for various values of TITs and pressure ratio.
sumed or destroyed in any real process. A process is bet-
The values of maximum TIT were taken to be 900C,
ter thermodynamically if less exergy is consumed. Con-
1000C, 1100C, 1200C, 1300C, 1350C, and 1400 C,
sequently, the ratio of the amount of exergy in the prod-
while the values of pressure ratios used in the calcula-
ucts to that supplied is a more accurate measure of the
tions were 2, 4, 6, 8, and 10.
thermodynamic performance of a system [4]. By defini-
Figure l shows the simple-cycle ceramic gas turbine
tion,
arrangement considered in this study. Fuel gas was used
W Eu in this analysis; however, the properties of any type of
e , (3)
Eo fuel can be fed to the computer program. Efficiencies of
the compressor, turbine, and combustion chamber were
where W is the overall exergy, Eu is the exergy con- assumed to be 82%, 84%, and 99%, respectively. These
tent of process heat produced, and Eo is the exergy assumptions were taken from catalogs provided by
content of input fuel. The quantity e is a second-law manufacturers and are expected to lead to realistic com-
efficiency. putational results.
The exergy factor of process heat u and the exergy Figure 2 shows thermal efficiencies at different maxi-
factor of fuel input o can be defined by the following mum TITs. TIT increases with the thermal efficiency.
expressions: The effect of atmospheric air temperature on thermal
Eu efficiency is shown in Figure 3. These values of thermal
u , (4)
Qu
50
E
th %
o o . (5)
Qo T=1400C
40
T=1350C
Then, the second-law efficiency may be written as T=1300C
q R ph u T=1200C
e . (6) 30 T=1100C
o R ph 1 T=1000C
T=900C
The exergy factor of process heat is always less than
20
unity. In the case of saturated steam, it increases with the 2 4 6 8 10
pressure of steam produced. This is consistent with the
second law of thermodynamics because the quality of the Figure 2. Overall thermal efficiency with various turbine
energy content in high-pressure saturated steam is greater inlet temperatures.
t=0C
t=5C combustion. The heat-recovery system produces satu-
t=10C
th
40 t=15C rated steam from the heat of the waste gas. For the ce-
t=20C
t=25C ramic gas turbine cogeneration process, it is 49.4 J per
t=30C 100-Joule input, which means an overall efficiency of
30 49.4%.
The exergy flow of a conventional gas turbine cogene-
ration process differs from a ceramic gas turbine coge-
20 neration process because the maximum TIT (900C) for
2 4 6 8 10 the conventional process is lower than that in the ceramic
turbine process (1350C). Only the amounts of the ex-
Figure 3. Overall thermal efficiency with various atmos-
pheric temperatures (TIT = 1350C). ergy flows differ. The conversion efficiency from fuel to
electricity is 25.8%. Apart from this, the exergy flow is
efficiency decrease as the atmospheric air temperature similar to that in the ceramic gas turbine cogeneration
increases for the same TIT (1350C). process.
Increases in the pressure ratio increase the thermal ef- To compare the two processes, characteristic data are
ficiency in some cases considered here. For pressure ra- condensed in Table 2. The boundary conditions for the
tios less than 8, the increase in the pressure ratio causes two plants are the same. Large exergy losses become
an increase in the thermal efficiency for a constant visible in all combustion process, e.g., for the combus-
maximum inlet temperature of 1350C, as shown in Fig- tion in gas turbines. The other conversion losses are com-
ure 3. Above a pressure ratio of 8, increases in the pres- paratively small.
sure ratio decrease the thermal efficiency at all values of According to the second law of thermodynamics, the
the assumed atmospheric temperature. However, at high- useful heat and power delivered by a cogeneration plant
er values of the atmospheric temperature, the rate of in- do not have the same unitary value, although they are
crease in thermal energy with pressure ratio becomes quantified in the same physical unit, Joule.
smaller. Electricity is a form of pure exergy, while the heat
The calculated exergy flow and energy flow are re- contained in process steam has an exergy content (or
presented graphically in Figures 4 and 5, respectively. economic value) that depends on the temperature at
The lower heating value of the fuel represents 100% of which it is available. Figure 4 presents exergetic dia-
the exergy input into the process. This input to the fuel is grams relative to the production of heat and power by
converted into two exergy flows and a loss. The exergy typical process units. These diagrams clearly show that
fed to the ceramic gas turbine is converted into electrical some of the heat cannot be converted into useful work.
Fuel input
100.0% Loss in combustion
36.2%
Exergetic efficiency
49.4%
28.9% 92.7%
Combustor Loss in turbine
3.7%
Turbine
Loss in Compressor
3.1%
Waste exhaust 16.3%
3.6%
Boiler
Loss in boiler Steam Process heat
4.1% 8.6%
Figure 4. Exergy flow diagram of a ceramic gas turbine cogeneration system.
This results from internal irreversibilities caused by im- ing the minimum and maximum electric and thermal
perfections in the conversion process; it measures the demands. Hourly fluctuations between the minimum and
degradation of energy entering the process (fuel) whose maximum demands are described by means of a daily
exergy content is close to unity. load profile that is made dimensionless with respect to
The situation is different in electricity production the total demand. Notice that the magnitude of the total
where only the exergy from the process is taken as the
useful output. This explains why thermal efficiencies Electricity
Process heat
based on the first law of thermodynamics easily reach 40.8%
26.4%
67% in Figure 5, while this sophisticated power plant Waste exhaust heat Required work for
hardly achieves 50% efficiency. 17.8% compressor
32.0%
3. Economic Evaluation
3.1. Definition of Energy Demand
Loss in combustion
In most cogeneration plants, both thermal and electric 15.0%
power demands experience wide variations over time.
Since the selected time step is 1 h and the plant simula-
tion is to be performed over an entire year, the most gen-
eral format of input data necessary to define each case Fuel Utilization Efficiency
would comprise an array of 8760 values. Besides making 67.1%
load specification very unpractical, such a format would
also require exhaustive computing times. On the basis of
the authors experience, the following simplified as- Fuel input
sumptions yield a sufficiently accurate load description 100.0%
for most practical situations. Figure 5. Energy flow diagram of a ceramic gas turbine
Monthly load variations can be described by specify- cogeneration system.
demand used for scaling daily profiles can change from defined as the ratio of energy saved by cogeneration to
month to month. It is assumed that there are only two fuel consumption in a conventional system. In the
types of daily dimensionless profiles, one for weekdays conventional system, electric power is purchased from a
and the other for weekends. A further distinction is in- utility (with 35% efficiency), and heat is produced by a
troduced between summer and winter. Thus, the entire boiler (with 90% efficiency). From the anticipated en-
year can be described by four daily profiles. ergy savings by cogeneration, a relationship was ob-
Under these assumptions, an entire year can be simu- tained between energy saving ratio and electric power
lated by optimizing only 24 days (two days for each supply per maximum demand in buildings. Using this
month); this results in substantial savings in computing relationship and the demand distribution in buildings,
time. In most practical cases, the accuracy of the results energy savings were estimated.
is much better than that of the load description. In the simulation model of the ceramic gas turbine co-
The maximum and annual demands at a hotel, a hos- generation plant shown in Figure 6, the source energy
pital, and an office building in Tokyo are shown in Table consumption of the system was estimated hourly. These
3 [6]. Monthly energy usage was allocated to both peak estimates were based on shaft power and recovered heat,
and off-peak periods. Hourly data on electric demand which were calculated from the partial-load efficiency of
were provided by the electric utility. The seasonality of a ceramic gas turbine, waste-heat recovery boiler, and
demand variations is the average weekday demand economizer.
shown for each of the two types of area of buildings of Using parameters of the generating efficiency of elec-
months. Monthly fuel usage was taken from daily boiler tric power, the overall efficiency of energy utilization
logs. While all boilers were capable of firing oil, only under partial loads, and the energy saving ratio, a plot of
natural gas was used. potential energy savings can be created, as shown in
Figure 7. Figure 7 indicates the values for energy saving
index of the hotel (20,000 m2), the hospital (20,000 m2)
3.2. Estimation of Energy Saving
and the office building (20,000 m2). This figure relates
To estimate the energy savings available from ceramic the energy saving ratio to the energy demand distribu-
gas turbine cogeneration, the energy saving ratio is tion. It is assumed that there are only two types of ce-
Purchased Electricity
electricity
Electric power generation
Ceramic gas Waste heat
Compressor recovery boiler Economizer Exhaust gas
Fuel turbine
Hot water
Steam Steam drain
Steam boiler
Steam absorption
refrigerator Cooling water
Steam
ramic gas turbines, as shown in Figure 7: fully loaded system with a conventional system, care must be taken to
and partially load. The fully loaded engine is CGT301, properly evaluate the unit energy costs in each case. With
whereas the partially loaded engine is CGT302. The cogeneration, electric utilization and contractual power
maximum saving energies in the partially loaded type for are generally lower, implying higher electricity costs.
the hotel and hospital are higher than those in the fully Moreover, the value for heat depends on the users
loaded type. In the range of electric power supplied per characteristics. Considering an example of business and
maximum demand, especially at lower values of supplied commercial use, a value for heat may be simply ob-
electric power, a large energy saving is not expected. tained as the product of the heat demand and the unit cost
of fuel used in the conventional system; but such a fuel
3.3. Analysis of Energy Cost cost can be the same as, lower than, or higher than that
for the cogeneration plant. Considering the users char-
When comparing the ceramic gas turbine cogeneration
acteristics, the computer program requires a value for
20
the cogenerated heat that must consider all differences in
fuel costs and efficiencies between the cogeneration and
19
conventional cases [7].
Energy saving ratio %
Full-load type 4
13 Part-load type
3
12 Full-load type
2
11 Part-load type
1
0 20 40 60 80 100
Electric power supply per maximum demand % 0 20 40 60 80 100
Electric power supply per maximum demand %
(a)
(a)
10
8
year
Energy saving ratio %
9
7
8 6
Pay-off period
7
5
Full-load type
6 Part-load type 4
5 Full-load type
3
Part-load type
4
2
0 20 40 60 80 100
0 20 40 60 80 100
Electric power supply per maximum demand % Electric power supply per maximum demand %
(b) (b)
13
12
12
11
11
year
Energy saving ratio %
10
10 9
Pay-off period
9 8
8
7
Full-load type
7 Full-load type
Part-load type 6 Part-load type
6
5
5
4
0 20 40 60 80 100
0 20 40 60 80 100
Electric power supply per maximum demand % Electric power supply per maximum demand %
(c) (c)
Figure 7. Values for energy saving index (20,000 m2) in a (a) Figure 8. Values for economical index (20,000 m2) in a (a)
hotel, (b) hospital, and (c) office building. hotel, (b) hospital, and (c) office building.
basis, and supplemental fuel costs, which are the costs of rived from improved system efficiencies.
fuel required for the conventional boiler and the duct
burner, were computed. The payback periods through
REFERENCES
cost savings derived from the efficiency of the ceramic
gas turbine cogeneration system for each building are [1] K. Honjo, R. Hashimoto and H. Ogiyama, Current Status
shown in Figure 8. Figure 8 indicates the values for of 300 kW Industrial Ceramic Gas Turbine R & D in Ja-
pan, Transactions of ASME, Vol. 115, No. 1, 1993, pp.
economic index of the hotel (20,000 m2), the hospital
51-57.
(20,000 m2) and office building (20,000 m2). The incre-
mental costs of operating this system are also presented. [2] Gas Turbine Society of Japan, Small Scale Ceramic Gas
Turbine: Research and Development of Advanced Gas
In the low range of electric power supply per maximum Turbine, NTS Inc., Tokyo, 2003. (in Japanese)
demand, the capacity of the ceramic gas turbine cogene-
[3] A. A. El Hadik, The Impact of Atmospheric Conditions
ration system is designed for payback periods of less than on Gas Turbine Performance, Transactions of ASME,
five years in the hotel and hospital. Vol. 112, No. 4, 1990, pp. 590-596.
[4] F. F. Huang, Performance Evaluation of Selected Com-
4. Conclusions bustion Gas Turbine Cogeneration Systems Based on
Many useful expressions have been developed for the First and Second-Law Analysis, Transactions of ASME,
Vol. 112, No. 1, 1990, pp. 117-121.
study of a ceramic gas turbine cogeneration system. Some
of the importance conclusions are as follows: [5] M. A. El-Masri, On Thermodynamics of Gas Turbine
Cycles: Part 1-Second Law Analysis of Combined Cy-
1) Specific output power, specific process heat produc- cles, Transactions of ASME, Vol. 107, No. 4, 1985, pp.
tion, fuel-utilization efficiency, and second-law efficiency 880-889.
improve with increases in the maximum inlet tempera- [6] New Energy and Industrial Technology Development Or-
ture. ganization, A Study of the Effect of Ceramic Gas Tur-
2) Second-law efficiency and power-to-heat ratio are bine Development, NEDO-P-8723, NEDO, 1988, p. 65.
better indicators of thermodynamic performance than fuel- (in Japanese)
utilization efficiency. [7] S. Consonni, Lozza and E. Macchi, Optimization of
3) In the high range of electric power supply per maxi- Cogeneration Systems Operation Part B: Solution Algo-
mum demand, maximum energy savings are realized. rithm and Examples of Optimum Operating Strategies,
4) The capacity of the system is designed for payback Proceedings of the 1989 ASME COGEN-TURBO III, 1989,
pp. 323-331.
periods of less than five years through cost savings de-
Nomenclature
Ee : waste exhaust exergy kJ/(kg/s); R ph : power-to-heat ratio;
Eo : exergy content of fuel input kJ/(kg/s); T or t : temperature C;
Eu : exergy content of process heat kJ/(kg/s); Ti : temperature in gas turbine cycle, i 1C - 11C;
Gi : mass flow rate in gas turbine cycle, i 1 - 11 kg/s; TIT : turbine inlet temperature C;
G f : mass flow rate of fuel in gas turbine cycle kg/s; Wc : required work for compressor kJ/(kg/s);
LWc : exergetic loss in compressor kJ/(kg/s); Wnet : electrical energy kJ/(kg/s);
LWh : exergetic loss in combustion kJ/(kg/s); Wt : turbine output work kJ/(kg/s);
LWP : exergetic loss in boiler kJ/(kg/s); e : exergetic efficiency (second-law efficiency) %;
LWt : exergetic loss in turbine kJ/(kg/s); q : fuel-utilization efficiency %;
Pi : pressure in gas turbine cycle, i 1 - 11 kPa; th : overall thermal efficiency %;
Qe : waste exhaust heat kJ/(kg/s); o : exergy factor of fuel input ( Eo Qo );
Qh : energy loss in fuel combustion kJ/(kg/s); u : exergy factor of process heat ( Eu Qu );
Qo : energy content of fuel input kJ/(kg/s); : pressure ratio.
Qu : energy content of process heat kJ/(kg/s);