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Fixx Jurnal Buimah
Fixx Jurnal Buimah
Fixx Jurnal Buimah
Abstract - When the level of water reservoirs from Brazilian hydroelectric stations is low, additional thermal
plants are turned on to complement the power of the national electric system. The fuels used in these plants are
generally natural gas, fuel oil and coal. The objective of this work is to analyze energetically and exergetically a
fuel oil thermal plant in operation in Brazil. Real industrial data were used in this analysis. The calculated total
work of the turbine is 120.73 MW, which is close to the real value of 120 MW. The cycle energetic efficiency is
36.8% and the exergetic efficiency is 34.4%. The highest exergy destruction was found to be in the boiler (177.11
MW), followed by the high pressure turbine (13.37 MW), due to larger irreversibilities in the processes of these
equipment. The exergetic analysis functioned as a complement to the energetic analysis, pointing out where the
greatest irreversibilities and improvement potential are: in the boiler.
Keywords: Electrical power generation; Efficiency; Exergy destruction.
In some cases, it is specifically applied to thermal 125 MW. In 1999, after some modifications, its capacity
power plants (Adibhatla and Kaushik, 2014; Aminov was increased to 131 MW. The energy source of the
et al., 2013; Aljundi, 2009; Kamate and Gangavati, plant is fuel oil 1A. The power delivered from the plant
2009; Kaushik et al, 2015; Regulagadda et al., 2010; to the electrical system varies according to the demand
Rosen and Dincer, 2003). Regulagadda et al. (2010) of ONS. In this work, operational conditions that result
emphasize the limitations of an energetic analysis of the in a gross power output of 120 MW are considered.
thermodynamic cycle, since it does not consider system The process of electrical energy generation in this
irreversibilities, environmental conditions and the plant consists of a Rankine cycle, and a simplified
degradation of energy quality. Therefore, an exergetic flow diagram of the plant is shown in Fig. 1. The water
analysis may be applied to minimize the limitations of stream extracted from the condenser (1) enters the
the energy balance (Regulagadda et al., 2010). condensate extraction pump (CEP) to be pressurized.
The objective of this work is to analyze It then passes through low pressure heaters (LPH1
energetically and exergetically a fuel oil thermal and LPH2), where it receives heat from the vapor
power plant in operation, which is located in the state extractions (I) and (II), which come from the low
of Minas Gerais, Brazil. Real industrial data are used pressure turbine (LPT). The partially heated water
in this analysis. The operating conditions used in this stream (4) enters the deaerator (DE), which operates
work were reported directly from plant operators and counter currently to remove dissolved oxygen. In this
represent actual adopted values in daily operations. equipment, there is also addition of the vapor extraction
(III), which comes from the medium pressure turbine
(MPT), and addition of the liquid extraction (B),
SYSTEM DESCRIPTION which comes from the high pressure heater (HPH1).
Water stream (5) moves to the boiler feed pump
The Igarapé Thermal Power Plant was built in 1978 (BFP), where it is once again pressurized, and passes
and its operation started with an installed capacity of through the high pressure heaters (HPH1 and HPH 2).
Figure 1. Process flow diagram: BFP – Boiler Feed Pump; CEP – Condensate Extraction Pump; DE – Deaerator;
DS – Desuperheater; ECO – Economizer; HPH – High Pressure Heater; HPT - High Pressure Turbine; LPH – Low
Pressure Heater; LPT – Low Pressure Turbine; MPT – Medium Pressure Turbine; RH – Reheater; SH – Superheater;
WWT – Water Wall Tubes.
Heat received in these equipments is from extractions · Heat loss in the heaters is neglected;
(IV) and (V), which come from the medium pressure · The operation in SH, RH, HPH1, HPH2,
(MPT) and high pressure turbines (HPT) respectively. LPH1, and LPH2 is isobaric;
The following stream (8) is split into stream (9) and · The turbines and the pumps operate
the desuperheater (DS) stream (20). The latter bypasses adiabatically;
the boiler to control its output temperature. Stream · The temperature of stream (2) was estimated
(9) enters the boiler and is heated in various sections. at 320.15 K;
After passing through the economizer (ECO), the water · Extraction (I) is saturated vapor;
stream enters the drum. It recirculates through the · The streams leaving the heater (A-D) and
water wall tubes (WWT), and saturated vapor leaves leaving the deaerator (stream 5) are saturated liquids;
the drum. Vapor stream (11) enters the superheater · The fuel oil is an incompressible fluid and has
(SH) and is then mixed with stream (20). Stream (13) a constant heat capacity;
enters the HPT and does work. The output vapor stream · The reference temperature is 298.15K;
(14) is split into stream (15) and into extraction (V). Table 2 presents real pressure data of the extractions
Stream (15) returns to the boiler and passes through the (I-V).
reheater (RH). Stream (17) enters the MPT and does The temperatures of the extractions (II), (III), (IV),
work. Three streams leave the MPT: extraction (IV), and stream (19) were calculated with interpolations.
extraction (III), and stream (18); the latter enters the Temperature, pressure, and entropy data from the
LPT and does work. The LPT has three output streams: vapor table were used, as well as thermodynamic
extraction (II), extraction (I), and stream (19). The properties of extraction (I) and stream (17). The mass
latter flows into the condenser, where it is cooled at low flow rates of streams (1-4; 6-19) were calculated in
pressure, closing the water cycle. mass balances. The mass flow rates of extractions (I-
V) were calculated in energy balances and are shown
in Equations (1a-1e).
CALCULATION METHODOLOGY
m 7 ⋅ ( h8 − h7 )
m V = (1a)
Table 1 shows real data of the streams 1 to 19 ( hV − hA )
provided by plant operators. Enthalpy and entropy
from each stream were obtained using public software
from Zittau/Goerlitz University (Zittau’s Fluid m 6 ⋅ ( h7 − h6 ) − m V ⋅ ( hA − hB )
Property Calculator, 2017). m IV = (1b)
( hIV − hB )
Some considerations were made for the calculations:
· The process is in the steady-state;
· Kinetic and potential energy variations are m 5 ⋅ ( h5 − h4 ) − ( m V + m IV ) ⋅ ( hB − h4 )
neglected; m III = (1c)
· The auxiliary vapor system used to heat the ( hIII − h4 )
fuel oil tubes and the vacuum system ejectors are
neglected; m 3 ⋅ ( h4 − h3 )
m II = (1d)
Table 1. Real data from plant operation. ( hII − hC )
T P m·
i
(K) (MPa) (kg·s-1)
m 2 ⋅ ( h3 − h2 ) − m II ⋅ ( hC − hD )
1 319.15 0.0474 - m I = (1e)
2 - 1.965 - ( hI − hD )
3 343.15 - -
4 378.15 - - .
5 424.15 0.494 114.72 Work rate (W) and specific work (w) of turbines
6 428.15 15.988 - and pumps are calculated from the energy balance, as
7 463.15 - - shown in Equations (2) and (3), respectively, where n
8 508.15 - -
9 - 15.302 -
is the number of output streams. As there are no data
10 526.65 - -
11 - 14.909 - Table 2. Real pressure data from turbine extractions.
12 804.15 13.635 - Extraction P (MPa)
13 802.65 12.948 - I 0.0474
14 688.65 3.329 - II 0.131
16 810.65 - - III 0.592
19 - 0.0114 - IV 1.376
20 - - 2.78 V 3.239
Brazilian Journal of Chemical Engineering, Vol. 35, No. 04, pp. 1395 - 1403, October - December, 2018
1398 M. M. C. Fraga et al.
from stream (18), the work of the MPT and LPT are We =WT − W BFP − WCEP (12)
calculated together.
n We
W
= ∑ m out ,i ⋅ ( hin − hout ,i ) − Q L
i =1
(2) η En =
( m f ⋅ LHV )
(13)
.
W The net power output (We) was also calculated from
w= (3) a global energy balance, which resulted in Equation
m in
(14).
.
The total work rate of the turbines (WT) is calculated Q − Q
in Equation (4). The energetic efficiencies of the
W=e B C (14)
turbines (ηT,En) and the pumps (ηB,En) are obtained from
Equations (5) and (6) respectively. Carnot efficiency
. (ηCarnot) is calculated in Equation
(15), where (Wrev) is the reversible work rate. The
=WT WMPT / LPT + W HPT (4) temperature in the boiler (TB) was considered to be
804.15 K, which is the temperature of the stream
leaving the superheater (SH) (stream 12). The
W temperature in the condenser (TC) was considered to
ηT ,En = (5)
(W + Q ) L
be 290.15 K, the temperature of water from the river
that cools the condenser.
η P ,En =
(W − Q ) L
ηCarnot
=
Wrev
=
(TB − TC )
(15)
(6) Q B TH
W
.
The heat rate output in the condenser (QC) and the The exergy of the streams, shown in Equation (16),
specific heat output in the condenser (qc) are calculated was calculated considering the reference state T0 =
in Equations (7) and (8) respectively. 298.15 K and P0 = 0.101325 MPa. Exergy represents
the maximum capacity of a stream to do reversible
Q C = m 19 ⋅ ( h19 − h1 ) + ( m I + m II ) ⋅ ( hD − h1 ) (7) work without heat transfer (Regulagadda et al. 2010).
ex = h − T0 ⋅ s − ( h0 − T0 ⋅ s0 ) (16)
Q
qC = C (8)
m 1
The exergy balance, shown in Equation (17),
. associates
. the variation. of exergy (Ex) with heat transfer
The heat rate input in the boiler (QB) and the specific rate (Q), work rate (W), exergy
heat input in the boiler (qB) are shown in Equations (9) . input, exergy output,
and exergy destruction rate (Id). Exergy destruction is
and (10) respectively. associated with generation of irreversibility. Equation
(18) shows the calculation of exergy destruction
Q B =m 8 ⋅ ( h12 − h8 ) + m 15 ⋅ ( h16 − h15 ) (9) for a steady-state process. Equation (19) shows the
calculation for an adiabatic process, as considered in
Q B the turbines and pumps.
qB = (10)
( m 12 + m 15 )
dEx 1 − T0
− W + ∑ ( m ⋅ ex ) − ∑ ( m ⋅ ex ) − I d
=Q ⋅ (17)
dt T
The energetic efficiency of the boiler (ηB,En) was in out
Equation (20). Since there are irreversibilities in the Table 3. Fuel oil composition.
process, which lead to exergy destruction, the exergetic Components Mass fraction
efficiencies of the turbines (ηT,Ex) and the pumps (ηP,Ex) Carbon 0.8493
are calculated in Equations (21) and (22), respectively. Hydrogen 0.1029
The exergy efficiency of the boiler (ηB,Ex) is defined as Sulfur 0.0412
Nitrogen 0.0033
the exergy added to the system divided by the exergy Oxygen 0.0033
of the fuel, as shown in Equation (23).
Table 4. Fuel oil, air and flue gas data.
Wrev ,max= ∑ ( m ⋅ ex ) − ∑ ( m ⋅ ex )
in out
(20)
Substance Property Value
Fuel oil Lower heating value (LHV) 40166.4 kJ·kg-1
Mass flow rate 7.917 kg·s-1
W Input temperature 413.15 K
ηT ,Ex = (21) Heat capacity 2.303kJ·kg-1.K-1
Wrev Air Input temperature 313.15 K
Oxygen excess 30%
Flue gas Output temperature 426.15 K
W
η P ,Ex = rev (22)
W
Considering that air is a mixture of nitrogen (N2)
and oxygen (O2), and that the fuel is completely
m 8 ⋅ ( ex12 − ex8 ) + ( m 15 ) ⋅ ( ex16 − ex15 ) converted into carbon dioxide (CO2), water (H2O) and
η B ,Ex = (23) sulfur trioxide (SO3):
( m f ⋅ ex f )
Id ,B = m f ⋅ ex f + m O 2in ⋅ exO 2in + m N 2in ⋅ exN 2in +
The exergy of the fuel (exf) is the sum of thermo- + m 8 ⋅ ( ex8 − ex12 ) + m 15 ⋅ ( ex15 − ex16 ) −
mechanical (extm) and chemical exergy (exchem) (29)
− m CO 2out ⋅ exCO 2out − m H 2Oout ⋅ exH 2Oout − m SO 3out ⋅ exSO 3out +
(Equation 24). The thermo-mechanical exergy (extm)
is calculated in Equation (25) and the chemical exergy + m O 2out ⋅ exO 2out + m N 2out ⋅ exN 2out
is calculated in Equations (26) and (27), where zi is
the mass fraction of the component i in the mixture. The mass flow rate of each air and flue gas component
Chemical exergy is based on fuel composition and is calculated in a molar balance. The specific heat of
lower heating value (LHV) (Szargut et al., 1988). each component is a function of temperature, and
Tables 3 and 4 present fuel oil, air and flue gas data. Equation (30) (Smith et al., 2008) is used to estimate
them, where A, B and D are parameters.
ex f exchem + extm
= (24)
c p (T ) = A + B ⋅ T + D ⋅ T −2 (30)
T
extm = c p ⋅ (T − T0 ) − T0 ⋅ c p ⋅ ln (25) In order to calculate the exergy of each air and flue
T0 gas component, Equation (16) is further developed.
∫c p dT − T0 ⋅ ∫T ⋅ c p dT
−1
ex
= (31)
To To
z z
β = 1.401 + 0.1728 ⋅ H + 0.0432 ⋅ O +
zC zC
(27) {
ex = R ⋅ A ⋅ T − T0 ⋅ (1 + ln (T / T0 ) ) +
z z
+ 0.2169 ⋅ S ⋅ 1 − 2.0628 ⋅ H + B ⋅ T 2 / 2 − T ⋅ T0 + T02 / 2 + (32)
zC zC
+ D ⋅ 2 ⋅ T0 / T 2 − 1 / T − 1 / T0 }
In order
. to calculate the exergy destruction in the
boiler (Id,B), a control volume in the whole boiler is The exergetic efficiency of the cycle is the net
chosen. For .a steady state process (dEx/dt = 0), no power output divided by the fuel exergy, as shown in
work
. done (W = 0), and no heat loss to the environment Equation (33).
(Q = 0), Equation (17) is turned into:
We
nEx = (33)
Id ,B= ∑ ( m ⋅ ex ) − ∑ ( m ⋅ ex )
in out
(28)
( m f ⋅ ex f )
Brazilian Journal of Chemical Engineering, Vol. 35, No. 04, pp. 1395 - 1403, October - December, 2018
1400 M. M. C. Fraga et al.
.
IP =(1 − η Ex ) ⋅ Id (35)
Brazilian Journal of Chemical Engineering, Vol. 35, No. 04, pp. 1395 - 1403, October - December, 2018
1402 M. M. C. Fraga et al.
Brazilian Journal of Chemical Engineering, Vol. 35, No. 04, pp. 1395 - 1403, October - December, 2018