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WER015 Final Report Assignment 1
WER015 Final Report Assignment 1
WER015 Final Report Assignment 1
REPORT
Västerås, den 5 Oktober. 2010
Thermal Engineering
Table of figures...........................................................................................................................3
Introduction.................................................................................................................................4
Background.............................................................................................................................4
Problems.................................................................................................................................4
Limitation of study..................................................................................................................4
Methodology...............................................................................................................................5
Optimization Method..............................................................................................................5
Efficiency Calculation..........................................................................................................18
Total Cost Calculation..........................................................................................................19
Main text...................................................................................................................................22
Under titles in different levels...............................................................................................22
Result........................................................................................................................................23
Conclusion................................................................................................................................25
Table of figures
Figure 1 Power production for the first case...............................................................................5
Figure 2 Power production for the second case..........................................................................8
Figure 3 Power production for the third case............................................................................11
Figure 4 Zoom-in of the third case...........................................................................................11
Figure 5 Power production for the forth case...........................................................................15
Figure 6 Zoom-in of the forth case...........................................................................................15
Figure 7 Total cost of first case.................................................................................................21
Figure 8 Setting up solver parameters......................................................................................21
Figure 9 Optimization of Case 2...............................................................................................23
Figure 10 Optimization of case 2..............................................................................................23
Figure 11 Optimization of case 3..............................................................................................23
Figure 12 Optimization of case 4..............................................................................................24
Figure 13 Construction cost sensitivity of case 4.....................................................................24
Figure 14 Fuel cost sensitivity of case 4...................................................................................25
In this exercise we will examine a district heating system with 100 MW installed load with
hot water boiler for the maximum load calculated by the load curve.
Problems
Find the best performance of boiler
Find the number and capacity of boilers after optimization
Compare the total energy production
Find heat energy production cost per MWh
Make a simple sensitivity analysis if;
o Fixed costs varies between 70-150%
o Fuel cost varies between 70–200%
Draw a total energy ratio diagram
Limitation of study
An experimental study has been performed on the 8 953 MW steam boilers that burn 3 types
of fuel compose of oil, wood, and coal to optimize boiler efficiency. Cost calculation is
consider economic criteria includes construction cost, staff cost, fuel cost, auxiliary power
cost, and interest rate as shown in table 1.
Methodology
Optimization Method
From the data given in excel Oil has lowest construction cost while has highest fuel cost. In
another Wood has high construction cost while has lowest fuel cost. So both Oil and Wood as
boilers have been choose for developed optimization methods by using Wood as much as
possible while Oil used as small as possible to produce the energies.
First Case
For this case we use 2 boilers, one for Oil as peak load and another for Wood as base load.
According to Figure 1,
1. Point A to B
At zero hour we run Wood Boiler at maximum load all the time and make up other
load with Oil Boiler until Oil cannot be operated at lower than minimum capacity,
10% of full capacity at point A. At this point to save fuel cost, we reduce running load
of Wood Boiler following the Oil Boiler run at the minimum load, point A to B. Now
we can shut down Oil Boiler and start up Wood Boiler only to produce the load until it
reach at minimum load of 25%,
2. Point B to C
We shut down Wood Boiler and start up Oil Boiler again, run it until end of year,
8760th hour. We have also a Standby Boiler in case of the largest boiler cannot work.
We have chosen Oil Boiler, because it has lowest cost compared with others two,
wood and coal.
Limitation of Boiler Capacity
To set up the Limitation of Boiler Capacity, first condition we assume that the maximum
capacity of Oil Boiler has to be greater than or equal to the minimum capacity of Wood Boiler
(0.25) at point C from figure 1.
The second condition is the summation of both main boilers has to be equal to the maximum
load curve.
From solving Eq. a_1 and a_2 we get possible maximum capacity of Oil Boiler and minimum
capacity of Wood Boiler.
For the third condition Oil Boiler must be able to run at minimum load curve, 6.303 MW.
Then we can get possible minimum capacity of Oil Boiler and maximum capacity of Wood
Boiler, with min.oil-load = 0.1.
Ppart = Pmax.wood-cap.
Point A to B,
Ppart = Load_Curve
IF condition in Excel: Load_Curve <= Pmax.wood-cap.
Ppart = 0
IF condition in Excel:
Load_Curve <= (min.wood-load * Pmax.wood-cap.)
Oil Boiler
0th to point A,
Point A to B,
IF condition in Excel:
(Load_Curve) – Pmax.wood-cap. <= (min.oil-load * Pmax.oil-cap.)
Point B to C,
Ppart = 0
IF condition in Excel:
Load_Curve <= Pmax.wood-cap.
Ppart = Load_Curve
IF condition in Excel:
Load_Curve <= (min.wood-load * Pmax.wood-cap.)
Second Case
The second case has been applied from the first case to reduce energy production from oil and
replace it by using the energy production from wood between point B and C. And another
thing of this case is instead of using only one Oil Boiler we use 2 Oil Boilers as peak load and
run them as the same ratio from each boiler. But disadvantage of this case is we have to install
2 of Oil Boiler so the construction cost will be more expensive than the big 1 Oil Boiler as
shown in Figure 2.
A
B
C
D
Ppart = Pmax.wood-cap.
Point A to B,
Point C to D,
Ppart = Load_Curve
IF condition in Excel:
Load_Curve <= Pmax.wood-cap.
Ppart = 0
IF condition in Excel:
Load_Curve <= (min.wood-load * Pmax.wood-cap.)
Oil_1 Boiler
0th to point A,
Point A to B,
Point B to D,
Ppart = 0
IF condition in Excel: Load_Curve - (min.oil-load * Pmax.oil 2-cap.) <= Pmax.wood-cap.
Point A to C,
Point C to D,
Ppart = 0
IF condition in Excel:
Load_Curve <= Pmax.wood-cap.
IF condition in Excel:
Load_Curve <= (min.wood-load * Pmax.wood-cap.)
Third case
In this case we change how to run both oil boilers. Instead of running both oil boilers as the
same load ratio we run Oil_1 Boiler at full load at the beginning and run Oil_2 Boiler to
produce other load. When Oil_2 Boiler is run at its minimum load we just shutdown it then
run another oil boiler. The reason is to use Oil_1 Boiler as much efficient as possible as
shown in Figure 3 and Figure 4.
E
F
Ppart = Pmax.wood-cap.
Point A to B,
Ppart = Pmax.wood-cap.
IF condition in Excel:
(Load_Curve) – Pmax.wood-cap. – Pmax.oil_1-cap. <= (min.oil-load * Pmax.oil_2-cap.)
Point B to C,
Ppart = Pmax.wood-cap.
IF condition in Excel:
(Load_Curve) – Pmax.wood-cap. <= Pmax.oil_1-cap.
Point C to D,
Ppart = Load_Curve
IF condition in Excel:
Load_Curve <= Pmax.wood-cap.
Point E to F,
Ppart = 0
IF condition in Excel:
Load_Curve <= min.wood-load * Pmax.wood-cap.
Ppart = 0
IF condition in Excel:
(Load_Curve) - Pmax.oil_1-cap. <= min.oil-load * Pmax.oil_2-cap.
Oil_1 Boiler
0th to point A,
Ppart = Pmax.oil_1-cap.
Point A to B,
Point B to C,
Point C to D,
Point D to E,
Ppart = 0
IF condition in Excel:
Load_Curve <= Pmax.wood-cap.
Point E to F,
Ppart = Pmax.oil_1-cap.
IF condition in Excel:
Load_Curve <= min.wood-load * Pmax.wood-cap.
Oil_2 Boiler
0th to point A,
Point A to B,
Point B to C,
Ppart = 0
IF condition in Excel:
(Load_Curve) – Pmax.wood-cap. <= Pmax.oil_1-cap.
Point C to D,
Ppart = 0
IF condition in Excel:
(Load_Curve) – Pmax.wood-cap. <= min.oil-load * Pmax.oil_1-cap.
Point D to E,
Ppart = 0
IF condition in Excel:
Load_Curve <= Pmax.wood-cap.
Forth Case
We develop this case from the third one. Instead of choosing Oil_1 in third case we just
choose wood as Wood_2 Boiler. And at ending of year we run only Wood_2 Boiler again. For
the capacity of Oil Boiler we don’t want to use it so much. The only thing choosing oil and
locate it as peak load is to make up this peak in short time. Because oil has lowest
construction cost but in otherwise it has highest of fuel cost. This case is our cheapest cost per
MW-h as shown in Figure 5 and Figure 6.
C
D
E
Ppart = Pmax.wood_1-cap.
Point A to B,
Ppart = Pmax.wood_1-cap.
IF condition in Excel:
(Load_Curve) – Pmax.wood_1-cap. – Pmax.wood_2-cap. <= (min.oil-load * Pmax.oil-cap.)
Point B to C,
Ppart = Pmax.wood_1-cap.
IF condition in Excel:
(Load_Curve) – Pmax.wood_1-cap. <= Pmax.wood_2-cap.
Point C to D,
Ppart = 0
IF condition in Excel:
Load_Curve <= min.wood-load * Pmax.wood_2-cap.
Wood_2 Boiler
0th to point A,
Ppart = Pmax.wood_1-cap.
Point A to B,
Point B to C,
Point C to D,
Point D to E,
Ppart = 0
IF condition in Excel:
Load_Curve <= Pmax.wood_1-cap.
Oil Boiler
0th to point A,
Point A to B,
Point B to C,
Ppart = 0
IF condition in Excel:
(Load_Curve) – Pmax.wood_1-cap. <= Pmax.wood_2-cap.
Point C to D,
Ppart = 0
IF condition in Excel:
(Load_Curve) – Pmax.wood_1-cap. <= min.wood-load * Pmax.wood_2-cap.
Point D to E,
Ppart = 0
IF condition in Excel:
Load_Curve <= Pmax.wood_1-cap.
Ppart = 0
IF condition in Excel:
Load_Curve <= min.wood-load * Pmax.wood_2-cap
Efficiency Calculation
When we run boiler the efficiency is not constant, it very with Part Load (P part). And the
formula of Part Load Efficiency is.
Example 1 We are running 30 MW Wood Boiler which has maximum capacity of 50 MW.
η partload=0.81432 Ans.
Power Input in each hour (MW) * 1 hour = Energy Consumption in each hour (MW-h)
( P part )
Power Input= ---- Eq. 2
( η partload )
Power Input=(P part)/(η partload=η full∗[0.6+0.8∗( P part /P full )– 0.4∗(P part /P full)2])
---- Eq. 3
( 30 MW )
Power Input=
( 0.81432 )
Power Input=36.84 MW
And from this Power Input we will get Energy Consumption in 1 hour.
Highlights are the yearly fuel consumption, for oil is 35638.9 MW-h fuel and for wood is
331451 MW-hfuel.
Now we want to find the optimization of total cost per MW-h (cell U9145 in figure 7). By
changing oil capacity (cell U121). And we also set up the constraints, 17.906 <= oil capacity
<= 63.03. Then we put all of this data in Data Solver (figure 8), we get the minimum cost per
MW-h equal to 282.98 Kr/MW-h from figure 7.
Figure 8 Setting up solver parameters
Result
We have done the optimization from each case as showing.
We also make the compariton table to find which is the cheapest case.
Finally we found that the forth case is the cheapest one. So we have also analyse sensitivity
curve with variation of both Construction Cost and Fuel Cost as shown in figure 13 and 14
restpectively. Base load ratio in both figures is the ratio of the biggest load to total load.
Conclusion
In this study, boiler size, fuel type and fuel consumption in period of time are optimized using
Microsoft Excel based on an hourly operating cost. This method is suitable for complicate
problem analysis because errors are less than integration method.
From construction cost sensitivity curves in figure 13 it’s very less variation of base load
ratio. But for fuel cost sensitivity curve in figure 14 we can see bigger change of base load
ratio about 3 times comparing with another one. Because the construction cost is very small
comparing with fuel cost. But this changing is also very small comparing with boiler size
changing. From this fact we can conclude that our case has very low size variation of boiler
when either construction cost or fuel cost.
The methodology described in this study provides an important and systematic approach for
design and analysis combination of boiler. The analysis shows the lowest energy production
cost is expected for the boiler. In addition the optimization gives the overview of results
obtained by the different combinations of parameters. This is useful in choosing the solution
to a given problem. In contrast analyzing all possible size by stimulation energy consumption
of each boiler is time consuming. Thus, by using stimulation based approach, we obtained the
optimum point at a lowest energy production cost.