Lesson 6 – Cogeneration Cycles

The Rankine Power Cycle

Cogeneration Cycles and Losses in Power Plants

Knowledge assumed in place:

•First Law for Control Volumes pg 139 – 143; 145 - 151
•Devices combined into cycles pg 158 – 160
READ YOUR TEXT
•Cycle Performance Parameters pg 185 – 186
BOOK and the
•The Carnot Cycle pg 189 – 194
Summary from the
•Isentropic Efficiency pg 225 – 226; 228
Eastop & McConkey
•Ideal Rankine cycle pg 278 – 290
Textbook
•Video Lectures – Steam Plant
 2

4/22/2021

Ideal Cogeneration Rankine Cycle

A cogeneration cycle is a power cycle that utilizes the
output of the boiler to produce more than one useful
form of energy. Up to two-thirds of the heat generated in
a power plant is not converted to useful power by the
turbine. The basic idea behind a cogeneration plant is to
make use of this waste heat
• Superheated steam from the turbine can be used in industrial
processes
• Hot water from the condenser can be used for various heating and
cooling processes.

NB!NB! Mass flow in a cogeneration Rankine cycle

is not constant. This is very important when you are
doing the energy balances around the equipment.
 3

4/22/2021

Ideal Cogeneration Rankine Cycle

Figure 8,27 The T-s diagram

Figure 8,26 A cogeneration cycle of an ideal cogeneration
(Kroos & Potter, pg 299 ) Rankine cycle (Kroos & Potter, pg
299)
 4

4/22/2021

Ideal Cogeneration Rankine Cycle

Utilization factor  : The ratio of the energy
used and the energy input to the boiler.
For cogeneration cycles we use the utilization factor
instead of the thermal efficiency as the performance
parameter

Σ𝑊𝑜𝑢𝑡𝑝𝑢𝑡 + 𝑄𝑃𝐻 + 𝑄𝐻𝑒𝑎𝑡

𝜀=
𝑄𝑖𝑛𝑝𝑢𝑡

The difference between a process heater and a feedwater

heater (their T-s diagrams seems very similar) is that the heat
leaves the cycle to be used in the process heater where
as no heat leaves the cycle with a feed water heater.
 5

4/22/2021

Ideal Cogeneration Rankine Cycle

Arrangement 1 Arrangement 2

Arrangement 3
 6

4/22/2021

Example

Steam leaves the boiler at 4MPa and 5000C. At 2MPa 10% of the steam
leaving the boiler is removed for process heating, before the remaining
steam enters the second turbine stage where it is expanded to 16kPa and
fed into the condenser. The turbine has an isentropic efficiency of 0.96.
The condensate leaving the condenser is under-cooled by 5.3K. 37% of
the condenser heat is used to humidify a greenhouse. Pump work needs to
be included for all calculations.
 7

4/22/2021

Example
As ALWAYS, start by identifying the condition of
the water at each point in the cycle; then find the
enthalpy at each point; then solve the energy balances
to find the work and heat flow in the cycle; then
calculate the efficiency
Ideal conditions that may be assumed:
• All pressure losses due to friction is ignored, this just means that the
boiler, the condenser and the process heater all work at constant
pressure.
• Adiabatic operation and complete heat exchange in the condenser
process heater, this just means that all the heat lost by the steam is
absorbed by the cooling water and used by the “process”. The liquid
leaving the condenser and process heater is a saturated liquid.
• Isentropic (this also implies adiabatic, no heat losses) operation of the
turbine and pump, this just means that there are no losses in the
system due to friction, the entropy in is equal to the entropy out.
 8

4/22/2021

Example
Ideal conditions: The mixing point of streams 2 and 8 is
handled as an adiabatic mixing point with P2 = P8 = P3. We
assume that the process heater operates adiabatically, and
that all the available heat is removed, with a saturated fluid
leaving at point 7.
In the textbook point 8 and point 3 is treated as the same
point. A more accurate solution is to do an energy balance
around the mixing point 𝑚2 ℎ2 + 𝑚8 ℎ8 = 𝑚3 ℎ3 . This equation
must be used to calculate the value for h3. This method gives
a point 8 that is nearly equal to point 2 not point 3. (NB! Take
note that when Qboiler is calculated in the textbook point 2 is used
not point 8)
In non-ideal conditions typically QPH or T7 or x7 is given in
stead of the mass flow
 9

4/22/2021

Example
Ideal conditions: Adiabatic operation and complete condensation.
This cycle is not ideal – we still assume adiabatic operation, but we
do not have complete condensation, the liquid is subcooled

𝑃𝑜𝑖𝑛𝑡 1 − 𝑃1 = 16𝑘𝑃𝑎 𝑎𝑛𝑑 ∆𝑇𝑆𝐶 = 5,3𝐾

𝑡1 = 55,3 − 5,3 = 50℃ (NB!! for t : K = °C)
𝑡1 < 𝑡𝑠𝑎𝑡 𝑎𝑡 16𝑘𝑃𝑎 − 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑
𝑘𝐽
ℎ1 = ℎ𝑓 𝑎𝑡 50℃ = 209,3𝑘𝑔

𝑃𝑜𝑖𝑛𝑡 2 − 𝑃2 = 4𝑀𝑃𝑎 𝑎𝑛𝑑 𝑖𝑛𝑐𝑙𝑢𝑑𝑒 𝑝𝑢𝑚𝑝 𝑤𝑜𝑟𝑘

ℎ2 = ℎ1 + 𝑃2−𝑃𝜌
1 = 209,3 + 4000−16 = 213,284 𝑘𝐽
1000 𝑘𝑔
ℎ2 < ℎ𝑓 𝑎𝑡 4000𝑘𝑃𝑎 − 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑

Ideal conditions: Isentropic operation of the pump.

This cycle is still ideal, even if we include the pump
 10

4/22/2021

Example
𝑃𝑜𝑖𝑛𝑡 4 − 𝑃4 = 4𝑀𝑃𝑎 𝑎𝑛𝑑 𝑇4 = 500℃
𝑡4 > 𝑡𝑠𝑎𝑡 𝑎𝑡 4𝑀𝑃𝑎 − 𝑠𝑢𝑝𝑒𝑟ℎ𝑒𝑎𝑡𝑒𝑑 𝑣𝑎𝑝𝑜𝑢𝑟

𝑘𝐽
ℎ4 = 3445,3𝑘𝑔
𝑘𝐽
𝑠4 = 7,0901𝑘𝑔𝐾

𝑃𝑜𝑖𝑛𝑡 5 − 𝑃5 = 2000𝑘𝑃𝑎 𝑎𝑛𝑑 𝜂 𝑇𝐿𝑃 ,𝑠 = 0,96

𝑘𝐽
𝑠5 = 𝑠4 = 7,0901𝑘𝑔𝐾
7,0901−6,9563 𝑘𝐽
ℎ5𝑠 = 7,1271−6,9563 × 3247,6 − 3137,0 + 3137,0 = 3223,641𝑘𝑔
ℎ5 = 𝜂 𝑇𝐿𝑃,𝑠 ℎ5𝑠 − ℎ4 + ℎ4
𝑘𝐽
= 0,96 × 3223,641 − 3445,3 + 3445,3 = 3232,507𝑘𝑔
ℎ5 > ℎ𝑔 𝑎𝑡 2000𝑘𝑃𝑎 − 𝑠𝑢𝑝𝑒𝑟ℎ𝑒𝑎𝑡𝑒𝑑 𝑣𝑎𝑝𝑜𝑢𝑟
TAKE NOTE!!
hreal is always more than hs
Check your answers
 11

4/22/2021

Example
𝑃𝑜𝑖𝑛𝑡 6 − 𝑃6 = 16𝑘𝑃𝑎 𝑎𝑛𝑑 𝜂 𝑇𝐿𝑃 ,𝑠 = 0,96
𝑘𝐽
𝑠6 = 𝑠4 = 7,0901𝑘𝑔𝐾
ℎ6𝑠 = 7,0901−0,7719
7,2149 × 2369,9 + 231,5 = 2306,858 𝑘𝐽
𝑘𝑔
ℎ6 = 𝜂 𝑇𝐿𝑃,𝑠 ℎ6𝑠 − ℎ4 + ℎ4
𝑘𝐽
= 0,96 × 2306,858 − 3445,3 + 3445,3 = 2352,396𝑘𝑔
ℎ𝑓 < ℎ6 < ℎ𝑔 𝑎𝑡 16𝑘𝑃𝑎 − 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑚𝑖𝑥𝑡𝑢𝑟𝑒 Not ideal
TAKE NOTE!!
hreal is always more than hs
Check your answers

𝑃𝑜𝑖𝑛𝑡 7 − 𝑃7 = 2𝑀𝑃𝑎
𝑘𝐽
ℎ7 = ℎ𝑓 𝑎𝑡 𝑃7 =2000𝑘𝑃𝑎 = 908,8𝑘𝑔
ℎ7 = ℎ𝑓 𝑎𝑡 2𝑀𝑃𝑎 − 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑
 12

4/22/2021

Example
𝑃𝑜𝑖𝑛𝑡 8 − 𝑃8 = 4𝑀𝑃𝑎
4000−2000
ℎ8 = 908,8 + 1000
= 910,8 𝑘𝐽Τ𝑘𝑔

𝑃𝑜𝑖𝑛𝑡 3 − 𝑃3 = 4𝑀𝑃𝑎
𝑚2 ℎ2 + 𝑚8 ℎ8
ℎ3 =
𝑚3
0,9×213,284 + 0,1×910,8
=
1
= 283,036 𝑘𝐽Τ𝑘𝑔
 13

4/22/2021

Example
If mass flow through the cycle is not known, we just do all
calculations using the mass fraction per 1kg of steam.

𝑊𝑜𝑟𝑘 𝑖𝑛𝑝𝑢𝑡 𝑡𝑜 𝑡ℎ𝑒 𝑝𝑢𝑚𝑝𝑠:

𝑃2 −𝑃1 4000 − 16 𝑘𝐽
𝑊𝑃𝑢𝑚𝑝 1 = 𝑚3 𝜌
= 0,9 × = 3,586𝑘𝑔
1000
𝑘𝐽
𝑊𝑃𝑢𝑚𝑝 2 = 𝑚7 𝑣𝑓 𝑃8 − 𝑃7 = 0,1 × 0,001 4000 − 2000 = 0,2𝑘𝑔

𝐻𝑒𝑎𝑡 𝑖𝑛𝑝𝑢𝑡 𝑡𝑜 𝑡ℎ𝑒 𝑏𝑜𝑖𝑙𝑒𝑟:

𝑄𝑏𝑜𝑖𝑙𝑒𝑟 = 𝑚3 ℎ4 − ℎ3 = 1 × 3445,3 − 283,036
𝑘𝐽
= 3162,264𝑘𝑔
 14

4/22/2021

Example
𝑊𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑡𝑢𝑟𝑏𝑖𝑛𝑒:
𝑊𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 𝑚4 ℎ4 − 𝑚5 ℎ5 − 𝑚3 − 𝑚5 ℎ6
= 1 × 3445,3 − 0,1 × 3232,507 − 0,9 × 2352,396
𝑘𝐽
= 1004,893𝑘𝑔

𝐻𝑒𝑎𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 𝑢𝑡𝑖𝑙𝑖𝑧𝑒𝑑:

𝑄𝐻𝑒𝑎𝑡 = 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑢𝑠𝑒𝑑 × 𝑄𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟
= 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑢𝑠𝑒𝑑 × 𝑚4 − 𝑚5 ℎ6 − ℎ1
= 0,37 × 0,9 × 2352,396 − 209,3
𝑘𝐽
= 713,651𝑘𝑔

Heat removed from the cycle for process heating

𝑘𝐽
𝑄𝑃𝐻 = 𝑚5 ℎ5 − ℎ7 = 0,1 × 3232,507 − 908,8 = 232,371𝑘𝑔
 15

4/22/2021

Example
Cycle (Thermal) efficiency

𝑊𝑇 −𝑊𝑃
𝜂= 𝑄𝐵 = 1004,893−3,786
3162,264 = 0,317

Utilization Factor

Σ𝑊𝑜𝑢𝑡𝑝𝑢𝑡 +𝑄𝑃𝐻 +𝑄𝐻𝑒𝑎𝑡

𝜀= 𝑄𝑖𝑛𝑝𝑢𝑡
1004,893−3,786 +232,371+713,651
= 3162,264
= 0,616
 16

4/22/2021

Example
 17

4/22/2021

Losses in Power Plants

A Carnot cycle operating between the same high and low
temperatures will have a much higher thermal efficiency than the
efficiencies we calculate for the simple, modified and cogeneration
Rankine cycles.

Actual steam power cycles have thermal efficiencies that are even
lower than those we calculate for the simple, modified and
cogeneration Rankine cycles, due to losses in all of the components
that make up the cycles

𝜂𝑐𝑎𝑟𝑛𝑜𝑡 = 1 − 𝑇𝑇𝐿
𝐻
Σ𝑊𝑛𝑒𝑡𝑡 𝑜𝑢𝑡𝑝𝑢𝑡
𝜂𝑅𝑎𝑛𝑘𝑖𝑛𝑒 = 𝑄𝑖𝑛𝑝𝑢𝑡
𝜂𝑃𝑜𝑤𝑒𝑟 𝑃𝑙𝑎𝑛𝑡 = 𝜂𝑖𝑑𝑒𝑎𝑙 × 𝜂𝑡𝑢𝑟𝑏𝑖𝑛𝑒 × 𝜂𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛 × 𝜂𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 × 𝜂𝑎𝑢𝑥𝑖𝑙𝑖𝑎𝑟𝑖𝑒𝑠
 18

4/22/2021

Problems: Solving Ideal Rankine Cycles

Your turn to work
E-mail or whatsapp me if you have any Questions

(a) Calculate the effect of the process-heater on the cycle efficiency of the
problem in the Example
(b) If the process heater is added as shown in Arrangement 2 (slide 5),
calculate the effect it will have on the cycle efficiency and on the utilization
factor. Draw the T-s diagram for this arrangement.
(c) If the process heater is added as shown in Arrangement 3 (slide 5),
calculate the effect it will have on the cycle efficiency and on the utilization
factor if make-up water is available at 100kPa and 17,5˚C. Draw the T-s
diagram for this arrangement.
(d) Calculate the Carnot efficiency for this cycle