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Performance Analysis and Evaluation of Muhoroni 60MW Gas Turbine Power

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Conference Paper · October 2021

DOI: 10.1109/ICECCME52200.2021.9591134

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 Proc. of the International Conference on Electrical, Computer, Communications and Mechatronics Engineering (ICECCME)
2021 International Conference on Electrical, Computer, Communications and Mechatronics Engineering (ICECCME) | 978-1-6654-1262-9/21/$31.00 ©2021 IEEE | DOI: 10.1109/ICECCME52200.2021.9591134
Performance Analysis and Evaluation of Muhoroni
60MW Gas Turbine Power Plant
Moses Jeremiah Barasa Kabeyi
Industrial Engineering
department
Durban University of Technology
Durban, South Africa
22064693@dut4life.ac.za
Abstract—This study was a performance analysis with the aim
of improving the performance of an operating gas turbine at
Muhoroni, Kenya. Data was collected by observation,
questionnaire, interview, and document analysis and used for
performance analysis and review. The analysis of the power plant
performance indicators showed that plant utilization is low with
low load factor and hence low generation from the power plant
because of high costs of generation and hence low demand which
is limited to peak power supply. The powerplant has two operating
gas turbines with recoverable exhaust heat energy of 119.4
MWthermal. The study recommends installation of a 20 MW
Rankine cycle steam turbine with exhaust heat boiler for
generation of steam. Recovery and applications for the hot cooling
air are recommended is also recommended.
Keywords—Gas turbine, power generation, combined cycle,
waste heat recovery, exhaust gas boiler, gas turbine fuels.
I. INTRODUCTION
Fossil fuels continue to dominate the global electricity mix
with most of the global electricity generation coming from fossil
fuel sources[1]. The use of fossil fuels is associated with
greenhouse gas emissions and the threat of global warming and
related consequences hence the need to control their usage[2].
Gas turbines use hot flue gases as working fluids and with the
main elements being the compressor, the combustor, the turbine
and auxiliary equipment[3]. Muhoroni Gas Turbine Power plant
consists of two open cycle gas turbines owned and operated by
the Kenya Electricity Generating Company Plc for supply of
reactive and active power to the national grid (KenGen). The
two gas turbines were first installed in 1986 for Gas Turbine 1
(GT1) and 1999 for Gas Turbine 2 (GT2). The GT1 was
commissioned in 1986 while GT2 were commissioned in 1999
at Kipevu 1. The two gas turbines were relocated to Embakasi
in Nairobi. They were later moved to Muhoroni in Kericho
County in 2016 for GT1 and 2019 for GT2 for use to meet
increasing electricity demand in Western Kenya. The two gas
turbines are the only plants owned by KenGen that are
contracted to supply both reactive and active power to [4].
By increasing the efficiency of the Gas Turbine in the
KenGen’s Muhoroni Power Plant, it will be possible to generate
978-1-6654-1262-9/21/$31.00 ©2021 IEEE
7-8 October 2021, Mauritius
Oludolapo Akanni Olanrewaju
Industrial Engineering
Department
Durban University of Technology
Durban, South Africa
oludolapoo@dut.ac.za
more power at the same cost hence making it more efficient and,
in the end, providing more electricity to the nation. One of the
ways in which energy is generated is by a rotary mechanical
device called turbine implied that the turbine is a rotating device
that transmutes machine-driven work from a gyratory shaft into
a useful power[5]. The objective is to improve performance
through development of exhaust heat recovery system to
improve efficiency of the Gas Turbine Power Plant at the same
cost, effectively making power production less expensive than
its current prices [6].
Gas turbines are characterized by high consumption of
energy in compressing, low thermal efficiency for the open
cycle gas turbines and environmental emissions from the
consumption of fossil fuels. Open cycle gas turbines also emit
exhaust at high temperatures with significant quantities of
recoverable thermal energy while The thermal efficiency of an
open cycle gas turbine is low, between 20 and 30% compared to
38 to 40% for a modern steam plant, which implies wasteful use
of fuel power [3, 7, 8]. The cycle or thermal efficiencies of the
open cycle turbines low as a result of the mentioned
inefficiencies hence the need to increase efficiency by use of
advanced cycles like combined cycles[9]. Low thermal
efficiency, high cost of fuel and environmental concerns
associated with fossil fuel sources have set in motion a transition
that seeks to increase energy efficiency and increased use of
renewable energy sources in power generation[10-12]. The main
limitations of gas turbine plants include; They are not self-
starting, have low overall thermal efficiency, they have very
high rotor speeds hence challenge with balancing , high degree
of irreversibilities and low part load efficiency [3, 8, 13].
The Muhoroni gas turbine is a subsidiary of the Kenya
Generating Company PLC (KenGen). KenGen produces 75% of
electricity installed in Kenya but still not sufficient to fully
electrify the country. Hence there is huge emphasis to improve
the efficiency and output of the KenGen Power plants. Through
proper modifications of the gas turbine power plant in
Muhoroni, a substantial improvement of the quality and quantity
of electricity supply in Kenya can be made. Gas turbine power
plants play a big role in the pollution of the environment through
emission of exhaust gases which in turn cause the depletion of
the ozone layer hence contribution to climatic changes and
allowing intense ultra-violet rays which are very harmful to the
human skin. Our ability to tap the exhaust gases and using more
productively through a Heat recovery system to drive a steam
turbine will substantially minimize the number of gases emitted
to the environment. This action will also assist us in improving
the efficiency and productivity of the gas turbine. The steam
generated from the heat recovery system generator is injected
into the combustion chamber of a gas turbine increasing the flow
through the turbine. The steam injection gas turbine reduces the
emission of nitrogen oxides into the environment. It is also very
economical. Steam injection leads to power augmentation hence
high output and efficiencies.
The gas turbine presents is a very attractive means of power
generation because of their ability to generate large quantities of
power in a self-contained assembly unit [3]. Conversion of the
open cycle to combine cycle improves the thermal efficiency of
the gas turbine to over 45% [3, 9]. The main advantages of gas
turbines are:
• They have perfect balancing hence low vibrations
• Low construction and operation space requirements
• Higher power density than diesel and petrol engines
• Have low capital cost requirements
• They have low installation and maintenance costs
• They have better torque characteristics compared to
diesel engine
• They have simple ignition and lubrication systems
• Can handle a wide range of fuels hence more flexible
• The specific fuel consumption of a gas turbine does not
increase with time as rapidly as diesel engine.[3, 8, 13,
14].
II. GAS TURBINE POWER PLANTS
There is a global commitment to reduce emissions from
fossil fuel sources and application of other measures to reduce
consumption of fossil fuels like increased efficiency and hence
consumption, a shift to green sources of power like geothermal
and other policy measures[10].
A. Design and Construction
There are three main parts of a gas turbine plant in addition
to auxiliary parts. These basic parts are the compressor,
combustor, and the turbine. Auxiliary equipment which include
fuel pumps and fuel system, compressed air system, lubrication
oil system, ducts[3]. Modern gas turbine powerplants have
modifications by provision of extra features like regenerators,
intercoolers, preheaters, exhaust gas boilers, cogeneration steam
turbines, based on specific modifications and improvements[3,
15, 16]. Gas turbines plants are further grouped into constant
pressure combustion and constant volume combustion gas
turbines plants. The constant pressure turbines are either open
cycle or closed cycle plants. The constant volume gas turbine
operates within constant volume space. The most common
design of gas turbines in use are the open cycle type which are
Identify applicable funding agency here. If none, delete this text box.
basic, cheap and motivated by availability of readily available
cheap fuel sources for gas turbine operation [3].
B. Application of Gas Turbines
The main application of gas turbines is in power generation,
oil and gas industry operations, marine propulsion and
aviation[3, 9]. The gas turbines are used in aviation industry
because of their high density while in power generation, they are
popular because of limited need of water, low space
requirements, quick construction, mobility and ability of quick
starting and quick stopping[3]. The gas turbines are popular with
oil and gas industry due to their quick installation, high
flexibility and mobility and ability of quick installation [7, 9].
The various application for gas turbines includes:
• Power generation as prime movers for peak and
emergency supply
• Aircraft propulsion
• Use in marine for ship propulsion
• Used for field operations in oil and gas development
• Supply of reactive power to the grid
C. Performance Inicators for Gas Turbine Power Plants
Various ratios and parameters are used to measure gas turbine
plant performance. They include.
• Pressure ratio: This is the ratio of the cycle’s highest
pressure usually the highest-pressure compressor outlet
to lowest pressure compressor inlet.
• Work ratio: This is the ratio of network output to total
work developed in the turbine.
• Compression efficiency: This is the ratio of work needed
for ideal air compression through a given pressure range
to actual work done in the compressor.
• Engine efficiency: This is the ratio of work developed by
turbine expansion through a given pressure range to what
would be realized under ideal conditions of expansion.
• Combustion efficiency: This is the ratio of heat released
by a unit mass of fuel to heat that can be released
theoretically under complete combustion.
• Thermal efficiency: This is the ratio of work done to total
energy input for a turbine plant.
• Load factor: This is the ratio of average load to
maximum load on the gas turbine power plant.
• Capacity factor: This is the ratio of power generated to
the design capacity of gas turbine power plant. It is an
indicator of capacity utilization of the gas turbine power
plant [3].
D. Fuels for Gas Turbines
Gas turbines are flexible and can use different types of fuel
with varying properties and quality. Both gaseous, solid, and
liquid fuels can be used. Gaseous fuels used include natural gas,
blast furnace gas and producer gas. Any liquid fuel used should
have proper volatility, viscosity and calorific value and be free
from moisture and suspended particles to protect the nozzles, 2 Kipevu 2 74 2001 2021
valves and plungers of fuel pumps commonly used liquid fuels (Psavo)
include distillate oils or residual oils. Additionally, elements 3 Kipevu III 115 2011 2031
like sodium, vanadium and calcium are harmful to turbine
blades. Crushed coal as opposed to pulverized coal is used in 4 Rabai Power 90 2009 2030
station
gas turbines as a fuel[3].
5 IberaAfrica 1 56 1997 Retired
E. Comparison of Fuels
The specific fuel consumption of kerosene is much lower 6 IberaAfrica 2 52.5 2004 2034
than that of kerosene due to its high calorific value 7 Athi River Gulf 80 2014 2034
(48000KJ/Kg) in comparison to that of Kerosene
(43000KJ/Kg). Therefore, less amounts of natural gas are used 8 Triump 83 2015 2035
to deliver the same power output in comparison to Kerosene.
9 Thika Power 87 2013 2034
For the same power output however, kerosene has higher cycle Plant
efficiency in comparison to natural gas [17, 18].The power
generation sector contributes one of the largest shares of carbon 10 Muhoroni Gas 27 1987 2021
Turbine 1
(ⅳ) oxide (CO2) emissions at about 40%. Gas turbines are key
contributor of this percentage due their use of hydrocarbon 11 Muhoroni gas 27 1999 2021
fuels. This percentage can be lowered by use of renewable Turbine 2
sources such as natural gas (NG). Due to high content of
hydrogen and carbon present in kerosene there is a high
percentage of unburnt hydrocarbons (UHC) unlike natural gas Where com stands for commissioning and dicom. Stands for
which contributes to low emissions of unburnt hydrocarbons. decommissioning.
Though the emissions are of unburnt hydrocarbons is From table I, it is noted that the current effective capacity
substantially low [17, 19]. of all thermal power plants in Kenya is 695.5 with 3 power
Kerosene has a very high content of Sulphur (ⅳ) Oxide plants with effective capacity 128 MW set to be retired in 2021.
which is harmful to humans due to reaction with bodily fluids They include Kipevu II and the Muhoroni gas turbines. The
to form sulphuric acid (H2SO4) whereas natural gas has a low Muhoroni gas turbines constitute7.8% of the total effective
Sulphur (ⅳ) Oxide. Natural gas also offers NOx and soot capacity of the thermal power plants.
(carbon) emission reduction when used instead of kerosene III. MATERIAL AND METHODS
which leads to high NOx and soot production due to high levels
of hydrocarbon. NOX which is normally a combination of Nitric Data was collected with the help of questionnaires,
oxide( NO) and nitrogen dioxide (NO2) which combine to form interviews, observation and document review and analysis. This
smog and acid rain and also lead to the formation of ground collected information was then tabulated and/or put in graphs.
These results were then used in thermodynamic formulae to
ozone and fine particles which have adverse health effects [20,
obtain certain parameters key in designing of the Heat Recovery
21]. Steam Generator which consists of the Economizer, Super
F. Thermal Power Plants in Kenya heater among other modules. Other key designs included steam
turbine, condenser, and cooling tower. A computer aided design
The thermal power plants in Kenya charge the highest rate
software was then employed in the design of the heat recovery
more than $0.20 per unit of electricity generated and supplied steam generator.
to the grid. This is about four times the cost of hydropower
which costs $0.05 and about twice the cost of geothermal and A. Combined Cycle Power Plant
wind electricity which costs $0.08 per unit. Other than high Combined cycle plants employ a basic employ a basic
cost, fossil-fueled power plants emit significant quantities of Bryton cycle/gas turbine cycle and another thermodynamic
greenhouse gases that cause global warming. However, the cycle like the Rankine cycle. Heat engines are only able to
fossil fueled power plants are ideal for supply of flexible utilize a small portion of the energy supplied to o useful work,
demand like peak demand as they are quick to start and stop normally less than 50%. In combined cycle plants, a gas turbine
compared to geothermal plants which are clean and cheap but is coupled to a generator for electricity generation while the
are not flexible in line with fluctuating load profile, just like waste heat in flue gases exiting the turbine is used to generate
nuclear power plants [22]. steam for operation of a steam turbine in a Rankine cycle for
extra power generation thus increasing the overall thermal
efficiency[24]. For maximum efficiency, the thermal difference
TABLE I. THERMAL POWER PLANTS IN KENYA [23]
between the heat source and heat sink must be as high as
Power plant Effective Year Planed possible. This objective is realized by using both the Brayton
name capacity of decom (gas) cycle and Rankine cycle (steam) thermodynamics cycle
(MW) Com.
1 Kipevu 1 60 1999 2023
[15, 16]. The gas turbine is hence the most important
component in the combined gas-steam cycle, provided that the
steam cycle utilizes the exhaust heat from the gas turbine by
means of a heat recovery steam generator (HRSG). In a
combined cycle powerplant, generally about 60% is generated
by the gas turbine and about 40% by steam turbines.
Fig. 1. Schematic diagram of combined cycle power plant[15]
Figure 1 shows the various elements of the combined heat
gas turbine power plant in addition to the basic elements
(turbine, combustor, and compressor). They include the Heat
recovery steam generator (HRSG), steam turbine, turbo
generator, condenser, cooling tower, feedwater pump [25].
Fig. 2. Schematic diagram of a combined cycle powerplant [26]
From figure 2, it is noted that in addition to the basic
elements/arts of an open cycle gas turbine, the combined cycle
powerplant has a Rankine cycle plant with a steam turbine,
exhaust gas boiler for steam generation and electric generator
which is coupled to the steam turbine.
The performance of individual parts or elements of a gas
turbine plant influence the overall performance of the entire
powerplant. Figure 3 below shows the general temperature
distribution between the superheater, evaporator, and
economizer.
Fig.3. Temperature variation with heat flow between[27].
Figure 3 shows the temperature or thermal gradient through
the superheater, evaporator, and economizer in a combined
cycle plant. It shows that in the evaporator, the temperature
remains constant through the process of steam generation as
latent from flue gases is supplied[24]. Heat supply in the
superheater called superheat leads to increase in temperature
and hence production of superheated steam. In the economizer
sensible heat is added leading to increase in the heat of feed
water.
The main components for performance analysis in the
current or existing design are the turbine itself, compressor, and
the combustion chamber. Component specifications and
operational data were summarized in form and used for the
performance analysis of Gas Turbine Power Plant in Muhoroni
[27].
Gas turbine cycle thermal efficiency can be expressed as:
Applying the heat balance equations between the gas turbine
exhaust and HRSG as given below: ms (h1 − h4) = meg c peg
(Td − Ta)
ms (h5 − h4) = meg c peg (Tx − Ta)
Heat rejected by exhaust gas is given by
Qeg = meg c peg (Td − Ta)
Where, ms = Mass flow rate of steam in kg/s and meg = Mass
flow rate of exhaust gas in kg/s
Ta = Cooling temperature of exhaust gas (HRSG stack
temperature), Tx = Temperature of exhaust gas at pinch point
Td = Temperature of exhaust gas at gas turbine outlet, and
meg = Specific heat of exhaust gas.
The capacities of the various components of the HRSG are
thus estimated as follows: Economizer:
Qec = Qeg ec × meg = (h5 − h4) ms
Evaporator:
Qev = Qeg ev × meg = (h6 − h5) ms flowing inside the tubes and the other flowing outside of the
Superheater: tubes or the shell side. Parameters to be designed include the
Qsh = Qeg sh × meg = (h1 − h6) ms tube diameter, number of tubes, length of tubes, the tube pitch,
HRSG capacity: and the tube arrangement. Tubular heat exchangers can further
QHRSG = Qec + Qev + Qsh be classified into. double pipe heat exchangers, shell, and tubes
Heat Loss heat exchangers and the Spiral tube type heat exchangers[24,
H L = Qeg − QHRSG 28].
Thermal Efficiency of HRSG,
ηHRSG = Q HRSG Shell and tube heat exchangers
Shell tube and tube heat exchangers are built of round tubes
Determining the net power output of the steam turbine at the mounted in large cylindrical shells with the tube axis parallel to
generator terminal, that of the shell. Tubular fin heat exchangers (shell and tube).
Steam turbine net power output Fins are protrusions on the surface of the tubes on the gas side
PNET = PST (actual) − Pp with the objective of increasing the heat transfer area.
Where Pp = pump power input (actual) = ms (h41 − h3) Flow arrangement (Tube configuration)
The capacity of a steam plant is often expressed in terms of Heat exchangers can be classified according to the fluid
steam rate or specific steam consumption (S.S.C) which is the flow path through the heat exchanger. The three basic flow
rate of steam flow kg/s required to produce unit shaft output i.e. configurations are. The different flow configurations are
1 kW[16]. parallel flow, cross flow, and Counter flow. For parallel flow
Figure 4 below illustrates a plant with a steam turbine exchangers the cold and hot fluid exit the heat exchanger enter
working on Rankine cycle and gas turbine working on Brayton and exit in the same direction. Counterflow heat exchangers
cycle. Power is generated by the two turbines simultaneously. are designed such that the hot and cold fluids flow in opposite
directions. For a single cross flow heat exchanger, the fluids
flow at right angles to one another[29].

C. Data Collection and Analysis

Fig.4. Schematic diagram of a steam and gas turbine [5].
This study involved data collection and analysis from an
operating gas turbine powerplant based at Muhoroni in Kenya.
Data was collected from the site by document analysis,
observation, interview, and questionnaire. Important data
included the operating parameters like temperatures, flow rates,
speeds and capacities of the main plant and equipment.
Generation and operation logs provided data on powerplant
actual technical operation and maintenance activities and status
as well actual power generation, consumption, and output.

Where Wnet = specific network output D. Power Plant Specifications

Table II below shows the technical and performance
Specific steam turbine work
indicators of Muhoroni Gas turbine power plant.
Wst = Pst (actual) / Ms
TABLE II. OPERATION PARAMETERS FOR THE
Specific Pump Work, MUHORONI GAS TURBINE POWER PLANT

Wp = Pp / Ms Component Parameter Unit Value

Compressor Inlet Temp ℃ 25

The condenser cooling water system heat transfer (heat rejected
Outlet Temp ℃ 364
to the condenser) gives
Q2 = ms (h2 − h3) Inlet pressure bar 1
Applying the energy balance equation between the condenser Outlet pressure bar 12.3
and the cooling water. Mass flow rate Kg/s 139
mw = c pw (t out − tin) = ms (h2 − h3 ) (air)
gases as working fluid while the steam turbine uses steam as Combustion chamber Fuel Kg/s 1.85
the working fluid. consumption (flow rate)

Inlet Temp ℃ 1100

B. Tube Analysis and Alignment
Multiple tubes are used in the heat exchangers to separate Table II shows the design parameters of the two similar gas
the hot and cold fluids i.e., flue gas and water with one fluid turbines with fuel flowrate of 1.85 kg/s and turbine inlet
temperature of 1100oC. Table II above summarizes the TABLE V. GAS TURBINE GENERAL INFORMATION
compressor and combustion chamber conditions. Parameter Value/Description

Gas Turbine Model Frame 6001B

TABLE III. THE COMBUSTION CHARACTERISTICS OF
THE GAS TURBINES AT THE MUHORONI POWER STATION Manufacturer General Electric
Speed 5100rpm
Device /component Parameter Unit Value
Fuel Kerosene
Air fuel ratio - 16:1
Compressor Axial type with 17 stages
Heat rate KJ/kWh -
Turbine Impulse type with 3 stages
Gas Turbine Outlet Temp ℃ 572
Cooling Fluid Distilled Water
Exhaust gas flow Kg/s 141
Other Data GT thermal % 34.01% Combustors 10 with reverse combustion
efficiency system
Generator Brush Electrical Machines
GT power output MW 30
Generator Frequency 50Hz
Compression Pressure Ratio 12:1
Table III above shows the Power plant fuel price and
GT Generator Type (Cooling) Air
ambient conditions. The highest temperature at temperature rise
in the combustor is 1075oC. The average turbine exhaust Number of Combustor Cans 10
temperature is 572oC whose flowrate is 141 kg/s which is higher Startup Time, 8-12 minutes
than average mass flow rate of the combustion air which is 139 Conventional/Peaking
kg/s.
Combustor outlet is 1100oC while the lowest temperature is at Table V shows that the turbine design speed is 5100 rpm
compressor inlet at 25oC. Hence the Energy content of flue and fuel used is kerosene. Tart up time of 8-12 means is fast
gases leaving the turbine = Qeg = meg c peg (Texhaust – Td) enough as an emergency and peak load powerplant. Table VI
below shows the average powerplant performance indicators
Where meg=mass flowrate of exhaust gas = 141kg/s for Muhoroni gas turbine powerplants.
Cpeg =Specific heat capacity of flue gases= 1.185kJ/kgK
TABLE VI. POWER PLANT PERFORMANCE FACTORS
Td =Design temperature for exhausts leaving after heat OF THE MUHORONI GAS TURBINE POWER PLANT
recovery= 170oC[9] Factors Value
Total energy for one gas turbine =1.185x 103x 141kg/s x(527- Installed capacity 61 MW
170oC) gas =59.7 MWheat Plant Use Factor 0.08

Texhaust= Exhaust gas temperature =572oC Plant Capacity Factor 0.31

Plant Operating Factor 0.27
The total recoverable heat in exhaust is =2x 59.7 MWheat=
119.4 MWheat from both turbines operating at full load. Load Factor 0.30
Reserve Factor 1.15
Environmental Conditions
The environmental conditions for Muhoroni are Diversity Factor 1.24
summarized in table IV below
From table VI, it is noted that that the powerplant has a
TABLE IV. POWER PLANT SITE INFORMATION very low use factor of 0.08 mainly because it is used as a peak
Parameter Value load powerplant hence its use is limited. The capacity factor is
low at about 0.31meaning that the powerplant capacity is not
Cost of Fuel KES. 98
fully used and is often loaded below capacity of 61 MW hence
Site Altitude 1450 m above sea level consumers could be paying for significantly idle capacity.
Ambient Temperature 24-30˚C Effort to reduce unit cost of power will make it more attractive
and will sell more to the grid earning more revenue for investors
and reduce idle capacity which is paid for by consumers.
Table IV above shows the average environmental conditions
which affect the performance of the gas powerplants. The site Performance Analysis of Existing Gas Turbine Power Plant
altitude which is 1450 above sea-level and average ambient
temperature which varies between 24 and 30oC. The The Muhoroni Gas Turbine Power Plant has an installed
specifications of the gas turbines are given in table V below. capacity of 60 MW and can be doubled since only one of the two
gas turbines are operational. The gas turbines both operate in an
open cycle configuration where exhaust products are ejected
into the atmosphere after expansion through the turbine blades.
A common shaft is used in the operation of both the turbine and
the compressor meaning the turbine must do greater work to
obtain network.
IV. RESULTS AND DISCUSSION
This study shows that several factors affect the power output
of the turbine such as relative humidity, ambient pressure, and
ambient temperature. The combined capacity of the power plant
is 61MW and consists of two gas turbines with total installed
capacity of 61MW. Based on exhaust gas design temperature of
170oC, the recoverable heat energy from the two turbines
operating at full load is 119.4 MWheat. This recoverable heat
will be subjected to heat recovery from the heat recovery steam
generator, the economizer, and superheater. The recovered
waste heat is then used to generate steam to run a steam turbine
for extra electricity generation.
Performance analysis of the powerplant shows that it has a
utilization factor of 0.08 which implies that the powerplant is
idle most of the time. This is because the powerplant is mainly
used for peak power supply and switched off most of the time.
Since the cost of power is a function of fixed and variable costs,
customers pay for idle power making it a burden to the
consumers and investors. This may be down to several issues
such as cost of production in terms of fuel consumption of the
gas turbines. Kerosene is priced at about KES.98 (1US$) which
at face value may seem cheaper than other fuels, this cost will
be reduced with our recommendation of use of Natural Gas.
Also, with the CCPP being incorporated, more power will be
produced for less and that will benefit both the producer
(KenGen) and the consumer of electric power from the gas
turbine plant. Therefore, fuel shift to cheaper sources is an
option worth consideration.
V. CONCLUSION
For our research to be successful, the Combined Cycle
Power Plant (CCPP) needs to be functioning properly i.e., the
gas turbine, steam turbine and the Heat Recovery Steam
Generator (HRSG) need to be functioning optimally. Various
operating parameters such as ambient temperature and
compression ratios were seen to have a telling say in the
efficiency of the power plant. The power plant in question
(Muhoroni Power Plant) has installed capacity of 60 MW with
two gas turbines of a capacity 30 and 31MW installed capacity
and operate at thermal efficiency of 25.68% efficiency at full
load. The current design of the gas turbines is an open cycle gas
turbine which is inefficient and therefore wasteful. An exhaust
heat recovery system is proposed for the recovery of waste heat
in flue gases to generate steam for extra power generation by a
Rankine cycle steam turbine. Total recoverable heat in exhaust
gases is 119.4 MWThermal
The study showed that it is possible to increase generation
by an extra 20.133 MW of electricity by installing a Rankine
cycle steam turbine and increase the overall cycle efficiency by
54.2%. This will increase total installed generation capacity to
80.133MW from current installed capacity of 61 MW. The
proposed design in this research also incorporates a deaerator on
the feed water loop for removal of dissolved gases from the feed
water. Dissolved gasses are undesirable as they bring about
corrosion on heat exchanger surfaces. A bypass diffuser is also
incorporated in the proposed design provide standby a route of
the exhaust gases whenever the (Heat recovery steam generator
(HRSG) is out of service, hence provide a direct exhaust path to
the atmosphere. Another feature is the catalytic reduction that
use ammonia in presence of a catalyst to convert nitrogen oxides
in the exhaust gases into harmless products of water and
hydrogen hence limiting environment pollution from the plant.
This will make the proposed powerplant more environmentally
sustainable.
VI. RECOMMENDATION
This study demonstrated that there is huge amount of
recoverable heat energy exhausted to the atmosphere. The
Rankine cycle is efficient and is commonly used in waste heat
recovery. The authors recommend similar studies with organic
Rankine cycle in place of the ordinary Rankine cycle adopted in
this study. Studies on recovery of heat from the compressor
cooling air for process or low temperature power generation is
also recommended. The heat from the cooling air can be used to
preheat the water before being taken to the super heater. We
recommend the introduction of intercoolers between the
compression stages to reduce the power consumed by the
compressor and generally improve the cycle efficiency. The
efficiency of a gas turbine can be improved by introducing an
intercooler between the compressor stages. The intercooler is
used to reduce the temperature at the high-pressure compressor,
causing reduces consumption power on compressor and lower
output temperature at high pressure [26].
Gas turbines power plants with high pressure ratios can use
an intercooler to cool the air between stages of compression,
allowing you to burn more fuel and generate more power.
Intercooling provides significant benefits to the Brayton cycle
gas turbine power plant through decreasing the work of
compression for the high-pressure compressor (HPC), which
allows for higher pressure ratios, thus increasing overall
efficiency. Switching cheaper and renewable fuel is another
feasible area for further investigation as a strategy to minimize
pollution from gas turbine powerplants.
AKNOWLEDGEMENT
The authors wish to thank Kenya Electricity Generating
company Plc. (KenGen) for allowing the research to be done on
their facilities and granting access. We also thank the
management, engineers and other workers who provided
invaluable data and guidance during the research. The research
would never have succeeded without their support.
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