Energy and the Environment (2006) 411-423 411

OPTIMIZATION OF A COGENERATION PLANT

USING PINCH METHOD

Viktor Dragičević, Zmagoslav Prelec, Bernard Franković

Faculty of Engineering University of Rijeka, Vukovarska 58, HR-51000 Rijeka, Croatia
Phone: +385 51 651-521, 651 520, 651-506, Fax: +385 51 675-801
E-mail: viktor.dragicevic@riteh.hr, zmagoslav.prelec@riteh.hr,
bernard.frankovic@riteh.hr

Abstract: In this work a cogeneration power plant has been analyzed in the pursuit of
possible process modifications that could reduce the energy consumption. The energy fluxes
in the power plant’s processes are analyzed using Sankey diagrams for various energy
subsystems (steam turbines, gas turbines, district heat distribution system). Using the pinch
analysis method, energy processes and energy flows in those subsystems have been analyzed.
Results of the performed analysis and suggestions for possible modifications to achieve lower
energy consumption are stated in the final paragraph.

Key words: cogeneration, pinch analysis, energy saving

1. INTRODUCTION

Cogeneration combined steam and gas cycles are very efficient energy systems for combined
electric and heat energy production. Production of energy using those types of energy cycles
ensures maximum levels of total energy efficiency. This work shows a simulation and
analysis of such a cogeneration power plant that is based on a real operating power plant
example. The commercial software package Thermoflex has been used for constructing the
model of the power plant and to obtain working parameters for steam generators, steam
turbines, gas turbines, and other important components of the plant. The energy efficiency
analysis of the power plant’s performance has been performed using Sankey diagrams that
show energy flows in the plant, and using pinch analysis of the entire power plant.

2. POWER PLANT LAYOUT AND BASIC TECHNICAL DATA

This work describes a complex cogeneration system with a steam cycle and a gas cycle, of a
cogeneration power plant in Zagreb that is currently in operation as part of the Croatian
electric power network. Besides electric energy, it distributes steam and district heat to the
western part of Zagreb. The plant has been described in previous papers and reports, by
numerous authors in both scientific and technical magazines, and therefore a model of the
plant has been constructed using this available data. The older part of the power plant consists
of three high pressure steam generators that produce steam for two steam turbines of 12,5
MW and 30 MW of electric power respectively. A low pressure steam generator is used for
producing steam for the nearby industry, and three hot water generators are used to heat
412 V. Dragičević, Z. Prelec, B. Franković, Optimization of a cogeneration ...

district heating water. The newer part consists of two gas turbines, each of 26 MW of electric
power output, equipped with heat recovery steam generators (HRSG) that produce steam that
is outputted directly or used for heating district heating water. The steam generators that still
operate in the older part of the plant use fuel oil and natural gas as fuel, while the gas turbines
in the newer part of the plant use only natural gas, with a possibility of switching to fuel oil if
necessary.
Basic layout scheme of the cogeneration power-plant
deminer alised w ater

BLOCK 1 BLOCK 2 BLOCK PTE

max 100 t/h max 100 t/h max 80 t/h

K6 115 bar K8 K9 115 bar K7 17 bar
GE 5371PA GE 5371PA
515 C 515 C 240 oC
(25 MW) (25 MW)

~ ~
TA- 1 TA-2
(12,5 MW) (30 MW) PTE PTE
64 t/h 64 t/h
chimney
~ ~ Heat e xch. fo r Heat e xch. fo r
DH ( 8 MW) DH ( 8 MW)

HEATI NG
CONDENSER
17 bar, 240 0 C 17 bar, 240 0 C

PTEZ-5
RS5 RS2

o
6 bar 160 C

RS3
VTZ- 3 VTZ- 4 CONDENSATE SYSTEM

2,5 bar 140 C

NTZ- 1 NTZ-2 CONDENSATE SYSTEM

Figure 1. The basic layout of the power plant

High pressure steam generators are tagged as K6, K8 and K9. The steam witch is produced in
steam generators K8 and K9 is used in steam turbine TA2 that can produce 30 MW of electric
power. There is also a possibility of throttling the steam to the pressure for 17 bar for the
direct use in the nearby industry. The steam turbine has two steam bleeds, one with the
pressure regulation, and the other without any regulation. The steam from this turbine is
conducted in the district heating condenser, using thus the condensing steam heat for heating
district heating water. The high pressure steam generator K6 produces steam for the steam
turbine TA-1 that produces approx. 12,5 MW of electric power. The steam turbine TA-1 is an
expansion turbine with two steam bleeds, one with pressure regulation, and the other without
any regulation. The steam from the turbine expands to 2,5 bar and is then led to the low
pressure steam manifold.
The only low pressure steam generator still in operation is K7. The low pressure steam
generator produces steam at 17 bar pressure, which is used mainly for the nearby industry’s
needs. The plant uses medium and low pressure steam (7 and 2,5 bar) for its own energy
needs, as well for heating district heating water. This steam is produced by steam bleed from
Energy and the Environment (2006) 411-423 413

the steam turbines and from throttling the high pressure steam (17 bar). The plant uses this
steam for heating deaerators in the boiler feed water system of each steam generator (low
pressure steam). An important amount of this steam is used in the feed water pre-heaters for
high pressure steam generators. To that end, medium pressure steam is used, and the resulting
condensate is fed to the deaerators. The water of the district heating system is heated by series
of various types of heat exchangers – condenser of the TA-2, and low- and high-pressure
water heaters (named NTZ and VTZ). The final water temperature, that is required by the
outside temperature conditions, is reached by heating the water in the heat generators (KW1 -
3), that use fuel oil and natural gas. District heating water flows through the low- and high
pressure heaters and this can be done both in series and in parallel flow. The way in which
water is passed through these heaters is determined by the amount of water that must be
heated. The temperature of the hot water that has to be reached at the plant’s exit is in direct
correlation with the outside temperature, and it is regulated by by-passing and reducing the
flow through the low- and high-pressure district heating water heaters.

The new part of the power plant consists of two gas turbines, GE5371 PA, each producing 26
MW of electric power, and two heat recovery steam generators. The combustion gases exit
the turbine with approx. 500 °C, and then enter the heat recovery steam generator to generate
steam. The exhaust gases, after passing additional heat exchangers, enter the chimney and
then are released in the atmosphere with a temperature of 100 0C.

3. ENERGY FLOWS IN THE POWER PLANT

For this analysis, the power plant is working in winter conditions, with average heat loads and
electric energy production that is characteristic for winter season. The conditions are
characteristic of an average winter day at 12:00 hours. The following table shows the load
conditions of the cogeneration power plant with heat and electric loads respectively.

Table 1. Heat and electric loads

Network Power Flow Temperature Pressure

requirements
Heating energy 160 MW 3440 t/h 800C/1200C 1.8 bar
output
Steam production - 140 t/h 2400C 17 bar
Electric energy 90 MW - - -
output (minimum)
414 V. Dragičević, Z. Prelec, B. Franković, Optimization of a cogeneration ...

Table 2. Load distribution in the power plant

Unit Mark Steam Steam Steam Heat Electric

flow pressure temperature produced power
0
t/h bar C MW MW
Steam generator K6 100 115 515 - -
Steam generator K7 80 17 240 - -
Steam generator K8 100 115 515 - -
Steam generator K9 100 115 515 - -
Steam turbine TA-1 100 115 515 - 12.5
Steam turbine TA-2 200 115 515 - 30
Gas turbine PTE1 64 17 235 - 25
Gas turbine PTE2 64 17 235 - 25
Total electric energy produced 92.5

High pressure PTEZ-5 64 17 240 34 -

water heater
Medium pressure VTZ-3 52.25 6 160 30 -
water heater
Medium pressure VTZ-3 52.25 6 160 30 -
water heater
Low pressure NTZ-2 36.6 2.5 140 22 -
water heater
Low pressure NTZ-2 36.6 2.5 140 22 -
water heater
Total heating energy produced 138
(outside the cogeneration process)
Hot water KW1 - 22
generator
.

To perform an efficiency analysis of the cogeneration power plant, a computer model has
been built and a simulation of the systems that are working in the plant has been performed.
Using this model it was possible to show exactly what the energy flows inside the power plant
are. The modeling and simulation was performed using the software package ThermoFlex,
taking into consideration characteristics of steam generators and turbines.

The energy flow through parts of the plant is shown using of Sankey diagrams, including the
energy flow between the three steam pressure levels. The system of condensate collection and
the according values are based on field data. The following figures show diagrams of various
independent subsystems followed by a Sankey diagram showing the flow of energy in those
energy subsystems.
 Energy and the Environment (2006) 411-423 415

BLOCK 1
bar °C
ton/h kJ/kg

Air pre-heater

Steam gen erator K06

1.01
135
113 22 17.0
7 7 23 240 4
6.24
17 17
1.01
2 158
5 120 RH2

4 2 8 HP stage MP stage LP stage

1.01 1.01 6.18 TA-1
15.0 15.0 160 TA-1 TA-1
113 113 6.24 RH1

14 15 16 11
12 13 G1 Exhaust
13,247 kWe steam
18 14 11 10 15 13 12 16
115 17.0 17.0 17.0 6.89 6.89 6.89 3.00 3 162.4 P=3 bar
515 318 318 318 250 250 250 162
100.0 100 35.0 65.0 65.0 10.0 55.0 55.0 55 2786

6.18 9 10
Deaerator 8 160
12.1
9 3
Water pre-heater
122 3 17 317.5 6.89 249.8
138 1.01 35 3073
25.0 10 2954
20 6.00 100.0 21 17.0
21 160 5 6 22 240 6.92
15.82 5.84
Take-off Teke-off
19 18 VT(17 bar) NT(6.89 bar)
20 1 19 6
2.40 2.40 122 6.67
57.4 105 108 163
82.1 100.0 100.0 5.84

7.01 MW LOSSES
51.46%

HP turbine s tage MP turbine s tage LP turbine stage

Generat or
4.457 MW 12.23 MW TA-1
32.72% 89.78% 64.41 MW 56.19 MW
81.44 MW 13.62 MW
4.684 MW
597.88% 472.87% 412.55% 100.00%
34.39% 94.30 MW
Deaerator 16.35 MW 692.29%
5.486 MW
120.03%
40.27% 29.87 MW
219.31%
Bolier
Feedwat er Water pre- Steam generator
heater 8.206 MW 42.47 MW
0.563 MW K6 60.24% 311.78%
4.13%
3.52 MW
5.011 MW 25.84%
36.79%
HP st eam MP st eam LP st eam
manif old manif old manif old

1.491 MW Air pre-

10.95% heater

Figure 2. Computer model of BLOCK 1 and the energy flow

(100% - electric power generated)
416 V. Dragičević, Z. Prelec, B. Franković, Optimization of a cogeneration ...

PTE block
G1 (gas turbine-HRSG)
26,049 kWe

6
5 GE 5371PA Heat exchanger
Superheater Economiser (district heat)
8 1.02 1.02 1.02 1.01
20.7 478 215 165 97.2
25.0 446 Evaporator 446 446 446
86.57 13 6 2 4 7
11 4 2 3
10 9
1.01 1.02
15.0 489
440 446

14 7 3 5
17.0 17.3 17.3 1.96
235 205 190 110
64.3 64.3 65.0 250

10 6.00
11 160
4.48
16
2 80
1
15 17.7 18 250 335.1
12 106 2.00
9 65.0 2.04 80.0
13 16 110 250
250
LEGEND: 1
2.44 2.00
bar °C 106 97.9
1.Pressure (bar) Deaerator 65.0 250
ton/h kJ/kg 12 14 2.04 110
2.Temperature (OC) 17
250 461.4
3.Mass flow (t/h)
A
B
bar °C Boiler feedwater
ton/h kJ/kg 19 pre-heater
2.44
65.0
60.5

17 2.49
15 15.0
60.5

26.04 MW
100.00%

Generat or
PTE-1

LOSSES
GE 5371PA 9.92 MW From DH
38.08% syst em
Heat exc.
Superheater Evaporator 24.8 MW Econom iser 18.10 MW dis tr. heat
95.21% 69.50% 23.26 MW
91.28 MW
89.30%
350.44%
60.63 MW 59.32 MW 8.186 MW
232.78% 227.73% 31.43%

6.579 MW
25.26%
4.6 MW 32.01 MW
17.66% LOSSES 1.49 MW 35.33 MW 122.90%
5.72% 135.66%
2.882 MW
11.06%
Feedwater
49.92 MW 14.58 MW Deaerator
pre-heater
191.64% 55.98%

8.004 MW 5.122 MW
30.73% 28.86%
1.61 MW
To DH syst em
49.92 MW 15.37%
191.64% Boiler feedwater

HP st eam
manif old

Figure 3. Computer model of the gas turbine – heat recovery steam generator (HRSG) and the
energy flow (100% - electric power generated)
Energy and the Environment (2006) 411-423 417

BLOCK-1 BLOCK- PTE K7

29.87 MW 100.6 MW 102.2 MW 51.39 MW
9.94% 33.51% 34.05% 17.11%

HP steam manifold (17 bar)

HP RS2-5
VTZ-PTE
112.4 MW 100.3 MW
37.42% 33.41% 51.39 MW
17.11%

BLOCK-1
8.206 MW
2.73%

RS-3
8.994 MW
2.99%

MP steam manifold (6 bar)

Plant
22.84 MW
7.64%

VTZ-1
40.37 MW
13.44%
VTZ-2
40.37 MW
13.44%

BLOCK-1
Let-off
42.75 MW
13.06 MW 14.23%
4.35% BLOCK-2
15.64 MW
5.21%

LP steam (2.5

Plant
22.95 MW
7.60% NTZ-1
27.93 MW
9.30%

NTZ-2
27.93 MW
9.30%

Total heat energy of the process

Qel = 300 MW (100% )

Figure 4. Energy flow between steam pressure levels (100% - total heat energy required by
district heating and steam)
418 V. Dragičević, Z. Prelec, B. Franković, Optimization of a cogeneration ...

The most notable losses that can be seen in the preceding diagrams are generated by throttling
steam from high pressure to medium pressure at the pressure reduction stations (throttling
steam valves). The energy flow passing through the throttling valves is about half of the total
energy used to heat water for the district heating system, and about one third of the total
energy entering the cogeneration system. The throttling of steam is an exergy loss and it
should be avoided. For that purpose, further analysis of the power plant is performed using
pinch method analysis, to see how these exergy losses could be avoided.

4. PINCH ANALYSIS

Pinch analysis is one of the most commonly used methods of analysis in the pursuit of PI
(Process Integration). This method is used for reduction of energy consumption in complex
energy systems in process and other industries. This method is becoming more popular since
it doesn’t only reduce energy consumption, but also lowers greenhouse gases emission, thus
making it a necessary measure for an ecological process improvement. Pinch analysis,
combined with the power of computer process simulation, provides a powerful tool for a
systematic analysis of industrial processes and interactions between parts of those processes.
The pinch method is an analysis by integration, so the basic principle of this method is
integration of heat flows. It enables the determination of minimal theoretical fuel, steam and
cooling water consumption. This is accomplished by analyzing the hot and cold energy
streams, or streams that need to be heated or cooled, and the possibilities of heat transfer
between those streams. These streams are used to construct composite curves for hot and cold
flows, or heat sources and heat sinks. To perform a pinch analysis it is imperative to correctly
identify all heat sources and sinks in the processes in the cogeneration power plant.

Heat sources are heat flows that require cooling or in this case heat sources are gas turbine
exhaust gases, exhaust steam from steam turbine bleeds, and waste heat form the steam
turbine TA-2 condenser. They can be shown in the Q& − T diagram.

600

0
T [ C]

500

400
Gas turbine
exhaust gases

300
Steam bleed TA1

200
Steam bleed TA1 and 2
(17 bar)
Exhaust steam TA -1 (2,5 bar)

100

Steam bleed TA-2

TA-2 condenser (0,97 bar)
0
0 20 40 60 80 100 120 140 160 180

Q& [MW]

Figure 5. Diagram Q-T for heat sources

Energy and the Environment (2006) 411-423 419

Heat sinks or cold flows are heat flows that enter the power plant and need to be heated like
return water from the district heating system and steam for the industry at 17 bar pressure 240
0
C temperature. For this analysis, the steam heat flow heating starts at 1050C, i.e. at feedwater
temperature in the deaerators. The steam that is used for heating feed water is not shown here,
but it is taken into consideration in the construction of the composite curves.
300

0
T [ C]

250

HP steam (ind.)- 140 t/h

(17 bar, 2400C)
200

150

District heating hot

water 160 MW
100

50

0
0 50 100 150 200 250 300
Q& [MW]

Figure 6. Diagram Q& − T for heat sinks

Using Q-T diagrams for heat sources and heat sinks, the following composite curves were
constructed:

500
0
T [ C]

450

400

350

300
Hot streams composite
curve
250

200

150
Cold streams composite
curve
100

∆Tmin = 8.75 C
0

50

0
0 50 100 150 200 250 300 350
Q& [MW]
Figure 7. Composite curve diagrams
420 V. Dragičević, Z. Prelec, B. Franković, Optimization of a cogeneration ...

After constructing the composite curves, the GCC (Grand Composite Curve) is constructed:
600
0
T [ C]

22 MW

500

400

300

0
HP steam (205 C, 17bar)
200

MP steam (158,80C, 7 bar)

0
LP steam (124 C, 2.5 bar)
100

0
0 20 40 60 80 100 120 140 160 180

Q [MW]

Figure 8. Grand Composite Curve (GCC):

In figure 8 the Grand Composite Curve (GCC) is shown, together with the saturation
temperature for the three steam pressure levels. Based on the GCC it is possible to analyze the
pressure levels at which it is best to add required additional energy for the process and
avoiding the excessive use of valuable high pressure steam.

The pinch analysis shows that this process doesn’t require additional cooling of heat sources
but only additional heating of heat sinks.

The total required additional heat is 22 MW, while the other heat energy is coming from the
steam turbine exhaust on TA-1, steam bleeds at TA-1 and TA-2, the heat of condensation
steam at the exit of condensing turbine TA-2, and the utilization of exhaust gases from the gas
turbines.

Required heat energy (steam and district heating) = 301 MW

Heat exchanged from the heat sources = 279 MW

Additional heating energy required = 22 MW

The GCC shows the optimum temperature levels for additional heat (utility pinch). Those
temperatures shown in figure 8 are saturation temperatures for various steam pressure levels
that are used in the power plant.

The additional heat can be entirely added at the temperature level of little above 100 0C. For
this purpose, heat generators are currently used to supply that amount of heat.
It would be far more efficient that this amount of heat is supplied at a higher pressure level. In
that way, the efficiency of the cogeneration process would be increased, because in addition
to heat, the energy input would produce also electric energy.
Energy and the Environment (2006) 411-423 421

Figure 7 shows that the pinch point of the process is at the exit of the steam turbine TA-2
condenser. The pinch is already low enough and the reduction of the pinch would result in a
small energy saving, but with additional investments required for new heat exchangers.

5. CONCLUSIONS

The results of the pinch analysis show that 22 MW of additional heating energy is necessary
for the analyzed cogeneration process in order to meet all the needs for heating district heating
water and for steam production in the case of considered energy balance.

The main suggested improvement from this pinch analysis is that this additional energy
should be brought in form of 115 bar pressure steam, and then let through a steam turbine
with bleed at 17 , 6 and 2,5 bar. The existing hot water generators can be used as a backup.
With this modification the CHP efficiency would improve significantly, especially in the
winter months.

Furthermore, the flow of steam through throttling valves RS2-5 should be brought to a
minimum, since this process represents a significant exergy loss. To avoid these losses,
production of middle pressure (7 bar) should be raised, and this could be accomplished by
installing dual-pressure heat recovery steam generators. These steam generators should be
able to produce steam of both 17 bar and 7 bar at the same time. This possibility was also
demonstrated by the pinch analysis. The high pressure heat exchanger (PTE-Z5) should be
eliminated and replaced, because it uses high pressure steam (17 bar and 2400C temperature)
to heat hot water with a far too great temperature differential.

In the end it should be noted that this analysis was performed on typical winter load
conditions for heat and electricity. The optimal configuration for this case isn’t necessary the
optimal configuration overall, but since the highest consumption of energy is in the winter
period, this configuration should result in significant fuel savings for the operation of the
power plant.

Suggested modifications:

1. Replacement of steam generator K7 with a high pressure steam generator (115 bar) of
the same capacity
2. Installation of a new steam turbine TA-3 with two steam bleed (17 and 6 bar) with an
exhaust pressure of 2,5 bar
3. Replacement of the gas turbine’s heat recovery steam generators (HRSG) with a dual
pressure heat recovery steam generator (HRSG)

The analysis of investment costs for the suggested modifications is out of the scope of this
work.
422 V. Dragičević, Z. Prelec, B. Franković, Optimization of a cogeneration ...

Modified basic layout of the power plant

demineralised water

BLOCK 1 BLOCK 2 BLOCK PTE

max 100 t/h max 100 t/h max 80 t /h

K6 115 bar K8 K9 115 bar K7 115 bar
GE 5371PA GE 5371PA
515 C 515 C
(25 MWel) (25 MWel)

~ ~
TA-1 TA-2
(12,5 MW) TA- 3
(30 MW) PTE PTE
64 t/h 64 t/h
dimnjak
~ ~ ~
Heat exc. for Heat exc. for
DH (8 MW) DH (8 MW)

HEATI NG
CONDENSER
0
17 bar, 240 C 17 bar, 240 0 C

RS2

o o
6 bar 160 C 6 bar 160 C

RS3
VTZ-3 VTZ-4 CONDENSATE COLLECTI ON

2,5 bar 140 C

NTZ-1 NTZ-2 CONDENSATE COLLECTI ON

Figure 9. The modified layout of the power plant

REFERENCES

[1] Prelec, Z., Energetika u procesnoj industriji, Školska knjiga, Zagreb, 1994
[2] Linnhoff, B., Pooley, G.T.,:General process improvements through pinch technology,
Linnhoff March Ltd.
[3] Ahmad, S., Hall, S., Morgan, S. Parker, S., Practical process integration – an
introduction to pinch technology, Aspen Technology Inc.
[4] Eastwood, A. R., Kelfkens, R.C., Development of site-wide energy strategies, Linhoff
March Linited, England
[5] Bošnjaković, F., Nauka o toplini 3, Tehnička knjiga, Zagreb, 1976.
[6] Thermoflex Users Guide, Thermoflow inc.
[7] Prelec, Z., Milošević, Š., Environmental aspects od cogeneration plants, Međunarnodni
kongres Energija i okoliš XVII, 221-222, Opatija, 2000.
[8] Klimisch, H. J., Andreae, M., Tillman, U, Summary of information on heavy fuel oils,
American Petroleum Institute (API), 2004.
[9] Medica, V., Franković, B., Toward low NOx hydrogen fueled internal combustion
engine, Hydrogen energy progress XII, Buenos Aires, 1317-1324, 1998.
Energy and the Environment (2006) 411-423 423

OPTIMIZACIJA KOGENERACIJSKOG SUSTAVA PRIMJENOM

PINCH METODE

Sažetak: U ovom je radu analiziran pogon jedne kogeneracijske termoelektrane-toplane u

cilju ocjene mogućih poboljšanja sa stanovišta uštede energije. Prikazani su energetski tokovi
u elektrani korištenjem Sankeyevih dijagrama za pojedine podsustave pogona (parno-
turbinski blokovi, blok plinskih turbina te sustav distribucije topline za kogeneraciju).
Analizirani su energetski procesi po pojedinim sustavima kao i energetski tokovi unutar
elektrane korištenjem pinch metode. U zaključku su navedeni rezultati provedene analize kao
i prijedlozi za optimizaciju i moguće uštede energije.

Ključne riječi: kogeneracija, ušteda energije, pinch analiza