Applied Thermodynamics –II/Thermal

Engineering -II

BASIC CONCEPTS OF RANKINE CYCLE

 UNIT-I

BASIC CONCEPTS OF RANKINE CYCLE

CONTENTS:
? Schematic Layout
? Thermodynamic Analysis
? Concept of Mean Temperature of Heat Addition
? Methods to Improve Cycle Performance
? Regeneration
? Reheating
INTRODUCTION TO RANKINE
CYCLE
 The Rankine cycle is a cycle that converts heat into work. The
heat is supplied externally to a closed loop, which usually uses
water. This cycle generates about 90% of all electric power
used throughout the world.
 The rankine cycle is an ideal reversible cycle for steam power
plants corresponding to carnot cycle.
 It is difficult if not impossible, to maintain perfect constant
temperature heat addition and heat rejection.
 • By using water as the working fluid, and considering the
latent heat concept can closely resemble the theoretical Carnot
cycle.
Schematic Layout Of Rankine Cycle:
T-s diagram:
? In a real Rankine cycle, the compression by the pump and the
expansion in the turbine are not ISENTROPIC.

? In other words, these processes are NON-REVERSIBLE

and entropy is increased during the two processes.

? This somewhat increases the power required by the pump and

decreases the power generated by the turbine.
? A Rankine cycle consists of the following processes:-

? Process 4 - 1 Isentropic Compression:

? Process 1 - 2 Isobaric Heat Supply:

? Process 2 - 3 Isentropic Expansion:

? Process 3 - 4 Isobaric Heat Rejection

Thermodynamic Analysis:

?Assume a Carnot cycle operating between two fixed

temperatures as shown.

T 2 3

1 4

s
The ideal Rankine cycle Isentropic
Reversible constant expansion to
pressure heat 3 produce work
T 3 (3 4) or
addition (2 3) * (3*
4*)

Isentropic
compressio
n (1 2)

1 4 4
*
Reversible constant
pressure heat
rejection (4
s
1)

T-s diagram
h-s diagram:

h 3
QH

W
OUT
W 2
IN
4
QC
1
Rankine cycle efficiency:
3
QH
W
OUT
WI 2
N 4
Q
1
Cs

s
W = − h4 W
OUT
NET (3)
W IN = h
h 32 − 1 η=
QH =
h
− h4 QH
h3
? SFEE for Boiler:
Q₁ = h₁ - h₄

? SFEE for Turbine:

Q₂ = h₂ – h₃

? SFEE for Pump

Wp = h₄ – h₃

? The efficiency of Rankine cycle:

Ƞ = Wnet / Q₁
= (Wt – Wp) / Q₁
= (h₁ – h₂) - (h₄ – h₃) / (h₁ - h₄)
? The capacity of a steam power plant is often expressed in terms
of Steam Rate or Specific Steam Consumption (S.S.C).

? Defined as the rate of steam flow (kg/s) required to produce

unit shaft output (1 kW).
Steam Rate (S.R.) = 1/Wnet ;kg/kW s

⮚ The cycle efficiency is sometimes expressed alternatively as

Heat Rate which is the rate of heat input (kJ/s) required to
produce unit shaft output.

? Heat Rate (H.R.) = Q₁ /Wt – Wp = 1/Ƞ; kJ/kWs

Simple Rankine cycle with saturated liquid at 0.007 MPa at
pump inlet. Saturated vapour at 3 MPa at turbine inlet Pump
efficiency: 60% Turbine efficiency: 80% Find: The overall
thermal efficiency
 Q
in Example-1: Ideal Rankine
2 3 Cycle
boile W
r Turbin out

e
W Consider the Rankine power cycle as shown.
in
Steam enters the turbine as 100% saturated
pum condens vapor at 6 MPa and saturated liquid enters
p er the pump at a pressure of 0.01 MPa.
4
1 If the net power output of the cycle is 50
MW. Determine:
Q (a)the thermal efficiency,
out
(b)the mass flow rate of the system,
T (c)the rate of heat transfer into the boiler,
3 (d) the mass flow rate of the cooling water
from the condenser, in kg/s, if the
cooling water enters at 20°C and exits at
2 40°C.

1 4
s
 Solution:
•At the inlet of turbine, P3=6MPa, 100% saturated vapor x3=1, from saturated
table A-5, h3=hg=2784.3(kJ/kg), s3=sg=5.89(kJ/kg K)

• From 3-4, isentropic expansion: s3=s4=5.89 (kJ/kg K)

• From 4-1, isothermal process, T4=T1=45.8°C (why?)

From table A-5, when T=45.8°C, sf4=0.6491, sfg4=7.5019, hf4=191.8,
hfg4=2392.8 x4 = (s4-sf4)/sfg4 = (5.89-0.6491)/7.5019 = 0.699
h4 = hf4+x4* hfg4 = 191.8+0.699(2392.8) = 1864.4 (kJ/kg)

•At the inlet of the pump: saturated liquid h1=hf1=191.8

qout = h4-h1=1672.6(kJ/kg)

•At the outlet of the pump: compressed liquid v2=v1=vf1=0.00101(m3/kg)

work input to pump Win = h2-h1 = v1 (P2-P1) = 0.00101(6000-10) = 6.05
h2 = h1 + v1 (P2-P1) =191.8 + 6.05 = 197.85 (kJ/kg)

• In the boiler, qin=h3-h2=2784.3-197.85=2586.5(kJ/kg)

 Solution (cont.)
(a) The thermal efficiency η = 1-qout/qin
= 1- 1672.6/2586.5=0.353=35.3%

?(b) Net work output (dW/dt) =50MW

=(dm/dt)(Wout- Win)=(dm/dt)((h3-h4)- (h2-h1))
? mass flow rate (dm/dt)
=50000/((2784.3-1864.4 )-(197.85- 191.8))= 54.7(kg/s)

?( c) heat transfer into the boiler

qin = (dm/dt)(h3- h2)=54.7(2586.5)=141.5(MW)
?(d) Inside the condenser, the cooling water is being heated from the heat
transfered from the condensing steam.
? q cooling water = qout = (dm/dt)(h4-h1) = 54.7(1672.6) = 91.49 (MW)
? (dm/dt)
cooling water
C (T
p out
-T )=q
in cooling water
C p, water = 4.177(kJ/kg K)
(dm/dt)cooling water = 91490/(4.177*(40-20))
= 1095.2 (kg/s)
Very large amount of cooling water is needed
 Example-2: Ideal Rankine Cycle:
• A steam power plant operates between a boiler
pressure of 42 bar and a condenser pressure
of
0.035 bar. Calculate for these limits the cycle
efficiency, the work ratio and the specific
steam consumption (ssc):
I. For Carnot cycle using wet steam
II. For Rankine cycle with dry saturated steam at entry to
the turbine.
III. For the Rankine cycle of (b) when the
expansion process has an isentropic efficiency
of 80%.
24
25
Concept of Mean Temperature of Heat
Addition:
? ηrankine = 1 – T₂/ Tm
? Lowering the condenser pressure, Higher will be the
efficiency of Rankine cycle.
? Higher the mean temperature higher will be the cycle
efficiency
? We can improve the efficiency of a Rankine power cycle by
increasing the pressure of the boiler and by decreasing the
pressure of the condenser.
T-s diagram:
Methods to Improve Cycle Performance:

? The efficiency of the steam turbine will be limited by water

droplet formation. As water condenses, water droplets hit the
turbine blades at high speed, causing ‘’pitting & erosion’’,
and so, gradually decreasing the life and efficiency of the
turbine.
? In order to avoid above disadvantages and improve cycle
efficiency, the followings are to be used wherever possible:
◦ Lowering the Condenser Pressure
◦ Increasing the Boiler Pressure
◦ Cycle with Superheat
◦ Cycle with Reheat
◦ Cycle with Regeneration.
Reheat Cycle:
1. Increases thermal efficiency
2.Increases dryness fraction of the steam at turbine exhaust, this
will reduce blade erosion.
3.Increase work done per unit mass of steam, thus reducing
boiler size.
4. Increases plant cost due to re-heater requirement and it’s long
piping system.
5.Increases condenser capacity due to the increas in steam
dryness fraction.
BLOCK
DIAGRAM: T-S DIAGRAM
? Energy analysis: Heat transfer and work output both
change
qin = qprimary + qreheat = (h3-h2) + (h5-h4)
Wout = Wturbine1 + Wturbine2
= (h3-h4)+(h5-h6)
Example-: Ideal reheat Rankine cycle

• Calculate the S.S.C if reheat is included in the plant

of example-2: the steam conditions at inlet to the
turbine are 42 bar and 500 oC, and the condenser
pressure is 0.035 bar as before. Assuming that the
steam is just dry saturated on leaving the first
turbine, and is reheated to its initial temperature.
Neglect the feed pump term.

36
Mollier Diagram (h-s diagram)

38
39
Re-generator cycle:
? Use regenerator to heat up the liquid (feedwater) leaving the
pump before sending it to the boiler, therefore, increase the
averaged temperature (efficiency as well) during heat addition
in the boiler.
? *Energy analysis: Heat transfer and work output both change
? *Energy analysis:
? qin = h5-h4, qout = (1-y)(h7-h1),
? Wturbine, out = (h5-h6) + (1-y)(h6-h7)
? Wpump, in = (1-y)Wpump1 + Wpump2
= (1-y)(h2-h1) + (h4-h3)
? Efficiency : Work Done/Heat Supplied
Advantages:

? It increases the thermal efficiency of the plant.

? The temperature stresses in the boiler are reduced due
to decreased range of working temperatures.
Disadvantages:
? The cost of the plant increases.
? Boiler size increases because of the capacity.
 Regenerative ideal Rankine cycle:

If the Rankine cycle of Ex. 2 modified to include one feed water

heater, calculate the cycle efficiency and the s.s.c.

3
5
BOILERS
CONTENTS:
•Classification Based on Working Principles & Pressures of
Operation
• L.P & H.P. Boilers
• Mountings and Accessories.
DRAUGHT: Classification – Height of Chimney for Given
Draught and Discharge, Condition for Maximum Discharge,
Efficiency of Chimney – Artificial Draught, Induced and Forced
Draught.
 Steam Generator (Boilers)
Essentials of Steam Power Plant Equipment:
• A steam power plant must have
following equipment :
(a) A furnace to burn the fuel.
(b) Steam generator or boiler containing water. Heat
generated in the furnace is utilized to convert
water into steam.
(c) Main power unit such as an engine or turbine to
use the heat energy of steam and perform
mechanical work.
(d) Piping system to convey steam and water.
• The function of a steam generator or a boiler is to convert
water into steam at the desired temperature and pressure to suit
the turbine which it serves.

• The basic components of steam generator are furnace and fuel

burning equipment, water walls, boiler surface (drum and
tubes), super heater surface, air heater (air pre-heater) surface,
re-super heater surface, economizer surface (feed water
heating), and several other accessories.
 Types of Boilers:
• Classification of boilers can be happen to according to several
methods.
A. According to fuel type:
• Coal
• Wood
• Waste material
• Oil fired
• Light or heavy fuel
• Gas fired
• Natural gas, LPG
B. According to fluid flow
• Natural circulation
• Forced circulation
• Once through
C. According to heat utilization
• Fire tube
• Water tube 4
7
 Horizontal, vertical or inclined boilers:

⮚ If the axis of the boiler is horizontal, the boiler is called

horizontal, if the axis is vertical it is called vertical boiler and if
the axis is inclined it is called inclined boiler.

⮚ Part of the horizontal boiler can be inspected and repair easily

but it occupies more space.

⮚ The vertical boiler occupies less floor area.

Fire Tube And Water Tube Boilers:
⮚ In the fire tube boilers, the hot gases are inside the
tube and water surrounds the tubes. for ex- cochran,
lancashire and locomotive boilers.

⮚ In the water tube boilers, the water is inside the tubes

and hot gases surrounds them. For ex- Babcock and
Wilcox, Stirling, Yarrow boiler etc.
• Water tube boiler: water circulates through tubes & hot flue gases flow over
them.
• Less liable to explosion, produce high pressure steam, high efficiency, heating
surface is large
• Fire tube boiler: hot flue gases pass through the tubes which are surrounded
by water.
• Low cost, compact in size, heating surface is small, cannot produce high
pressure steam, liable to explode, low efficiency

a.Water tube boiler b.Fire tube boiler

⮚ The advantage of fire tube boiler:-
1) It is quite compact in construction.
2) Fluctuation of steam demand can be met easily.
3) It is also quite cheap.

⮚ The disadvantage of fire tube boiler:-

1)As the water required for operation of the boiler is quite large, it
requires long time for rising steam at desired pressure.

2)As the water and steam are in same vessel the very high pressure
of steam is not possible
3) The steam received from fire tube boiler is not very dry.
 WATER TUBE BOILER
⮚ Used for high steam
demand and pressure
requirements.
⮚ Capacity range of 4,500
– 120,000 kg/hour.
⮚ Combustion efficiency
enhanced by induced draft
provisions.
⮚ Advantages of water tube boiler:-
1)Larger heating surface can be achieved by using more
numbers of water tubes.
2) Due to convectional flow, movement of water is much faster
than that of fire tube boiler; hence rate of heat transfer is
high which results into higher efficiency.
3)Very high pressure in order of 140 kg/cm2 can be obtained
smoothly.
⮚ Disadvantage of water tube boiler

1)The main disadvantage of water tube boiler is that it is not

compact in construction.
2) Its cost is not cheap.
3) Size is a difficulty for transportation and construction.
EXTERNALLY AND INTERNALLY FIRED TUBE BOILERS:

⮚ The boiler is known as externally fired if the fired is

outside the shell. For ex-Babcock and Wilcox boiler,
Stirling boiler.

⮚ In case of internally fired boilers, the furnace is located

inside the boiler shell. For ex- cochran, lancashire boiler
etc.
 FORCED AND NATURAL CIRCULATION:

⮚ In forced circulation type of boiler, circulation of

water is done by a forced pump. For ex- Velox,
Lamont, Benson boiler etc.
⮚ In natural circulation type of boiler, circulation of
water in the boiler takes place due to natural
convention currents produce by application of heat.
For ex- Lancashire, Babcock and Wilcox boiler etc.
 High And Low Pressure Boilers:
⮚ The boilers which produce steam at pressure of 80
bar and above are called high pressure boilers. For
ex- Babcock and Wilcox, Velox, Lamount, Benson
boilers etc.
⮚ The boiler which produce steam at pressure below
80 bar are called low pressure boiler. for ex-
Cochran, Cornish, Lancashire and locomotive
boilers etc.
STATIONARY AND PORTABLE:

⮚ Stationary boilers are used for power plant steam,

for central station utility power plant, for plant
process steam etc.

⮚ Portable boiler include locomotive type, and other

small units for temporary use at sites.
 Single And Multi – Tube Boiler:

⮚ These are basically types of fire tube boilers.

⮚ If single tube is used to pass hot gases then it is

called single tube boiler. For ex- Cornish boiler.

⮚ If many tubes are used to pass hot gases then it is

called multi-tube boiler. For ex- Lancashire,
Babcock and Wilcox etc.
Selection of A Boiler:
⮚ Working pressure and quality of steam.
⮚ Steam generation rate.
⮚ Floor area available
⮚ Accessibility for repair and inspection .
⮚ Comparative initial cost.
⮚ Probable load factor.
⮚ The fuel and water available.
⮚ Operating and maintenance cost.
HIGH PRESSURE BOILERS:
?A boiler is called a high pressure boiler when it operates with a steam
pressure above 80bar. The high-pressure boilers are widely used for
power generation in thermal power plants.
?Example: Lamont boiler, Benson boiler, loeffler boiler, Babcock and
Wilcox boiler
?Features of High pressure Boilers

1. Forced circulation of water

2. Large number of small diameter tubes
3. Higher steam pressure and temperature
4. Improved mode of heat transfer and heating
5. Pressurized combustion
6. Compactness
7. High efficiency
8. Once through construction
 1. La Mont boiler:
• It is high pressure, water type boiler

• The water circulation is maintained by

centrifugal pump.

• La Mont boiler generates approximately 45

to 50 tonnes of steam per hour at a pressure
of 13 bar and a
temperature of 500°C.

Advantages of a La Mont Boiler:

1. Small diameter tubes are used,

so that
high heat transfer rate is maintained.

2.The multiple tubes circuit gives flexibility for

suitable location of heat transfer equipments.
2.Benson boiler:
Difficulties of bubble formation is
eliminated.

The transport of Benson boiler parts is

easy as no drums are required and
majority of the parts are carried to the
site without pre-assembly.
Required smaller floor area.

The super heater in the Benson boiler is

an integral part of forced circulation
system therefore no special starting
arrangement for super heater is required.

It has very little storage capacity

compared to drum type boiler.
3. Loeffler boiler:
•Difficultiesof deposition of salt and
sediment is eliminated.

•Most of the steam is generated outside

from the feed water using part of the
superheated steam coming out from the
boiler.

•Loefflerboilers with generating capacity

of 94.5 tones/hr and operating at 140
bar have already been commissioned.
Mountings and Accessories:
BOILER MOUNTINGS

Mainly mountings are required and essential to a Boiler :

1. Safety valve
2. Two water level indicators
3. Pressure gauge
4. Fusible plug
5. Steam stop valve
6. Feed check valve
7. Blow-of cock
8. Man and mud hole
1.SAFETY VALVE 2. WATER LEVEL INDICATOR
3. FUSIBLE PLUG 4. PRESSURE GAUGE
 6. FEED CHECK VALVE
5. BLOW OFF COCK

7. STOP VALVE
Boiler Accessories:
1. AIR PREHEATER 2. ECONOMISER

3. SUPER HEATER
Thank you