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The document describes energy and exergy analysis of a coal-fired non-reheat thermal power plant. It discusses how exergy analysis can identify locations and magnitudes of irreversibilities to improve efficiency. The power plant analyzed has 3 units of 55 MW capacity each, using coal as fuel. Equations for calculating the exergy of fuel, streams, and components are provided. Exergy destruction in each component and the overall plant are determined to identify areas for improvement.

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0% found this document useful (0 votes)
64 views14 pages

13 - Chapter 3 PDF

The document describes energy and exergy analysis of a coal-fired non-reheat thermal power plant. It discusses how exergy analysis can identify locations and magnitudes of irreversibilities to improve efficiency. The power plant analyzed has 3 units of 55 MW capacity each, using coal as fuel. Equations for calculating the exergy of fuel, streams, and components are provided. Exergy destruction in each component and the overall plant are determined to identify areas for improvement.

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Abhishek Gupta
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CHAPTER-3

ENERGY AND EXERGY ANALYSIS OF COAL


FIRED NON-REHEAT THERMAL POWER PLANT
3.1 INTRODUCTION
India’s energy market is one of the country’s fastest developing sectors. Annual demand
for electricity has increased from 1713 MW in 1950 to 150323.41 MW (30.06.2009).The
electricity generated from thermal power plants constitutes 64.6 % of total generation.
From, the Fifth Five year plan onwards i.e. 1974-79, the Government of India got itself
involved in a big way in generation of power to supplement the efforts at the state
Government level and took upon itself the responsibility of setting up the large power
projects based upon the coal as well on other resources like hydro, nuclear etc.. NTPC
NHPC and NPC were set up for these purposes in 1975.

The size of the generating unit that has been used in the country in coal based power
stations has progressively increased from about 15 MW to 500 MW but now-a-days 660
MW and 720 MW units are being installed. With the introduction of more and more
power plants, certain difficulties are arising in their efficient and smooth operation and
maintenance. The availability of coal in the country is such that the higher grades of coal,
which have higher calorific value, have been exhausted and progressively lower grades of
coal are being made available for generation of electricity in power plants. This had
resulted in poor thermal efficiencies of power plants. Shortage of power is being felt from
all comers of India and National Electricity Policy (NEP) stipulates the power for all by
2012. To fulfill the objective of NEP, a capacity addition of 78,700 MW has been
proposed for the 11th Plan. The share of thermal power plant would be 75.8% in this
capacity addition.

This growing demand of power all over the world has made the power plants of
scientific interest and also for the efficient utilization of resources. This has led to
development of various analysis techniques for improving the performance of power

27
plants. The most commonly used method for the analysis is the First Law of
Thermodynamics. However there is increasing interest in the combined utilization of first
and second law of thermodynamics, using the concepts such as exergy and exergy
destruction in order to evaluate the efficiency with which the available energy is
consumed. Exergy analysis provides the tool that provides the distinction between the
energy losses to the environment and internal irreversibilities in the processes [Moran M
J, (1989)].

The exergy balance of system allows us to allocate and calculate irreversibilities in the
production process and to identify which units and what for reason they affect the overall
efficiency. In recent years the second-law based exergy analysis of thermal power plants
has increasingly attracted engineer’s attention [Szargut J et al. (1988), Kotas T J (1985),
Bejan et al. (1996)]. Engineers and scientists have been applying first law to calculate
enthalpy balances for more than a century to quantify the loss of efficiency in a process
due to loss of energy. An exergy assessment allows one to quantify the loss of efficiency
in a process due to loss of quality of the energy. This analysis can indicate where the
process can be improved and, therefore, what areas should receive more attention. The
exergy analysis sometimes referred to in literature as thermodynamic availability,
available energy or useful energy.

The majority of the causes of thermodynamic imperfection of thermal and chemical


processes of thermal power plants cannot be detected by means of an energy analysis. For
example, irreversible heat transfer, throttling, and adiabatic combustion are not associated
with any energy loss, but they lead to decrease the energy quality, reduce its ability to be
transformed into other kind of energy and therefore increase the operational cost of
installation. These effects of the aforementioned irreversible phenomenon can be detected
and evaluated by only second law of thermodynamics. The main purpose of the exergy
analysis is to detect and evaluate quantitatively the causes of the thermodynamic
imperfection of thermal processes. The exergy analysis can therefore give the information
about the possibilities of improving thermal processes, but cannot state whether or not the
possible improvement is practicable. Such a question can be answered only by the
economic analysis and has been discussed in Chapter IV. Recently a large number of

28
studies based on exergy analysis have been carried out by the researchers [Aljundi I H
(2009), Bejan A (1988), Moran J (1982), and Oh S et al. (1996)] to evaluate the thermal
power plants at designed and operating conditions and gas turbines. A recent advances in
exergy analysis has been discussed by Tsatsaronis (2008).

3.2 SYSTEM DESCRIPTION

The power plant consists of three units of 3X55 MW at full load. Figure 3.1 shows the
schematic diagram for 55 MW power plants for one unit. Boiler of considered unit is
designed for coal of calorific value of 23100+. 840 KJ/kg with ash content of 22% and
volatile matter of 38%. However, the coal received is of 16765KJ/kg with ash content of
38% and 26% volatile matter Plant consists of HP and LP turbines without any reheating.
Steam after expanding in LP turbine is exhausted in condenser. The condensed steam
passes through the LP and HP regenerative feed water heaters. The hot water is then fed
to boiler drum through the two economizers. Cycle has been analyzed with following
assumption.

1) Specific exergy of fuel has been calculated as in Bejan et al. (1996).


2) Gross calorific value has been used in calculations.
3) Intensive properties of the environment are not changing due to any
process.

3.3 ENERGY AND EXERGY ANALYSIS

The mass and energy conservation laws have been applied to each component and also
for whole system. The energy and exergy analysis for the base condition of 55MW and at
40MW condition has been performed to pinpoint the location and magnitude of process
irreversibilities. Further, the deviation of first and second law efficiency has been
estimated.

The major streams entering and leaving the components of the plant are shown in the
Figure 3.1.To identify the sources of the availability destruction, the entire plant has been
split into different control volumes, viz. Boiler with its inputs and outputs, generator

29
Hot Air Supply

Air in 44

43 Flue gases to Stack

Figure 3.1 Schematic diagram o f non-reheat thermal power plant


condenser and regenerative system and the entire cycle with boiler, turbine, generator,
condenser and regenerative system. This would help to find out the individual
contribution towards the gross irreversibility of the plant, as well as, the response of
different parts towards exergy destruction with base and operating conditions. A general
energy and exergy-balance equations, applicable to any component of a thermal system
may be formulated by using the first and second law of thermodynamics; the specific
thermo-mechanical exergy (neglecting kinetic and potential energy) is evaluated from the
following equation:

(3.1)

The total rate of exergy with any stream can be estimated as

Ej=mjej (3.2)

and total rate of energy with any stream can be estimated as

Bj =mjhj (3.3)

where the m, j ,h, s and 0 denotes mass flow rate of stream, energy or exergy flow
streams entering or leaving the component at any point, specific enthalpy, specific
entropy and thermodynamic properties at ambient conditions respectively in above
Equations.

Chemical exergy (based on dry and ash free) evaluation, required for the fuel only, has
been evaluated separately.

eDAF -(HHV)dAF ~T0[spaf + V(J2 so2-vco *sc()2-vH0*s VS02


*sso2-vNi *sNi] (3.4)
H,U

+ [VC02 *%of + Vff20 *eH20 +VS(>2 -CH ,, * -(.7/ 1


+ vN 2 CN 2 ~v02 e02 J

DAF and HHV denote dry and ash free and higher heating value respectively.

31
Out of it the exergy flow rate leaving with flue gas is:

<3-5>

where, the summation applies over all the components of the flue gas and superscript g is
for flue gas.

A detailed exergy analysis includes calculating the exergy destruction and loss in each
component. The exergy balance equation for any component (without decomposing)

(3.6)

The subscripts e, i, k and q denote exit, inlet, component and heat transfer respectively.

E and W denote the Exergy rate and work transfer rate in Equation 3.6.

The exergy destruction rate in a component is calculated from exergy balance

<3-7>

/ e

The exergy destruction ratio yn k represents the exergy destruction rate Er> in the klh

component with total exergy destruction rate in the system.

yD,k=ED.k/lLED,k
(3.8)

The general definition for exergetic efficiency for a thermal system is

Exergetic Efficiency = 1------ ^xer^ ^oss — (3.9)


All Input Exergies

Appendix 1 shows the equation used for calculating exergy destruction and exergy
efficiencies for plant subsystem.

32
Table 3.1 Pressure, temperature, mass flow rate, energy and exergy flow rate for the
streams of power plant at 55 MW (Base case design)

Pressure Temperature Flow Energy Exergy


Stream
(bar) (K) (kg/s) (KW) (KW)
1 93.166 803.000 72.220 249720.000 105090.000
4 25.988 663.000 3.658 11762.000 4186.900
6 25.988 496.050 3.710 3500.700 744.850
7 10.787 590.000 3.910 11297.000 3521.300
9a 10.787 456.200 3.910 5684.700 989.000
10 2.187 460.000 1.654 4699.900 1057.000
12 2.187 397.250 1.654 856.540 94.185
13 0.932 413.000 2.960 8160.600 1463.200
15 0.932 370.750 4.613 1886.300 149.380
16 0.588 384.520 9.070 24523.000 3809.400
18a 0.588 358.650 13.683 4931.200 326.000
19 0.098 319.000 51.200 132300.000 8015.000
20 0.098 316.760 51.200 9350.600 148.020
21 10.788 325.000 65.575 14294.000 416.010
22 10.788 352.000 65.575 21702.000 1293.500
23 10.788 377.000 65.575 28595.000 2536.500
24 10.788 391.200 65.575 32478.000 3408.700
25 10.788 391.200 65.575 200670.000 3408.700
26 3.923 421.000 72.894 200670.000 48928.000
27 132.394 421.000 72.894 45563.000 7054.400
28 132.394 443.000 72.894 52433.000 9167.100
29 132.394 467.000 72.894 59993.000 11797.000
30 132.394 467.000 72.894 59993.000 11797.000
31 132.394 526.000 72.894 80145.000 19730.000
32 132.394 542.000 72.894 85818.000 32009.000
323 105.910 588.000 72.894 104240.000 30761.000
39 0.024 832.000 387.440 1561600.000 76667.000
40 0.024 673.000 387.440 1224900.000 55175.000
41 0.024 635.000 387.440 1145800.000 50139.000
42 0.024 500.000 387.440 914490.000 32975.000
43 0.024 416.150 387.440 706840.000 22050.000
44 1.013 298.000 377.700 112960.000 0.000
46 1.058 481.000 377.700 5323900.000 15273.000
47 1.058 613.000 377.700 6768300.000 37900.000
47 1.058 613.000 377.700 6768300.000 37900.000
48 1.013 298.150 9.740 224800.000 247660.000
49 1.013 306.000 2960.000 407590.000 2651.800
50 1.013 315.000 2960.000 518910.000 7179.500
51 1.013 298.000 0.692 434.300 0.000

33
3.4 RESULT AND DISCUSSION
In this work, an energy and exergy analysis has been performed on 55MW Non-Reheat
coal based thermal power plant. A schematic diagram of this unit with its various
significant components is shown in Figure 3.1 .Table 3.1 shows relevant thermodynamic
data. For normal running of plant at 55MW, boiler generates the 72.22 kg/s of
superheated steam at 93.17 bars. The superheated steam produced in super heaters enters
into the HP turbine. After expansion in HP turbine, steam enters into LP turbine without
any reheat. Finally, the exhaust of LP turbine is condensed into the condenser and used
for closed cycle. For regenerative heating of condensate, steam extracted from various
points as shown in Figure 3.1.The relevant performance characteristic and boundary
characteristic are in the form of process flow and operating data is provided by plant
operation personnel of the power plant. These data includes the mass flow rate,
temperature and pressure of steam at 40 and 55MW. The reference state for water, air and
fuel is 25°C.

The analysis of actual thermal power plant and its components is highly complex and
tedious in nature due to huge amount of data associated with large number of system
components, different operating conditions and nonlinear behavior of steam properties. In
present work a program in MATLAB has been developed. The program calculates total
energy, total exergy at different plant load conditions. Using these intensive and
extensive properties, program calculates subsystem effectiveness at rated load and part
load conditions. Main subsystems of thermal power plant are boiler, turbine, and
condenser and feed water heaters.

The relevant steam operating data for power plant at 40 and 55MW load were supplied as
an input and the values of enthalpy, exergy and effectiveness has been computed as an
output data. Table 3.1 shows the computed values of energy and exergy of various flows
in the plant.

Table 3.1 contain relevant thermodynamic data i.e., pressure, temperature, energy and
exergy for steam power plant at 55MW. Similar calculations were also performed for
40MW. Corresponding energetic and exergetic efficiencies of subsystems and of the

34
whole plant at 55MW is shown in Figure 3.2. From energetic point of view turbine is
maximum efficient component with an efficiency of 96.53%. The Feed water heaters,
boiler and condenser are equally efficient components with the efficiencies of 84.82,
84.35 and 84.14% respectively. The energetic efficiency of plant was estimated as
24.52%. From Second law point of view, the turbine remains as the maximum efficient
component with exergetic efficiency of 66.25% and boiler is the least efficient
component with exergetic efficiency of 37.67% whereas the exergetic efficiencies of
feed water heaters and condenser are 83.14% and 59.46% respectively and lies between
the exergetic efficiencies of turbine and boiler. The exergetic efficiency of the whole
plant has been estimated as 22.21%.
K>
o
O
o
Efficiency (%)
OO

| First Law efficiency


o
ON
o

□ Second Law efficiency


-P*.
o
FO
o
o

Boiler Turbine Condenser ni0„f


Feed Water "lant
Heaters

Figure 3.2 Efficiencies ofplant and subsystems at 55 MW

Figure 3.3 shows the First law efficiency at full and part load condition of 40MW. From
energy or the first law standpoint view the overall plant efficiency varies 24.52 at 55MW
to 22.01% at 40MW. The component-wise variation in the First law efficiency is also
indicated in Figure 3.3. The efficiencies of boiler, turbine, condenser and feed water

35
120

100
Efficiency (%)

0 55 MW

140 MW

Boiler Turbine Condenser Feed Water Plant


Heaters
Figure 3.3 First law efficiency for subsystems and overall plant

100
Efficiency (%)

□ 55 MW

140 MW

Boiler Turbine Condenser Feed Water Plant


Heaters
Figure 3.4 Exergetic efficiencies for subsystem and plant

36
heaters drop to 82.84, 92.88, 43.19 and 75.29% respectively. The condenser operates
with lowest efficiency at 40MW as indicated in Figure 3.3. Figure 3.4 shows second law
or exergetic efficiency of subsystems and overall plant at rated full load and part load
condition. The exergetic efficiency of plant at designed rated condition, which is 22.10%
drops to 19.94% at part load of 40MW, which is very low. This indicates that tremendous
opportunities are available for the improvement. However, part of this irreversibility
cannot be avoided due to physical, technological and economic constraints. The exergetic
efficiency for boiler varies from 37.67 to 36.50%, for turbine, the efficiency is improved
to 68.25% at 40MW, for the condenser, the second law efficiency varies from 59.46% at
full load to 15.05% at part load of 40MW and for, feed water heaters and the exergetic
efficiency varies from 83.12% at 55MW to 75.08% at 40MW.

100
Exergy destruction (%)

| 55 MW

□ 40 MW

Boiler Turbine Condenser Feed Water


Heaters
Figure 3.5 Exergy destruction (%) within subsystems

Figure 3.5 shows the exergy destruction in percentage (exergy destruction in a


component to the total exergy destruction in plant) in subsystems of plant at 55MW and
40MW. This figure shows that maximum exergy destruction takes place in the boiler and

37
least exergy destruction takes place is feed water heaters at 55 and40MW. The exergy
destruction in the boiler increases from 78.83% to 80.20%. It is observed that maximum
exergy destruction of total exergy destruction occurs within the boiler and destruction
rate increases at part load conditions. There are many sources of irreversibility within the
boiler. The major sources of exergy destruction firstly, is chemical reaction in boiler
combustion chamber where chemical reaction is the most significant source of exergy
destruction causing the incomplete combustion in a combustion chamber which is the
irreversible combustion itself. Primary source of destruction is that high potential fuel is
consumed in the spontaneous combustion. The exergy destruction at part load increases
due to improper heating of inlet combustion air. Secondly, the exergy destruction in the
combustion chamber also significantly affected by excess air and inlet temperature of air.
The efficiencies of combustion can significantly increased by preheating the inlet
combustion air effectively and controlling the air-fuel ratio effectively. As discussed
earlier maximum exergy destruction occurs in the boiler due to incomplete combustion,
excess air, and poor performance of air pre-heaters and use of low grade fuel other than
designed fuel. The temperature of air supplied to the boiler at full load is 340°C where as
at 40MW part loads this temperature is 303°C. Thirdly and lastly, the exergy destruction
also caused by the poor heat transfer from flue gas to steam which is the irreversible heat
transfer between the hot combustion products and the fluid in the boiler tubes. The coal
temperature at mill outlets should be in the range of 65-80°C where as actual temperature
is in range of 84-89°C at the all mills. A steep fall in the condenser efficiency may be
seen at part load condition because of the actual high back pressure and high terminal
temperature difference against designed values. Lowering the condenser temperature,
consequently, lowers cycle average temperature. Essential effect is that, the exergy lost
through condenser-ambient heat transfer decreases. Quality and quantity of raw water
supplied to cooling tower is poor. Equivalent mineral acidity and KMNO4 is very much
above design values. The performance of regenerative system is very poor particularly at
part loads. There are 2 HP heaters and 3LP heaters provided in the system. The main
approach is to maximize the cycle high temperature. Counter flow heat transfer between
the two streams raises temperature of feed water near to boiling point. The intended
outcome of feed heating is to avoid the degradation of heat transfer from bleeding steam

38
in the course of heating the feed water. Feed heating shown in Figure 1 derives its
irreversibility from two main sources, first, the mixing of sub cooled liquid with a
saturated mixture of higher temperature, and, in the case of the later feed heating stages
and second, the mixing of superheated steam with a saturated mixture of lower
temperature. The thermodynamic data provided for of regenerative system were
insufficient for calculation purpose. However based on some assumed data, calculation
for exergetic efficiency has been made. It is observed from the data that at part load, LP1
is not in the service as there is no temperature gain in the heater. In turbine exergy
destruction drops from 16.70 % to 14.54% indicating that turbine performance improves
at part load condition from second law point of view whereas in the condenser the exergy
destruction increases from 3.01% to 4.20% and for the feed water heaters exergy
destruction increases from 1.45% to 2.50%.

According to First Law analysis turbine and feed water heaters are most efficient parts
whereas the boiler and condenser are equally efficient but comparatively not efficient as
turbine. On comparing the Figure 3.3 and Figure 3.4, it is observed that boiler
performance is not as good as from the exergetic efficiency point of view and same
conclusion may be drawn from other subsystems also. In this sense first law analysis is
misleading by taking an example of condenser; in condenser, the energy expulsion in the
condenser is practically useless for the electric power generation. For example, a Carnot
cycle operating between the condenser temperature of 46°C and the reference
environmental temperature of 25°C used in this analysis would have an efficiency of
9.42%. Given that the energy (heat) expulsion from the condenser is 45.4MW, it follows
that maximum possible power production from the energy expelled in the condenser is
about 4.3MW, thereby increasing the plant first law efficiency to 26.5% at the most. First
law analysis should hence not be used to pinpoint prospective areas for improving the
efficiency of electric power production. Second Law Analysis serves to pinpoint the true
power generation inefficiencies occurring throughout the power plant.

39
3.5 CONCLUSIONS

In this work an energy and exergy analysis has been performed on a 55MW actual
thermal power plant at 40MW and 55MW output to pinpoint the losses taking place in
the plant. Exergy and percent of destruction along with energetic and exergetic
efficiencies have been evaluated. In the considered power cycle, maximum energy loss
was found in the condenser. Feed water heaters and boiler were the next. On the other
hand, the exergy analysis of the plant showed that lost energy is thermodynamically
insignificant due to its low quality, particularly at part load where energy loss at
condenser increases. In the terms of exergy destruction, it was found that exergy
destruction rate of boiler is dominating over all other irreversibilities in the plant. Next to
it was turbine where approximate 16% (at 55MW) of the total exergy destruction in the
plant was destroyed. The percentage exergy destruction in the condenser and feed water
heaters is very low. Calculated exergetic efficiency of plant is 22.10% at 55MW which is
very low as compared to modem power plants.

Nonetheless, efficiencies based on the energy analysis can often be non-intuitive or


misleading [Rosen M (2002)], in part because it does not provide a measure of ideality.
In addition, losses of energy can be large quantity while it is thermodynamically
insignificant due to its low quality. Exergy based analysis provides a measure of
approach to ideality or deviation from ideality.

40

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