Energy conservation in the refinery by utilizing reformed fuel gas and furnace flue gases

Decrease of fuel supplies and cost increases make it vital for industries, especially energy intensive ones, to consider conserving available sources and convert losses into sources of energy.In this paper, a gas turbine-based cogeneration system is suggested to utilize a refinery's reformer gas in the gas turbine, and furnaces flue gases together with the engine exhaust gases in a heat recovery steam generator, HRSG. This is proposed as an alternative to the currently used system where the gas turbine and the steam generator are used separately. Operating variables comprising compressor pressure ratio and turbine inlet temperature are varied widely to evaluate performance; namely power, SFC, overall efficiency and annual fuel savings at design and off-design loading conditions using a dedicated computer program.Results show that the proposed system offers 100% higher overall efficiency and $5.25 million annual fuel saving for a 12 MW_e gas turbine.     

Gas turbine exhaust gas heat recovery at South Baghdad (Iraq) power plant

Gas turbine exhaust is usually relatively clean, especially the exhaust from natural gas turbines. The use of such gases to improve the overall thermal efficiency of a steam power plant has the advantage of reducing the cost of cleaning the equipment and reducing the maintenance costs of the heat recovery equipment used in the application.In this paper, two proposals for recovering the waste energy of the exhaust gases from a gas turbine unit, fuelled by natural gas at south Baghdad Power Plant (Iraq) are discussed. The proposals cover improvements to the thermal efficiency of a steam power plant installed near the gas turbine unit. The first proposal is to use the exhaust gases to preheat the feed water at four feed water heaters, in order to increase the power output. This arises because of the savings in the amount of steam extracted at a different level used for preheating the feed water line. The second proposal is to use the thermal energy in the exhaust gases to reheat the extracted stream, at five points at a high thermal potential, to increase the thermal gain at the preheating feed water line. This avoids the complexity associated with rejection of the extracted steam. The first roposal shows that a 1.22–14.9% saving in fuel consumption is achievable and the overall thermal efficiency of the steam power plant becomes 29–34% (at different gas turbine plant loads). The second proposal shows that a 2.3–7.35% saving in fuel consumption can be attained and the corresponding thermal efficiency will be 30.3–32%.     

The effect of the operating parameters of heat recovery steam generators on combined cycle/sea-water desalination plant performance

Combined gas/steam turbine cycle plants have been proposed for cogeneration of electricity and process steam. Examples are combined-cycle power plants coupled with sea-water desalination, district heating plants, chemical industries, etc. In combined heat and power plants, the gas turbine exhaust heat is utilized through the use of heat recovery steam generators (HRSG's). As a result, these waste heat generators (boilers), whether fired or unfired, control the performance of the combined plant lower side (bottoming cycle). Moreover, any changes made in the HRSG operating parameters (i.e. the pinch point, approach temperature, first and second stage pressures, and mass ratios) can greatly affect the HRSG performance and will eventually affect the overall combined plant performance. This paper presents a method to predict the performance of the heat recovery steam generators (HRSG)/steam bottoming cycle combined with sea-water desalination plant at various steam and exhaust gas conditions.     

Effect of control modes and turbine cooling on the part load performance in the gas turbine cogeneration system

This work aims to analyse the part load performance in a cogeneration system which consists of a single shaft gas turbine and a heat recovery steam generator. Two distinct part load control modes are considered: the constant air flow and the variable air flow. Meanwhile, the effect of variation in the coolant fraction is evaluated, whose purpose is to maintain the blade temperature as high as possible and thus minimise the coolant consumption. The design point parameters of the heat recovery steam generator are determined by the limiting factors on the part load operation, which are represented by the pinch point temperature difference and the approach temperature difference. It turns out that for both air flow control modes, the variable control of coolant fraction leads to improvement of the gas turbine efficiency, while it reduces the heat recovery potential. On the whole, the variable control of coolant fraction has a favourable effect on the overall fuel economy in the cogeneration system.     

The gas turbine-jet pump coupling in cogeneration plants

When a steam driven jet pump is coupled to a gas turbine it can decrease the exhaust total pressure of the turbine and thus increase its output and the gas turbine thermal efficiency. If the steam is generated in a waste heat recovery the thermal efficiency of the engine may increase by 2–3%. The present paper studies the gas turbine-jet pump coupling, at various partial loads, by incorporating the long exhaust diffuser as a water preheater. In addition, additional firing may be introduced at the boiler inlet to keep the temperatures of the boiler constant. The results indicate that the efficiency of the gas turbine increases by 3–4% at optimum conditions.     

Fuel cost charged to desalters in co-generation power-desalting plants

In combined power-desalting (plants, high available steam (at high pressure temperature) is expanded first in a steam turbine (and thus produces work) before its extraction (from the turbine) as a heat source to the desalters. The amount of energy consumption charged to the predominantly used multi-stage flash (MSF) desalter in this combined heat and power plant is a question of great concern in the Gulf area. The following are among the methods used to answer this questions (i) the available energy of the heat supplied to the desalter; (ii) work loss from the lower pressure stages of the steam turbine due to steam extracted to the desalter; (iii) energy charged if a separate boiler was used to supply the desalter with its required heat; and (iv) the excess energy supplied to the combined power desalting plant as compared to a single purpose power plant producing the same power output. There would be a different rating method of the power producing process associated with any of the above mentioned charging methods. In this paper, the MSF desalting method and its power consumption are outlined, together with the rating method of the power-desalting plants and the energy charged to the desalter methods. These rating methods are applied to real cases of dual purpose plants working in Kuwait.     

Improvement of CANDU-1000 MW(e) power cycle by moderator heat recovery

Four different moderator heat recovery circuits are proposed for CANDU-1000 MW (e) reactors. The proposed circuits utilize all, or part, of the 155 MW(th) moderator heat load (at 70°C moderator outlet temperature from calandria) to the first stage of the water heating system. An economics study was carried out and indicated that the direct circulation of feed water through the moderator heat exchanger (with full heat recovery) is the most economical scheme. For this scheme the saved steam from the turbine extraction was found to produce additional electric power of 8 MW(e). This additional power represents a 0.7% increase in the plants nominal electric output. The outstanding features and advantages of the selected scheme are also presented.     

新型燃煤发电-CO2捕获-供热一体化系统

本文在深入分析燃煤电站CO₂捕获和汽水系统热平衡的基础上,提出一种新型燃煤发电-CO₂捕获-供热一体化系统。该系统通过汽水流程、碳捕获流程及地暖供热流程的有效集成,实现了系统中、低温余热的高效利用,降低了碳捕获对电厂效率的影响。分析结果显示,本文提出的一体化系统,在CO₂回收率90%时,供电效率可达31.32%,供电效率降低8.96%,而传统化学吸收法碳捕获电站效率惩罚普遍在10～12个百分点或更高。同时,该系统可供热350 MW,全厂（火用）效率达34.49%,全厂热效率高达55.88%;该系统以较少的能耗代价实现高效供电、供热与CO₂减排,为燃煤发电机组碳减排提供了独特的学术思路与技术方案。     

Enhancing gas turbine performance by intake air cooling using an absorption chiller

The performance of gas turbines, operated either as a simple cycle or a combined cycle, is critically constrained by the prevailing ambient temperature, particularly in arid and tropical climates. This paper investigates the option of cooling the intake air to the compressor of the gas-turbine system using an absorption chiller in order to increase the gas turbine capacity. High-temperature waste heat from the exhaust gas may be utilized to produce steam in a recovery boiler. Part of the steam produced could then be used to drive a lithium-bromide double-effect absorption chiller which in turn could cool the incoming air. An analysis carried out by taking the weather data of Bangkok (Thailand) indicates that reducing the temperature from ambient condition to 15°C could help to increase the instantaneous power output between 8 and 13%. As an outcome, as much as 11% additional electricity could be generated from the same gas turbine power plant.A simple economic assessment indicates that the proposed scheme will require a minimal investment as compared to the commissioning cost of a new gas turbine unit to meet the corresponding capacity increment. The latter will need nearly four times higher initial cost than the amount estimated for the proposed scheme. Thus, implementation of such a system would significantly abate the negative impact of the ambient temperature, while providing an economically and environmentally attractive option for energy producers in most developing nations of the world which are located in arid and tropical zones.     

Optimizing a refinery using the pinch technology and the mind method

The Pinch Technology and the MIND method are combined in the analysis of a Swedish refinery. The heat exchanger network of the crude distillation system is analysed using the Pinch Technology. The results show that the steam demand from the boiler units in the energy supply part of the system can be reduced by 20% in the optimized heat exchanger network and by 21% when a heat pump is added to the system. A multi-period cost optimization of the operating strategy is performed using the MIND method. The results from the Pinch analysis are then input to the MIND optimization. The system cost of the total energy system of the refinery is optimized with regard to flexibility in the process system as well as changes of energy costs and the operating conditions of the cogeneration unit. The combination of methods shows that significant capital savings can be achieved when the energy saving potential of the process system is integrated in the overall operating strategy of the energy system. It is, in this case, possible to compare investments in energy saving measures to investments in increased steam production capacity.     

Simulation of a combined cycle power plant based on a pressurized circulating fluidized bed combustor

A comprehensive mathematical model for the simulation of a pressurized circulating fluidized bed combustor will be presented. The model consists of a combustor model describing the combustion chamber, the cyclone and the external heat exchanger as well as of a gas turbine model. The results of the simulation for the combustor at full load and different pressures and for the combined cycle power plant at full and part load are presented in form of temperature-, flue gas composition- and heat transfer-profiles in the combustor. Especially, energy fluxes from the combustor to the water-/steam cycle and the output of gas- and steam-turbine will be shown. The validity of the model will be shown by comparative simulation of an existing plant for the special case of atmospheric conditions.     

The key role of heat exchangers in advanced gas-cooled reactor plants

The use of helium as a nuclear reactor coolant has been successfully demonstrated in plants built and operated in the U.K., U.S.A., and Germany. Following the pioneering proof of principle plant, two small power plants were operated for several years and this led to the construction of two commercial power stations. For the next generation of gas-cooled reactors new criteria have been developed, namely, the plants will be smaller, simpler, safer and of lower cost. The base case Modular High-Temperature Gas-Cooled Reactor (MHTGR) utilizes existing technology to offer a tried and proven power generating plant using a conventional steam turbine power conversion system that could be in utility service just after the turn of the century. The capability of the MHTGR to operate at very high temperatures will be exploited early in the next century in the form of advanced variants to meet the needs of the power generation and process industries. A key component in the MHTGR is the heat exchanger, since this is where the reactor thermal energy is transferred to the prime-mover or process system. This paper addresses the various roles that heat exchangers will play in advanced MHTGRs, recognizing that the requirements for the steam cycle, gas turbine (direct- or indirect-cycle), and process heat reactor are unique. Topics include thermodynamic considerations, differing configurations, and construction types; materials (metals, composites, ceramics); germane technology bases; and advanced heat exchanger technologies.     

Refuse-fired,pressurized, fluidized-bed combustion combined cycle analysis

Use of pressurized, fluidized-bed combustion (PFBC) has given a new opportunity to use municipal refuse as fuel for combined gas and steam power cycles keeping the pollutants of sulphur and nitrogen oxides to a minimum at reduced capital cost.In combined gas and steam power cycles, the heat energy in the exhaust gases of a simple gas turbine cycle is used to generate steam in a waste-heat boiler and the generated steam is used in the steam turbine for power generation.The effects of gas turbine pressure ratio and inlet temperature on the main parameters of refuse-fired, pressurized, fluidized-bed combustion combined cycles are determined.The results indicate a maximum combined cycle thermal efficiency and work output at a possible range of optimum pressure ratios between 10 and 12 for a range of gas turbine inlet temperatures of 750–1000°C.     

400MW级IGCC机组变工况性能计算

1引言一个多世纪以来,煤一直是世界上主要的发电燃料,这一趋势将在较长的时间内一直保持下去。对于中国这样一个以煤作为一次能源的国家,这一现象尤为突出。特别是随着全球性能源危机的出现以及环境保护要求的提高,使得洁净煤技术（CCT）受到普遍关注。在众多的洁净煤发电技术中,IGCC技术以其特有的高效率、低污染等特点,被认为是下世纪最有发展前途的洁净煤发电技术之一。鉴于IGCC系统结构与组态非常复杂,涉及煤的气化、净化、燃气轮机、余热锅炉、蒸汽轮机、空气分离等关键技术,因此建立IGCC系统的性能模型,对IGCC机组的…     

Coordinated optimization of the parameters of the cooled gas-turbine flow path and the parameters of gas-turbine cycles and combined-cycle power plants

In the present paper, we evaluate the effectiveness of the coordinated solution to the optimization problem for the parameters of cycles in gas turbine and combined cycle power plants and to the optimization problem for the gas-turbine flow path parameters within an integral complex problem. We report comparative data for optimizations of the combined cycle power plant at coordinated and separate optimizations, when, first, the gas turbine and, then, the steam part of a combined cycle plant is optimized. The comparative data are presented in terms of economic indicators, energy-effectiveness characteristics, and specific costs. Models that were used in the present study for calculating the flow path enable taking into account, as a factor influencing the economic and energy effectiveness of the power plant, the heat stability of alloys from which the nozzle and rotor blades of gas-turbine stages are made.     

乳品行业低温余热回收系统性能分析

针对乳品行业排风风量大但品位低的特点,本文提出利用排风余热代替蒸汽来预热干燥空气的余热回收系统.在构建预热器、回热器和主加热器等部件热量流模型的基础上,建立了不包含中间节点参数的系统整体热量流模型.结合某奶粉厂运行数据对模型进行求解,结果表明,该系统将排风温度由90℃降低到42.58℃.在给定热负荷下,通过匹配中间回路...     

Cogeneration by combining gas turbine engine with organic rankine cycle

The gas turbine engine is known by its relatively low efficiency especially at part load. Therefore, to conserve energy and reduce the operating cost, waste heat is recovered by combining a heat-exchange gas turbine cycle with closed organic Rankine cycle. A computer programme was made to calculate parametrically the individual and combined cycle performances, namely the work and efficiency of each. The parameters considered were: gas turbine pressure ratio; maximum cycle temperature; fluid-air mass ratio; and type of working fluid.This analytical study shows that R113 is the optimum choice because it gives the smallest, hence the most economical, size of turbo-expander. Maximum cycle temperature and pressure ratio are relatively the most important parameters. Economic analysis indicates very good rate of return on investment, related with heat recovery by cogeneration.     

单轴恒速燃气轮机及其功热并供装置的典型变工况特性

利用作者在本期给出的单轴恒速燃气轮机及其功热并供装置的变工况显式解析解，本文给出它们的变工况典型性能．当变工况性能均以其设计值的比值表示时，不同设计值机组的各种无因次变工况性能曲线均分别在一条狭带之中，尤其是燃气轮机的效率基本就在一条线上，而且此线与实际数据相当符合．对以饱和蒸汽供热的功热并供装置，本文特别指出当设计蒸汽压力较高时，其余热锅炉逼近温差在低工况下很容易变为负值，要注意其安全运转问题．     

Cao吸附CO2系统能耗分析及热集成系统研究

本文以通用流程模拟软件Aspen为平台,对一个600 MW电厂排放的CO₂吸收过程进行了模拟,分析了关键参数对吸收系统性能影响。研究了采用余热锅炉回收系统热量后对整个电厂性能的影响规律,比较了采用25MPa,566/566℃;28MPa,580/580℃和30 MPa,600/600℃三种不同蒸汽参数时整个电厂性能。研究结果表明,采用钙法回收电厂CO₂并合理利用余热后系统效率下降约5个百分点。本文研究成果为基于火电站脱除CO₂提供有益的参考。     

排气全燃型联合循环设计点性能简明估计公式

排气全燃型联合循环设计点性能简明估计公式蔡睿贤（中国科学院工程热物理研究所北京１０Ｏ０８０）关键词：排气全燃型联合循环，热力分析主要符号表Ｈｕ燃料热值Ｌ燃料理论空气量ｌ比功Ｐ单位能量价格Ｒ燃气轮机与蒸汽轮机的功率比α过量空气系数β摩尔燃料系数△增量η...