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544 J SCI IND RES VOL 70 JULY 2011Journal of Scientific & Industrial ResearchVol. 70, July 2011, pp. 544-553

*Author for correspondence

E-mail: [email protected]

Performance improvement of a simple gas turbine cycle through

integration of inlet air evaporative cooling and steam injection

Shyam Agarwal1, S S Kachhwaha2* and R S Mishra 1

1Department of Mechanical Engineering, Delhi Technological University, Bawana Road, Delhi 110 042, India2School of Technology, Pandit Deendayal Petroleum University, Raisan, Gandhinagar 382 007, India

Received 18 February 2011; revised 18 May 2011; accepted 26 May 2011

Among many available retrofitting technologies to improve power generation capacity and efficiency of simple cycle gas

turbine, inlet air cooling (IAC) and steam injection gas turbine (STIG) are considered most effective ways to modify an existing

simple cycle unit. In this study, a simple cycle generation unit is considered as base unit and STIG and IAC features are

sequentially retrofitted to the system. To evaluate individual effects after system modifications, a computer program has beendeveloped in EES (Engineering Equation Solver) software to stimulate performance parameters. Retrofitting of simple cycle

combined with IAC and STIG has been found to boost power output from 30 MW to 48.25 MW, while generation efficiency can

be increased from 29.9% to 33.4%. Exergy destruction rate per MW of power output reduces for combustion chamber, compres-

sor and HRSG, while increases for gas turbine for retrofitted cycles.

Keywords: Exergy destruction, Gas turbine, Inlet air cooling (IAC), Retrofitting, Steam injection gas turbine (STIG)

Introduction

Simple gas turbine power generation systems are

widely used in Indian industries due to quick startup and

shutdown capabilities. Steam injection gas turbine (STIG)

and inlet air cooling (IAC) by evaporation are the most

common practices to enhance performance of powergeneration. Kumaret al1 developed design methodology

for parametric study and thermodynamic performance

evaluation of a gas turbine cogeneration system (CGTS).Wang & Chiou2 concluded that implementing both STIG

and IAC features cause more than a 70% boost in powerand 20.4% improvement in heat rate. Bouam et al3

studied combustion chamber steam injection for gas

turbine performance improvement during high ambienttemperature operations. Srinivas et al4 concluded that

steam injection decreases combustion chamber and gasreheater exergetic loss from 38.5 to 37.4% compared to

the case without steam injection in combustion chamber.

Minciuc et al5focused on solutions of tri-generation plantsbased on gas turbine or internal combustion engine with

absorption chilling machine. Moran et al6 developed

design and economic methodology for gas turbine

cogeneration system. Nishida et al7 analyzed

performance characteristics of two configuration ofregenerative steam-injection gas turbine (RSTIG)

systems and concluded that thermal efficiencies ofRSTIG systems are higher than those of regenerative,

water injected and STIG systems.

IAC technology is simply to cool down inlet airentering compressor with a cooler. Sinha & Bansode8

studied effect of fog cooling system (FCS) for IAC andshowed improvement in turbine power and heat rate.

Chakeret al9 have developed formulation for fog droplet

sizing analysis. Salvi & Pierpaloli 10 have studiedoptimization of IAC systems for steam injected gas

turbines and proposed technique of compression IAC

through an ejection system supplied by exhaust heat ofgas turbine. Bassily11 studied performance improvements

of intercooled, reheat and recuperated gas turbine cycleusing absorption inlet-cooling and evaporative after-

cooling. A parametric study on effect of pressure ratio,ambient temperature and relative-humidity, turbine inlet-

temperature (TIT), and effectiveness of recuperated

heat-exchanger on performance of varieties of cycles iscarried out. Bhargava & Homji12 showed effects of inlet

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545AGARWAL et al: PERFORMANCE IMPROVEMENT OF A SIMPLE GAS TURBINE CYCLE

fogging on a large number of commercially available gas

turbines.This study presents performance improvement of a

simple cycle generation unit taken as a base unit andSTIG and IAC features are sequentially retrofitted tothe system.

Experimental Section

System Description

Simple cycle gas turbine system integrated with IAC

and STIG features (Fig. 1) comprises a base unit that

includes compressor, combustor, gas turbine and agenerator. An HRSG was installed at downstream exit

of turbine (state point 5) to recover heat from exhaustgases. Fraction of superheated steam generated from

HRSG is used for STIG (state point 9) and remainingsuper heated steam is used for process application. An

FCS is installed to cool ambient air (state point 1). FCSuses very fine fog droplets of high pressure water injectedthrough special atomizing nozzles located at discrete

points across inlet duct at high pressure to create cooling

effect. Amount of fog is to be monitored based on dryand wet bulb ambient conditions to achieve requiredcooling. A typical FCS consists of a high pressure pump

skid connected for feeding to an array of manifoldslocated at a suitable place across compressor inlet duct.Manifolds have a requisite number of fog nozzles6, which

inject very fine droplets of water into inlet air. Dischargethrough each nozzle is around 3 ml/s and produces 3

billion droplets per second. Fine fog evaporates very fast,thus dropping inlet air temperature.

Modeling and Computer Simulation

Formulations

Assumptions considered for present study are as

follows: i) Molar fraction (N2= 0.78981, O

2= 0.20989,

CO2= 0.00031 and H

2O = 0) is assumed of 1 mole of

dry air; ii) Heat loss from combustion t:chamber is 2%

of lower heating value of fuel (All other componentsoperate without heat loss); iii) Fog cooling system has

been maintained for 100% saturation of ambient air atwet bulb temperature of air; iv) pressure of water injectedfrom nozzle into evaporative cooling chamber has been

assumed 138 bar and converts into fog (fine droplets),absorbs latent heat of air through adiabatic mixing; and

v) Combustion chamber has been maintained at constant

temperature.A computer program has been developed in

Engineering equations solver (EES) to formulate and

simulate retrofitting techniques over simple gas turbine

with a set of steady-state governing equations includingmass, energy, entropy and exergy balances using control

volume analysis sequentially for compressor, combustor,gas turbine and HRSG. Results of program were validated

with available data6. After successful validation, EES

program has been developed for analysis of IAC, STIGand integrated technologies retrofitted with simple gas

turbine. For complete combustion of natural gas (methane)with steam injection in combustion chamber, chemical

equation takes following form:

[ 1 , N 2 1 , O 2 1,CO24 2 2 2? CH X N X O X CO+ + + +

]2 ' , O 2 2 ' ,CO2 2 ' , H2 O2 2 2X O X CO X H O+ + (1)

Mole fraction of N2,

1,N22 , N 2

XX

1=

+ + (2)

Mole fraction of O2,

1,O22,O2

X 2X

1

=

+ + (3)

Mole fraction of CO2,

1,CO22,CO2

XX

1

+ =

+ + (4)

Mole fraction of H2O,

1,H2O2,H2O

X 2X1

+ + =+ +

(5)

where is steam injection ratio defined as ratio of mass

of steam injected to mass of air supplied.

as mm &&= , gs mm &&= , ( ) += 1 ,

f

s

m

m

&

&= ,

= (6)

where is ratio of mass of steam injected to mass ofcombustion gases formed and is ratio of mass ofsteam injected to mass of fuel supplied2. Maximumamount of permitted STIG is 20% of mass flow rate of

inlet air2.Heat transfer between exhaust gases and condensate

water has been taken place in water heat recovery boiler

]1 , H2 O 22X H O H O+ [ ] [ 2 ' , N 2 21 X N + + +

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546 J SCI IND RES VOL 70 JULY 2011

where superheated steam is generated as

( )condw hhmhh = sup76exhm , where mexh and mw

are mass flow rate of exhaust gases of turbine and

condensate water; h6, h

7, h

supand h

condare enthalpies of

exhaust gases at state 6 and 7, super-heated steam and

condensate water. Also, PP sat PPT T T= + and

AP sat APT T T= , where T

pp, T

satand T

APare pinch

point temperature, saturation temperature of water and

approach point temperature, respectively. PPT is pinch-

point difference and APT is approach point difference

at saturation temperature.Temperature of air after fog cooling can be obtained

from an energy balance on dry air, water spray andair-born water vapour before and after the system.

Assuming adiabatic mixing, energy gained by sprayed

water is balanced by energy lost by dry air, and originalair-born mixture, after cooling such that

)hh(m)hh(m)hh(m1v1va11a1aa1w1vw

+=

, where

mw

and 1wh

are mass flow rate and enthalpy of cooling

water, mais mass flow rate of dry air, ( 11 aa hh ) is

enthalpy change of dry air, ( 11 vv hh ) is enthalpy change

of water vapour during cooling. Humidity ratio (1 ) can

be specified as11

11

622.0

=

v

v

PP

P , where 1vP is partial

pressure of water vapour and 1P is total atmosphericpressure. From conservation of mass, amount of water

evaporated is equal to the mass of water vapour at point

1 minus water vapour originally in air at point 1 as

aw mm )( 11 = , where 1 is humidity ratio of

air after cooling. Partial pressure of water vapour (Pv)

can be found from respective relative humidity (RH) ( )

assatv

PP = , wheresat

P is saturation pressure of water

vapour for corresponding temperature. Pressure loss in

adiabatic mixing is neglected. Enthalpy, entropy, and

exergy can be determined at each state point using massand energy balances.

Performance Parameters

Performance parameters required for

thermodynamic analysis of simple cycle and retrofitted

systems include thermal efficiency, which is ratio of net

work output (net

W& ) to total heat input (f

Q& ) of a fuel

given asf

ne tTh

Q

W

&

&

= . Relation forfQ

& (kW) is given

by fuelff CVmQ = && , where m

fis mass flow rate of

fuel (kg/s) and CVfuel

is calorific value of fuel (kJ/kg).

Generation efficiency of a thermal system is the ratio of

electrical power output (W&el) to the total heat input of

fuel ( fQ& ) given as

elG e n

W

Q =

&

& . Relation between elW&

and netW& is given by netelel WW

&& = , where el is

effectiveness of electrical generation system. Heat rate

is the ratio of heat produced by fuel (f

Q& ) to electrical

power output (el

W& ) of thermal system and given as

el

f

W

QHR

&

&

= . Heat rate is reciprocal of generation

efficiency. Specific fuelconsumption of a thermalsystem is the ratio of mass of fuel to net work output. It

is reciprocal of specific net work (Wspec

) and given as

net

f

W

mSFC

&

&= .

FirstLaw efficiency ( ) is the ratio of all useful

energy extracted from system to the energy of fuel input,

and given as( )

f

oPrel

I

Q

QW&

&& += , where (process

heat rate) is given as ( ) ( )76Ppro hh1mQ = && ,

wherePm& is mass flow rate (kg/s) of combustion products

and 6h and 7h are enthalpies (kJ/kg) at states 6 and 7

respectively. SecondLaw efficiency ( ) is the amount

of exergy associated with fuel and given as

( )

f

proel

II

E

EW

&

&& += , where is exergy of process heat

and is exergy of fuel input.ProCH,ProPH,pro

.

EEE += ,

where ProPH ,E and ProCH,E are physical and chemical

exergy of process heat, respectively. Similarly,

fCH,fPH,f

.

EEE += , where fPH ,E and fCH,E are physical

and chemical exergy of fuel, respectively.

Exergetic efficiency of component () is the ratioof exergy rate recovered from component (

RE& ) to

exergy rate supplied to component ( SE& ) and given as

.

E.

E.

E.

E

.

E.

E.

E.

E

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DR

D

DR

R

S

R

EE

E

EE

E

E

E

&&

&

&&

&

&

&

+=

+== 1 . Exergy

destruction rate (DRE

& ) is given asto t,D

D

DR

E

EE

&

&& = .

Results and Discussion

In present study, following three configurations with

retrofitting have been studied in comparison to simple

gas turbine cycle: i) Simple gas turbine cycle with IAC;ii) Simple gas turbine cycle with STIG; and iii) Simple

gas turbine cycle with both IAC and STIG.

Initial conditions for system analysis were as follows:

Ambient air temperature at state 1, 298.15 K; Ambient

air pressure at state1, 101.3 kPa; Ambient air RH at

state1, 60%; Spray water temperature at state1 , 298.15

K; Spray water pressure at state1 , 13800 kPa; Air inlet

pressure to compressor (P1), 101.3 kPa; Air inlet

temperature to compressor (T1), 298.15 K; RH of inlet

air to compressor at 1, 100%; Pressure rat io of

compressor (rp), 10:1; Isentropic efficiency of compressor

(SC

), 0.86%; Isentropic efficiency of Turbine (ST

),

0.86%; Lower heating value of fuel (LHV), 802361 kJ/

kmol; Mass flow rate of air ( am& ),81.4 kg/s; Turbine

inlet temperature (TIT), (T4), 1520 K; Injection pressureof fuel (methane) (P

f), 1200 kPa; Injection temperature

of fuel (methane) (Tf), 298.15 K; Pressure drop in

combustion chamber,( )combustion chamber

p , 5%; Exhaust

pressure of combustion products after HRSG (P7), 1.013

bar; Exhaust temperature of combustion products after

HRSG (T7), 403.15 K; Pressure of steam generation

(P9), 2000 kPa; Pressure of condensate water at inlet of

Table 1Comparison of various performance parameters of simple gas turbine cycle and retrofitted cycles

Performance parameters Simple gas Simple gas Simple gas Simple gas

turbine cycle turbine cycle turbine cycle turbine cycle

with fog with STIG with fog

cooling cooling &

STIG

First law efficiency ( I ), % 30.54 30.72 72.57 72.69

Second law efficiency ( II ), % 29.51 29.70 55.3 55.2

Power generation efficiency ( Gen ), 29.93 30.11 33.33 33.4

%

Thermal efficiency ( Th ), % 30.54 30.72 34.01 34.08

Fuel-air ratio () 0.0431 0.04355 0.0493 0.04967

Steam injection ratio (), per kg of 0.1 0.1mass of air

Heat rate (HR), kW/kWh 12029 11958 10800 10780

Specific net work (etSpecidficN

.

W), 15274 15364 17012 17043kJ/kg of fuel

Specific fuel consumption (SFC), 0.2357 0.2343 0.2116 0.2112

kg/kWh

Work-heat ratio (WHratio

), kJ/kJ 0.8823 0.8826

Power-to-heat ratio (PHratio

), kW/kJ/s 0.8647 0.8649

Specific work ISO ( SOSpecidficI

.

W ), 361.2 367.2 460.2 464.8kW-s/kg of air

Turbine work ( Tur.

W ), MW 56.48 57.31 64.71 65.54

Compressor work ( Comp.

W ), MW 26.48 26.38 26.48 26.39

Net power output ( net.

W ), MW 30 30.93 38.23 39.15

Electric work done ( el.

W ), MW 29.4 30.31 37.46 38.36

Process heat( pro

.

Q ), MW 43.32 44.35

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HRSG (P8

), 2000 kPa; Temperature of condensate waterat inlet to HRSG (T

8), 298.15 K; Pressure drop in HRSG

on the gas side, ( )HRSG

p , 5%; Amount of steam

injected ( ), 10% of mass flow rate of air; Temperatureof superheated steam STIG (T

9), 753.15 K; Approach

point (TAP

), 2 K; and Pinch point (Tpp

),20 K. In the

calculation, steady state operation is assumed withoutconsidering turbine blade cooling. Performance analysis

of these retrofitted gas turbine system is done bypreparing a computer program in EES validated with

available data 6 . Temperature, pressure and gas

concentration in each component are calculated by taking

into consideration of compositions and proportions ofgases and consequently, various performance parametersand exergy loss in these systems are estimated. Net

power output and power generation efficiency for simple

cycle are 30 MW and 29.93% respectively (Table 1).Attachment of evaporative cooler with simple cycle

improves performance parameters (system efficiencies,heat rate and specific power output etc.). Gas turbine

inlet air fogging is a commonly used method of cooling

intake air, where demineralized water is converted intofog droplets by means of special atomizing nozzles

operating at 138 bar. Evaporation of small size (5 - 20 )droplets in - intake duct cools - air and consequently

increases - moist air mass flow rate to improve power

performance. This technique allows close to 100%evaporation effectiveness in terms of attaining saturation

conditions and wet bulb temperature at compressor inlet.Thus variation in ambient temperature influences exit

air temperature of compressor, entry and exit temperature

of turbine, mass flow rate, specific work, specific fuel

consumption and power. When the ambient temperature

drops, net power supplied by the machine increases.Therefore, it is useful in many cases to cool compressorinlet air to obtain a greater production of electric powerassociated with reduction in compressor work. Using

evaporative cooling, available air (25C and 60% RH)can be cooled up to 19.5C. Impact of evaporative coolingwill be higher in dry summer season when dry bulb

temperature is higher and RH is lower.Comparison of simple cycle gas turbine with and

without fog cooling shows (Table 1) that net power output

increases by 3.1% and various efficiencies increase by0.18% while heat rate decreases by 0.6%. Comparisonof simple cycle gas turbine with and without STIG shows

(Table 1) that net power output and thermal efficiencyincrease by 27.4% and 3.5% respectively, while heatrate decreases by 10.2%. In the process of recovering

energy from exhaust gases via HRSG, temperature atoutlet of stack (state point 7 in Fig. 1) is usually keptabove 127C (dew point temperature of acid) in order to

prevent condensation of SO2

and NO2, which ultimately

hydrolyzed into sulphuric acid (H2SO

4) and nitric acid

(HNO3) and finally cause scale and corrosion to air

preheater of HRSG. Pinch point difference and approach

point difference for present analysis are taken as 20 Kand 2K respectively. Under these conditions, maximum

flow rate of generated superheated steam at 753.2 Kand 20 bar is 21.51 kg/s. If all generated steam is injectedinto combustor (STIG only), maximum injection ratio

(msteam

/mair

) is 0.26. Therefore, there is a wide range ofSTIG available to optimize power cycle. Calculated

power output for injection ratio (0.1) shows that effect

of STIG is quite substantial. Net power output is increased

Fig. 1Simple cycle gas turbine with fog cooling and STIG

5

Fog coolingsystem

Water

Compressor

Fuel f

Combustion chamber4 Turbine

Steam-injection9

Condensate water

7 Exhaust gases

Remaining superheatedsteam

P

3Air

Fogged & cooled

air

Combustion products

Heat recovery

steam generator

?

(1-? )

G

Ambient air 8

1 6

2

1

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Fig. 2Net work output for retrofitting cycles in comparison to simple cycle

Fig. 3Comparison of generation efficiency for different retrofitted cycles

Cycles

Netincreaseinwork

40

30

20

10

0

Generationefficiency,%

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Table2Comparisonofex

ergydestructionincomponentsforsimplegasturbinecycleandretrofittedcycles[*

Exergydestructionrate(%)istheratioof

exergydestruction

ratewithinacomp

onenttototalexergydestructionrateofthesystem]

EE

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to 38.23 MW. Profound effect from STIG alone isbecause the required pressure of injected steam is

obtained from pump. Since pumping work is 2 to 3 ordersof magnitude smaller than that of compressor, net power

output produced by steam is, thus, higher than that of air

per unit mass flow rate. Besides, this specific heat ofsuperheated steam is almost double the value of air and

therefore, enthalpy of steam is higher than that of air ata certain temperature. Therefore, STIG method is a very

effective way to boost net power output and to increase

overall efficiency of gas turbine. Simple gas turbine cyclewith STIG (steam injection ratio 0.1) significantly

improves system efficiencies. Comparison of simple cyclegas turbine integrated with FC (fog cooling) and STIG

shows that net power output increases by 30.5% and

thermal efficiency increases by 3.54%, while heat ratedecreases by 10.4%. Comparison of simple cycle gas

turbine with and without FC (Table 1) shows thatexergetic efficiency gets also improved by 0.2%.

However fuel-air ratio increased by 1%. As compared

to this, simple cycle gas turbine with and without STIGshows that exergetic efficiency gets improved by 25.8%,

however fuel-air ratio increased by 14.4%. Integrationof simple cycle with STIG and evaporative (fog) cooling

further improves system performance in terms of

exergetic efficiency, which improved by 25.69% and fuel-air ratio increased by 15.24%.

There is net increase in work output for differentretrofitted cycles in comparison to simple cycle (Fig. 2).

Maximum increase in work output obtained is 18.25 MW

for simple cycle combined with STIG (injection ratio 0.2)

and fog cooling. Maximum generation efficiency achievedis 37.66% for integrated fog cooling and STIG retrofitted

cycle with injection ratio 0.2 (Fig. 3). Thus combinationof fogging and STIG with simple cycle gas turbine cycle

is a good approach to enhance performance of system

on the basis of first and second laws. Benefit of addingSTIG feature can be estimated from Fig. 4, which shows

effect of STIG on generation efficiency, first lawefficiency and process heat for fixed inlet air conditions

as air gets saturated up to 100% RH due to fog cooling.

First law efficiency falls with increasing amount of steaminjection ratio, may be because slope of decreasing

process heat is steeper than slope of increasing generationefficiency or reduction in process heat takes place with

faster rate. In present case, maximum amount of injection

steam is limited by available energy recovered from

HRSG. Maximum injection ratio taken as 0.2 is still belowthe allowable injection limit (prescribed by manufacturer)for available industrial turbines.

Exergy destruction rate (MW) represents waste of

available energy. While examining relative exergydestruction for all components, combustor has largest

exergy destruction and shows major location ofthermodynamic inefficiency because of large

irreversibility arising from combustion reaction and heat

transfer (Table 2). Steam injection will increase exergydestruction due to mixing of high temperature superheated

steam (753.2C) and compressed air (at 594.8C) in

combustor. Exergy-losses at position 7 (Fig. 1) areconsidered as exergy loss through stack. Since part of

exhaust heat is recovered in HRSG, exhaust exergy outof stack can be reduced substantially after retrofitting.

Exergy losses through stack will not only waste availableexergy but also dump thermal pollution to living

environment. For a retrofitted cycle with fog cooling and

STIG, exergetic efficiencies are as follows: compressor,91; turbine, 93; combustor, 68; and HRSG, 75%. Although

exergy destruction rate of combustor is highest, exergyefficiency of combustor is higher than that of HRSG.

Therefore, a greater improvement margin exists for

HRSG as compared to combustor. Exergy destructionrate of each system component except compressor

increases due to increasing mass flow rate of air andsteam mixture. Exergy destruction rate increases with

increasing STIG quantity in combustion chamber, turbine

and HRSG (Fig. 5). Exergy destruction in combustionchamber is highest among all system components.

Increasing steam injection amount reduces stack-losses

Fig. 4Effect of steam injection ratio on first-law efficiency,

generation efficiency and process-heat for simple cycle integrated

with fog cooling and STIG

Efficiency,%

Processheat,MW

Steam injection ratio (% of mass flow rate of air)

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as large amount of heat of exhaust gas has been utilized

to convert into superheated steam (at state point 7 inFig. 1). Exergy destruction in combustion chamber

increases with increasing amount of STIG due toincreased amount of mass flow rate of air and steam

mixture. Due to significant increase in power output, rate

of exergy destruction per MW of power output reduces(Fig. 6) for combustion chamber, compressor, HRSG and

stack gases, while increases for gas turbine due toincrease in mass flow rate (mass flow rate of air from

compressor plus mass flow rate of injected-steam with

lower exergy).

Conclusions

In this study, an existing simple cycle gas turbine

was considered as basic system and has been converted

into modified retrofitted system with either IAC or /andSTIG features. Steam needed in STIG feature is

generated from energy recovered from systems ownexhaust gases. Under average local weather conditions

Fig. 5Comparison of exergy destruction rate of system components for simple and retrofitted cycle integrated with fog cooling and

STIG

Fig. 6Comparison of exergy destruction rate (MW) per MW of output for system components

Exergydestructionra

te(MW)

Components

60

40

20

0

Exergyde

structionrate(MW)

MWo

fpoweroutput

1.5

0.5

0

1

Components

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(25C and 60% RH), benefit of adding STIG feature

can substantially improve power output from 30 MW to39.15 MW and power generation efficiency from 29.93%to 33.4%. Maximum power that can be reached by the

system with both IAC and STIG features is 48.25 MWfor steam injection pressure ratio at 0.2. Although steam

injection will increase total exergy losses, exergy lossper MW output is smaller than that of simple cycle. Italso reveals that degree of energy wasting and thermal

pollution can be reduced through retrofitting.

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