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CHAPTER-1

INTRODUCTION

1.1 BACKGROUND

To improve the economy of country energy is the basic need. India rans !or"d#s fifth

"argest energy consumer accounting for about $.%& of !or"d#s tota" energy consumption'

but per capita energy consumption of energy is very "o! at ($1)h as compared to

!or"d consumption of *+,$)h. Conventiona" sources such as therma"' hydro and

nuc"ear are maor sources of generation of e"ectricity in India. ver the years /since

10%2 the insta""ed capacity of a"" India po!er generation has increased to 1'%1'3$3.%3

4). The breaup of the insta""ed capacity is given as under in Tab"e 1.1 and Tab"e 1.*5

Tab"e 1.1 Tota" insta""ed capacity6

Tab"e *.* 7ue" based insta""ed capacity6

68ource !!!.po!ermin.nic.in

The therma" and hydro po!er p"ants contribute the (3.( and *3.,& respective"y. The

therma" po!er stations in the country are most"y based on the fo""o!ing techno"ogies9

a2 8team po!er p"ants

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b2 :as turbine po!er p"ants

1.1.1 8TEA4 P)ER P;AR@I


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Cyc"e :as Turbine P"antB. In a gas turbine' "arge vo"umes of air are compressed to high

pressure in a mu"tistage compressor for distribution to one or more combustion gases

from the combustion chambers po!er an aia" turbine that drives the compressor and the

generator before ehausting to atmosphere. In this !ay' combustion gases in a gas turbine

po!ered the turbine direct"y' rather than reuiring heat transfer to a !ater or steam cyc"e

to po!er a steam turbine' as in the steam p"ant. The "atest gas turbine designs use turbine

in"et temperatures of 1'%oC /*',$o72 and compression ratios as high as $91 /for

aeroderivatives2 giving therma" efficiencies of $% percent or more for a simp"e cyc"e gas

turbine.

Figure 1.1 Open cycle gas turbine power plant.

4ost of the open cyc"e gas turbine po!er p"ants in the country use the natura" gas as fue".

ut of the tota" production of natura" gas' 31& is used by gas po!er p"ants. The natura"

gas is most"y preferred because it is environmenta" friend"y' has high efficiency and cost

is a"so charming. 4ost of the production of gas comes from !estern offshore area of

country. The gas brought to Ha=ira is sour gas !hich is proper"y mae s!eet bye"iminating s"upher. After s!eetening the gas some part of gas is uti"i=ed in Ha=ira and

the remaining gas is send to Ha=ira-@iaipur-?agdishpur /H@?2 pipe"ine. In northern part

of country' the gas is supp"ied through Ha=ira-@iaipur-?agdishpur pipe"ine.

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:enerating the mechanica" po!er !ithout "oss and po""uting the environment is a maor

aim of therma" po!er p"ants. In vie! of shortage of energy production and rapid increase

in demand' there is need to conserve it in a"" possib"e !ays. Recovering the energy from

!aste and uti"i=ing the !aste heat are becoming the common so"ution for improving the

system efficiencies. The present energy crisis has forced the scientist and engineers to

ep"ore the possibi"ities to conserve the energy and a"so to design the therma" systems

that are not on"y economica""y perfect but a"so thermodynamica""y and environmenta""y

feasib"e. Therma" po!er p"ants are the vita" component for gro!th of country. Therefore

it is desirab"e rather necessity to provide a base for reducing the energy "oss and design of

therma" po!er p"ants from the thermodynamics' economica" and environmenta" point of

vie! because improving a system thermodynamica""y !ithout considering the economics

is mis"eading. The energy conservation in therma" po!er p"ants has vast potentia" and

therefore' present thesis aimed to ep"ore the various irreversibi"ities in the p"ant in every

aspect i.e. therma" as !e"" as economic point of vie!.

The investigations taen in this thesis are of eisting p"ants and can create a base for

further R D activities in the direction of energy conservation and a"so heat recovery

options !hether the saving is economica" or not. The present thesis is an attempt to

ep"ain the irreversibi"ities from the eergy economic or thermoeconomics point of vie!

of designed and under the different operating conditions.

1.2 CONCEPT AND APPLICATION OF EXERGY, EXERGETIC

COST & EXERGY ECONOMIC OR THERMOECONOMICS

ANALYSIS

To no! !hat amount of energy eact"y !e are using to produce goods force engineers to

ana"y=e and estimate the system by using some concept for decision-maing. The origins

of energy ana"ysis are very diverse. 7or the "ast three decades' !e have been hearing

about energy crisis !hich in turn forced us to thin about its conservations. 8o demand of

saving energy move us for!ard to find ne! ana"ysis techniues concerned !ith concept

of eergy.

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To avoid confusion !ith fami"iar energy-based methods for ana"ysis and design of

therma" systems' a carefu" distinction must be dra!n bet!een energy and eergy. Energy

conservation "a! is app"icab"e every!here. Energy entering !ith fue"' e"ectricity' f"o!ing

stream of matter and so on can be accounted for in the products and byproducts. Energy

can not be destroyed. The idea that something can be destroyed is usefu". It can not be

app"ied to energy' ho!ever' but to another variab"e9 eergy. 4oreover' it is eergy and not

energy that proper"y gauges the ua"ity /uti"ity2 of' say' one ? of e"ectricity generated by

a po!er p"ant versus one ? in the p"ant coo"ing !ater stream. E"ectricity c"ear"y has the

greater ua"ity and not incidenta""y' the greater economic va"ue. The simp"ified e"ectrica"

generating po!er cyc"e sho!n schematica""y in 7igure 1.* high"ights the distinction

bet!een energy and eergy. 7igure 1.* /a2 is on an energy basis' and indicates that out of

1 energy units entering !ith the fue"' $ energy units are obtained as the e"ectricity and

the ba"ance , units are discharged to the surroundings' say to coo"ing !ater. Invoing an

oft-used approimation !e may consider that 1 units of eergy a"so enter !ith the fue"

as sho!n in 7igure 1.* /b2 since the generated e"ectricity is eergy in transit' $ units of

eergy eit by this means. 8o there is a ba"ance of , units to be accounted for5 but !hen

these , eergy units are considered' !e find that (, to (+ units of this eergy are

destroyed !ithin the p"ant by various irreversibi"ities and ust * to $ units are discharged

to the surroundings. A"though considerab"e energy is discharged to the coo"ing !ater' its

ua"ity /uti"ity2 is "o! because the !ater used for coo"ing typica""y comes out the p"ant at

a temperature s"ight"y higher than that of the surroundings. According"y' to improve the

performance' the energy ana"ysis is mis"eading. The eergy ana"ysis on the other hand not

on"y sho!s that the discharge is a re"ative"y minor area of concern but a"so that

significant performance improvement can come on"y by identifying and remedying

sources of inefficiency !ithin the system.

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Figure 1.2 Power cycle

4oreover it is the eergy that has economic va"ue in the maret p"ace and serious

misestimations can resu"t !hen cost ana"ysis of the systems are carried out on energy

basis FGenney /10+32.

7irst "a! of thermodynamics is the base of ana"ysis. There can never be an energy "oss'

but energy transfer to the environment in that case it is use"ess. 7or pinpointing and

uantifying the irreversibi"ities' an eergy ana"ysis is being performed over the years.

T!o basic concepts' eergy and irreversibi"ity' gave rise to a variety of derived concepts'

techniues and criteria performance. A"though the eergy method is usua""y regarded as

ne! techniue. )e can say eergy ana"ysis is same as usefu" energy.

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In the absence of nuc"ear' magnetic' e"ectrica" and surface tension effects the tota" eergy

of a system is

CH PT KN PH E E E E E +++= /1.12

The sum of "ast three terms on Right hand side is referred as thermomechanica" eergy

F@ean et a". /100(2' 4oran /10+0' 100%2. The superscripts PH, KN, PT and CH

represent the physica"' inetic' potentia" and chemica" eergy respective"y in Euation

1.1. The tota" specific eergy on a mass basis i.e. unit mass basis is given by

CH PT KN PH eeeee +++= /1.*2

!here' e denotes the specific eergy. If !e assume that system is on rest then

/ == PT KN ee 2' the tota" specific eergy of system is sum of physica" and chemica"

eergy. The tota" physica" eergy of a c"osed system at a specified state is given by

2/2/2/ 11111 T ! ! p" " E PH

−−−+−= /1.$2

!here' ", p, !, T, and denotes the interna" energy' pressure' vo"ume and entropy

respective"y at a specified state. The subscript represents atmospheric condition.

7or c"osed system chemica" eergy is given by

2/ ∑ −= #

# # #

CH N E µ µ

/1.32

!here N is the number of mo"es of species # in miture and µ denotes chemica"

potentia".

2/2/2/2/ ∑ −+−−−+−== # # # #tot N T ! ! p" " E E µ µ

/1.%2

7or c"osed system tota" specific eergy is given by

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2/2/2/ ∑ −+−−−== #

# # #

tot N s sT $$ee µ µ

/1.(2

In eergy ana"ysis our aim is to find the performance of every component by getting

eact va"ue of generated entropy by each component. ;et us consider P J as the product

and F J as the fue"' for a process' both are eva"uated in the terms of their individua"

eergy. 8o according to this given euation shou"d be satisfied9

g T % % P F !here' =≥=− /:ouy-8todo"a theorem2 is the irreversibi"ity i.e. eergy

destruction. The thermodynamic efficiency of process !i"" be given by

1K ≤= F P e&ergeticη . The inverse of this efficiency represents the unit eergetic cost of

product5 vi=. 1K1K ≥== e&ergetic P P F ' η .Economic estimation shou"d a"so be done

considering interna" f"o!s and products. There are t!o environment for therma" systems 9

/i2 the physica" /ra! materia"2 and /ii2 the economic environment /maret prices2 .

Physica" environment is considered to estimate products of a system' and in this refrence

eergetic cost is the main variab"e' !hich informs us of the actua" amount of eergy that

is needed to produce them F;o=ano et. a" /100$2.

In case of economic environment' there are t!o etra factors9 maret prices / F c

2 andcost of depreciation needed for productive process / ( 2.7or optimi=ation purpose' the

main aim is the unit cost of the product' vi=. ( ) P ( ' c P ( F cc P F F P KK +=+= .

@y combining the concepts eergy !ith economic ana"ysis ne! method of ana"ysis and

research !as deve"oped' ca""ed as eergoeconomics. Eergoeconomic investigation

ca"cu"ate the unit cost of products. A comp"ete eergoeconomic ana"ysis consists of /a2

energy and eergy ana"ysis' /b2 economic ana"ysis' /c2 eergy costing' and /d2 an

eergoeconomic estimation of each p"ant component.

1.3 OBJECTIVE OF THE THESIS

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Therma" system design and ana"ysis invo"ves princip"es from many fie"ds of Therma"

Engineering. In this thesis' thermodynamics aspect of design is hand"ed.

Among the therma" systems' coa" based po!er p"ant and open cyc"e gas turbine are

ana"y=ed by advanced thermodynamic topics. These topics inc"ude the eergy ana"ysis'

eergetic cost based and eergy economic or thermoeconomic ana"ysis. The eergy

economic ana"ysis is cited by many researchers to be a strong too" for assessing the p"ant

performance from thermodynamic and economic point of vie!. Therefore this techniue

has been used in many industries "ie e"ectrica" generation companies in Europe but it is

not surprising"y used by a"" industries.

This !or !ou"d dea" !ith the fo""o!ing9

1. To perform the detai"ed second "a! based eergy ana"ysis of cyc"es to gets proper

insight from thermodynamic point of vie! and to point out epected energy

saving.

*. To perform the eergetic cost based ana"ysis.

$. To perform the eergy economic or thermoeconomic ana"ysis of po!er p"ant

cyc"es in order to9

a2 To find individua""y the costs of each product in cyc"e for different

components.

b2 To no! the cost configuration process for !ho"e p"ant and p"ant components.

c2 8tudy of thermoeconomic variab"es and performance estimation of eisting

system.

3. To study the effects of conc"usion variab"es on eergy' eergetic cost and

thermoeconomic variab"es.

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The genera" methodo"ogy adopted in this thesis "ies !ith the approach proposed by

FAhern ? E /10+2' @ean A /10++2' @ean et a". /100(2' entice 4 et a". /100+2' Ge""y 8

et a". /*02' Gaushi 8 C et a". /*%2' Gotas T ? /10+%2' ;o=ano 4 A /100$2 and

4oran 4 ? /10+02.

1.3 CHAPTERWISE SUMMARY OF THE THESIS

A chapter !ise summary of thesis is as fo""o!s9

C!"#$% 1 I'#%()*+#('

This chapter presents an overvie! of current status of energy generation in country and

basic concepts of po!er p"ants' eergy' eergetic costs and eergy economic estimation

of po!er p"ants. The chapter discusses the obective of proposed study. At the end of

chapter organi=ation of thesis has been provided.

C!"#$% II L#$%!#*%$ R$-$

A detai"ed re"evant "iterature survey for eergy' eergetic cost and eergy economic or

thermoeconomics ana"ysis for therma" systems has been inc"uded. The various methods

of thermoeconomic techniues deve"oped and the effort made by researchers in the past

for the deve"opment of fie"d has been discussed. The various therma" systems ana"y=ed in

researchers are inc"uded.

C!"#$% III E'$%/0 !') E$%/0 A'!0 (4 C(! F%$) T$%5! P($% P!'#

In this chapter eergy and energy ana"ysis has been carried out for the coa" based non

reheat therma" po!er p"ant. The epressions for therma" efficiency based on the

thermodynamics first "a! and ' eergy destruction and eergetic efficiency in components

has been used. 8econd "a! efficiency at part "oad condition for the components and

!ho"e p"ant has a"so been investigated.

C!"#$% IV E$%/0 $+('(5+ !'!0 (4 C(! 4%$) #$%5! "($% "!'#

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In this chapter the eergy princip"es are combined !ith economic princip"es. The cost of

various components of the p"ant has been considered for eergy economic estimation. @y

eergy economic methodo"ogy' each product cost in the p"ant and f"o! rate cost !ith a""

streams has been ca"cu"ated. The thermoeconomic variab"e for the designed and at part

"oad condition has been investigated.

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CHAPTER-*

LITERATURE REVIEW

2.1 INTRODUCTION

The !ord LEnergy# is derived from the :ree9 en and ergon /i.e. interna" force or !or2.

The concept !as first formu"ated in the midd"e of the 10 th century by Ge"vin and ?ou"es.

The !ord eergy is derived from the :ree e& and ergon /i.e. outer force or !or2 and

the concept !as first noticed in 1+*3 by Carnot in the re"ation of heat and !or. A further

rigorous "iterature revie! on eergy and eergy economic ana"ysis for the past period has

been performed to get more insight in this research fie"d. The boo LTherma" esign D

ptimi=ation# by @ean et. a". /100(2 provides a comprehensive and rigorous introduction

to therma" system design and optimi=ation from a contemporary perspective. A detai"ed

description of eergy ana"ysis' eergy economics has been presented !ith case study for

design of gas turbine cogeneration system in "iterature surveyed.

2.2 DEVELOPMENTS IN EXERGY AND ITS BENEFITS

The number of pub"ications dea"ing !ith second "a! of thermodynamics andKor eergy or

avai"ab"e energy has been pub"ished during past. A"" these researches and deve"opments

aim at for higher therma" efficiency for therma" systems. This has moved ahead

deve"opment of various ana"ysis techniue based on thermodynamic "a!s. Eergy

ana"ysis is based on second "a! of thermodynamics. The use of avai"ab"e energy /andKor

eergy2 in the ana"ysis of po!er p"ants and refrigeration systems has been !e""

estab"ished. In the "iterature' eergy ana"ysisK second "a! ana"ysis for Ranine' @rayton'

combined D cogeneration and gas turbine po!er p"ants have been performed by Gaushi

8 C and Tyagi 8 G /1000.

Gha"i A and Gaushi 8 C' /*32 eamined from the 8econd "a! point of vie! the

@raytonK Ranined combined po!er cyc"e !ith reheat. They investigated the effect of '

cyc"e temperature ratio ' pressure ratio' pressure drop and cyc"e number of reheats. Their

investigations have revea"ed that over %& eergy devastation occurs in combustion

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chamber. In other studies' the effect of pinch point on first and second "a! efficiency has

been studied.

@esides above mentioned !or' Habib' 4. et a". /100*2' a"so have eamined performance

of regenerativeMreheat po!er p"ants. The second "a! /eergy2 ana"ysis has been

identified an efficient too" for identifying and uantifying both the consumption of usefu"

energy /eergy2 used to derive a process as !e"" as the irreversibi"ities and "osses of

eergy.

8urvey revea"s the use of eergy princip"es that enhances the understanding of

therma"Kchemica" processes and a""o!s the sources of incompetence to be uantified.

8uch essentia" thermodynamic considerations can be integrated !ith princip"es of

engineering economics to determine the potentia" for cost effective improvement of

eisting systems. FAyres et a". /100+2' @ean et a". /100(2' @i"gen E /*32' Conne""y ;

/*12' Corne"isen R ; /100,2' entice 4/100+2' Ebadi 4.?. /*%2' :ranovsii 4 et a"

/*+2' Hermann ) /*(2' Hor"oc ? H /*2 etc. A ne! sustainabi"ity inde has been

deve"oped as a measure of ho! eergy efficiency affects sustainab"e deve"opment.

Eergy has better identified environmenta" benefits and economics of energy

techno"ogies than energy FRosen 4 et a". /*+2. The eergy ana"ysis is a"so using in

designing FN 4 EI-8ayed /**2 to get minimum costs and maimum efficiencies.

2.3 APPLICATIONS OF EXERGY

The eergy and eergy costing princip"es has been used at initia" design state to deve"op

the systems that are optimi=ed in annua"i=ed cost. Indeed' the primary fie"d of app"ication

of eergy ana"ysis no!adays is in the therma"Kchemica" systems design and optimi=ation.

The eergy ana"ysis has a"so been used to assess the rea" effect of off-design conditions

on individua" components or overa"" p"ant FGim 8 et a". /100+2' Tsatsaronis et. a". /10032'G!a et a". /*$2 and Er"ach et a". /10002.

8econd "a! based eergy ana"ysis has not on"y been app"ied to therma" po!er p"ants but

a"so to diese" engine po!er generation' refrigeration cyc"es' and process

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industriesFAbusog"u A et a". /*+2' Gamte 8 et a". /*02' Goroneos C et a". /*$2'

4odesto 4 et a". /*(2' 4orosu T et a". /*02' Ta"ens I et a". /*,2' )a"" : /100+2.

In "iterature' eergy is one of the best too" by !hich !e can uti"i=e the resources as much

as possib"e. Energy be"ongs to uantity !hi"e eergy can be used as a sca"e for uantity

as !e"" as ua"ity of the energy sources .


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• Incorporated gasification combined-cyc"e po!er p"ants.

• Coa" fired concepts.

• Advanced gas turbine systems.

• Crude oi" disti""ation systems.

• Refrigeration systems.

In the same direction' some of fresh app"ications are high"ighted here. @hargava et. a".

/**2 ana"y=ed an intercoo"er reheat gas turbine' !ith and !ithout recovery' for

cogeneration app"ications using the eergy economic princip"es. Their study provides the

usefu" resu"ts for se"ection of gas turbine cyc"e for cogeneration app"iance. Atta"a et a".

/*12 have used eergy economics as a design too" for the rea"i=ation of a gas-steam

combined po!er p"ant princip"e !hereas 4ishra et a". /*$' *%2 have optimi=ed a

sing"e and doub"e effect vapour absorption refrigeration systems. 8ahoo /*+2

performed eergy economic ana"ysis of a cogeneration system and optimi=ed the cyc"e.

4any other researchers !ho contributed their efforts are Abusog"u et a". /*02' Accadia

et a". /*32' Agui"ar et a". /*,2' A"varado et a". /10032' Arena A et a". /10002' @oregertet a". /*32' Can A et a". /*32' Caranosa et a". /*32' Corti et a". /10002' entice et a".

/100+2' 7rangopou"os et a". /10+,' 1003' Hamed et a". /*(2' Hebecer et a". /*%2'

Hua et a". /100,2' im et a". /100+2' G!a et a". /*$2' G!on et a". /*12' ;ior et a".

/100,2' 4ishra et a". /*%2' Piacentino et a". /*,2' Rosen et a". /*$2' 8ahoo et a".

/*+2' 8a"a et a". /*(2' 8ciubba et a". /*12' Temir et a". /*32' Traverso et a".

/**2' et.

2.8 METHODS OF EXERGY ECONOMICS

4any methods for performing the eergy economic ana"ysis have been deve"oped and

app"ied !ith varying degrees of success F;o=ano et. a". /100$2' @ean et. a". /100(2' and

Er"ach et. a". /10002. These methods are named as

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• Thermo economics

• 8econd "a! costing

• Eergy costing

• Eergy economics.

;ong time eergy-economic researcher Tsatsaronis /100,2 identifies the four types of

eergy economic methodo"ogies' depending upon any of the fo""o!ing of the techniue9

/a2 Eergy-economic cost accounting'

/b2 Eergy-economic ca"cu"us ana"ysis'

/c2 Eergy-economic simi"arity numbers'

/d2 ProductKcost efficiency diagrams'

8evera" detai"s of a"" these techniue has been discussed FTsatsaronis /100,2' 8ayed et.

a". /10+02.

2.9 DEVELOPMENTS IN EXERGY ECONOMICS AND THEIR

APPLICATIONS

;o=ano and Oa"ero /100$2 mae formu"as to find the cost and efficiency of system.

Energy concept' fue" product concept and mathematica" formu"ation are the pi""ars of

ana"ysis theory. App"ications are9 /i2 assessment of a"ternatives for energy savings' /ii2

cost a""ocation' /iii2 operation optimi=ation' /iv2 "oca" optimi=ation of subsystems' /v2

energy audits and assessment on fue" impact of ma"functions. It is found that eergyconcept is very po!erfu" too" to identify' assign' measure and attribute a cause to the

inefficiencies of the rea" p"ant.

Eergetic cost concept deve"oped by ;o=ano and Oa"ero /100$2 has been app"ied to

therma" systems. Oa"ero et a". /10032 ep"ained the strategy for optimi=ing the therma"

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system using the Exergetic Cost Theory (ECT) and symbolic exergoeconomics. ECT

permits the a""ocation of costs to each of the f"o!s of insta""ation. The symbo"ic

eergoeconomics permits to re"ate the efficiency and cost of its f"o!s and products to

efficiencies of components. The ECT he"p to enhance physica" mode" of p"ant and not

therma" mode" but this information can be used to improve "oca" optimi=ation. entice et

a". /100+2 has app"ied this techniue for the estimation of refrigeration and heat pumps.

4ishra et a". /**2 used this theory for the estimation of ;i@rKH * vapour absorption

system. 4odesto et a". /*(2 app"ied the theory for a po!er p"ant for stee" mi"". The

system has been assessed by t!o theories' theory of Thermoeconomic Functional

Analysis and eergetic cost deve"oped by 7rangopou"os /10+,2.

Ear"ier !or by Tribus' Evans and EI-8ayed on thermoeconomics "ed to the deve"opmentof ‘thermoeconomic isolation (TI)’ Any therma" system component may be regarded as

thermo economica""y iso"atedJ from other system components !hen its economic

interactions are comp"ete"y described by a set of sing"e numerica" va"ues of stab"e

;agrange mu"tip"iers for each interaction. Eamp"es of usefu" energy ana"ysis are

mentioned for feed-!ater heaters' condensers' evaporators and condensers in

refrigeration systems Evans /10+2. In order' to approach the thermoeconomic iso"ation'

Evans /10+2 made use of the functions or the purposes of therma" systems components

to obtain the TI under some conditions. The attempt to derive the comp"ete set of

conditions for TI "ed to the deve"opment of a ne! method for optima" design or

improvement of comp"e therma" system' !hich is named as thermoeconomic

functional analysis (TFA)F 7rangopou"os /10+,' 10032.

Tsatsaronis et a". /10+%2 app"ied the thermoeconomic approach to energy conversion

p"ants. They verified that approach a""o!s the monetary estimation of costs caused by the

irreversibi"ities "osses' as !e"" as the comparisons bet!een these costs and investment

and operating costs for each component of p"ant. This information can be used for

improvement in p"ant. Tsatsaronis et a". /10032 have simp"y app"ied this theory to the

C:A4 prob"em. In presented study' Tsatsaronis' Ta!fi et a". /10032 app"ied the

techniue to t!o GR)-@ased I:CC po!er p"ants supported by epartment of Energy'

>8A. 8evera" configurations of I:CC p"ant !ere deve"oped. ne of these configurations

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has been ana"y=ed from eergoeconomic /thermoeconomic2 vie! point. 8evera"

conc"usions and recommendations !ere made for improving the performance of p"ant

and a"so considerab"e cost saving. @y using the iterative exergy aided cost minimization

method' for optima" case' 3%& overa"" eergetic efficiency has been reported.

In this "iterature recent ru"es of optimi=ation for mu"tiproduct systems are a"so added. The

ru"es contain the "oss of unit cost due to irreversibi"ities in a subsystem. Comparison of

ne! and o"d ru"es for the case of a cogeneration.

Er"ach et a". /10002 proposed the tructural theory of thermoeconomics! According to

Tsatsaronis' there are t!o main groups of thermoeconomics methods9 /a2 cost accounting

method' and /b2 optimi=ation methods. )hen comparing the different methodo"ogies'

many nomenc"atures' concepts and names are faced by readers. This !as one of reason

impeding the faster deve"opment of thermoeconomics. To avoid the unnecessary

confusion' the need of common mathematica" "anguage !as fe"t. This common

mathematica" "anguage is provided by the 8tructura" theory of thermoeconomicsJ.

Torres et a". /**2 introduced the method based on the structura" theory and symbo"ic

thermoeconomics. It integrates the thermoeconomic methodo"ogies deve"oped unti" no!'

such as fue" impact' technica" eergy saving and a"so computes the additiona" fue"

consumption and ma"function costs of p"ant components.

The structura" theory is ab"e to predict eact"y tota" additiona" fue" that the p"ant

consumed on ma"functioning the some p"ant component ang et a" /*(2.

In the case of thermoeconomics' the effect of ma"function is uantified in terms

additiona" fue" consumed for same production' !ith respect to base case design condition.

The main methodo"ogies has been discussed in ;o=ano et a". /100$2' Oa"ero et a". /10032'

@ean et a". /100(2' Oa"ero et a". /**2 ' ang et a". /*(2' entice et a". /100+2'

entice et a". /100+2' 4ishra et a". /**2'

G!a et a". /*$2 has ana"y=ed a % 4) combined cyc"e p"ant' the eergy and

eergetic cost ba"ance for each component and for the !ho"e system have been

considered carefu""y. The eergoeconomic mode" has been used to visua"i=e the cost

$%


19/67

formation process and productive interaction bet!een the components. At the 1& "oad

condition measured and ca"cu"ated eergetic efficiency are %, and %3.+& respective"y.

The unit cost of e"ectricity is direct"y proportiona" to the unit cost of fue".

2.: CONCLUSIONS

Theory of eergetic cost have been app"ied to therma" po!er p"ants abroad and it is

obvious from previous researcher#s !or that it is a po!erfu" too" for assessing the

therma" systems.


20/67

CHAPTER-$

EXERGY AND ENERGY ANALYSIS OF COAL

FIRED NON;REHEAT THERMAL POWER PLANT

3.1 INTRODUCTION

In India annua" demand for e"ectricity has increased from 1,13 4) in 10% to

1+$*$.31 4) /*132.The e"ectricity generated from therma" po!er p"ants constitutes

(3.( & of tota" generation. 7rom' the 7ifth 7ive year p"an on!ards i.e. 10,3-,0' the

:overnment of India got itse"f invo"ved in a big !ay in generation of po!er to

supp"ement the efforts at the state :overnment "eve" and too upon itse"f the

responsibi"ity of setting up the "arge po!er proects based upon the coa" as !e"" on other

resources "ie hydro' nuc"ear etc..


21/67

)e use 7irst ;a! of Thermodynamics for this.@ut as time passes both eergy and energy

both concepts are reuired in po!er p"ant to find efficiecny.

The eergy ba"ance of system a""o!s us to a""ocate and ca"cu"ate irreversibi"ities in the

production process and to identify !hich units and !hat for reason they affect the overa""

efficiency. An eergy assessment a""o!s one to uantify the "oss of efficiency in a process

due to "oss of ua"ity of the energy. This ana"ysis can indicate !here the process can be

improved and' therefore' !hat areas shou"d receive more attention.

)e are not ab"e to find main thermodynamic f"a! in different processes in therma" po!er

p"ants by using ust an energy ana"ysis. These effects of the aforesaid irreversib"e

phenomenon can be detected and eva"uated by on"y eergy ana"ysis. The eergy ana"ysis

can therefore give the information about the possibi"ities of improving therma" processes'

but cannot state !hether or not the possib"e improvement is practicab"e. 8uch a uestion

can be ans!ered on"y by the economic ana"ysis and has been discussed in Chapter IO.

3.2 SYSTEM DESCRIPTION

The po!er p"ant consists of three units of )* + %%$ at fu"" "oad. 7igure $.1 sho!s the

schematic diagram for %% 4) po!er p"ants for one unit. @oi"er of considered unit is

designed for coa" of ca"orific va"ue of *$1Q- +3 G?Kg !ith ash content of **& and

vo"ati"e matter of $+&. Ho!ever' the coa" received is of 1(,(%G?Kg !ith ash content of

$+& and *(& vo"ati"e matter P"ant consists of HP and ;P turbines !ithout any reheating.

8team after epanding in ;P turbine is ehausted in condenser. The condensed steam

passes through the ;P and HP regenerative feed !ater heaters. The hot !ater is then fed

to boi"er drum through the t!o economi=ers. Cyc"e has been ana"y=ed !ith fo""o!ing

assumption.

12 8pecific eergy of fue" has been ca"cu"ated as in @ean et a". /100(2.

*2 :ross ca"orific va"ue has been used in ca"cu"ations.

$0


22/67

3.3 ENERGY AND EXERGY ANALYSIS OF NON REHEAT COAL

BASED THERMAL POWER PLANT

In ana"ysis conservation of mass and energy "a!s are used for individua" as !e""s as tota"

system. @oth eergy and energy ana"ysis condition are app"ied on %%4) and at 34)

to find process irreversibi"ities.

The maor streams entering and "eaving the components of the p"ant are sho!n in the

7igure $.1.To identify the sources of the avai"abi"ity destruction' the entire p"ant has been

sp"it into different contro" vo"umes' vi=. @oi"er !ith its inputs and outputs' generator

3


23/67

Hot Air 8upp"y

3+

3,

Coa"

1 * $

$% $(

Eit 8H HP ;P Turbine

3 ,$3 $, 1 1$ 1( 10

P"aten

8H Co"d )ater in 30

$$ $+

Hot !ater out %

;T8H 0 *% *

eareator

$* $0

1+

Economi=er * 3 3,

% + *( 11 13 1,

$1 31

3( *+ *, *3 *$ ** *1

Economi=er 1 3*

$ *0 0a 1* 1%

(

4ae up-)ater

%1

31

B($% U'#

:

C(')$

%

Hot

)e""

AP 2

B FP

L

PH

1

;P

H*

L

PH

3

H

PH

1

H

PH

2

AP 1

CEP

ID F!'


24/67

Air in 33 3%

3$ 7"ue gases to 8tac

3*

Figure .1 c$e-atic diagra- o non/re$eat t$er-al power plant


25/67

condenser and regenerative system and the entire cyc"e !ith boi"er' turbine' generator'

condenser and regenerative system. @y doing this !e can a"so ca"cu"ate the part of each

component irreversibi"ity in gross irreversibi"ity of the p"ant. A genera" energy and

eergy-ba"ance euations' app"icab"e to any component of a therma" system may be

formu"ated by using the first and second "a! of thermodynamics5 the specific thermo-

mechanica" eergy /neg"ecting inetic and potentia" energy2 is eva"uated from the

fo""o!ing euation9

2/2/ 111 s sT $$e 0 0 0 −−−=

/$.12

The tota" rate of eergy !ith any stream can be estimated as

0 0 0 e- E =

/$.*2

and tota" rate of energy !ith any stream can be estimated as

0 0 0 $- 1 =.

/$.$2

!here the -, 0 ,$, s and denotes mass f"o! rate of stream' energy or eergy f"o!

streams entering or "eaving the component at any point' specific entha"py' specific

entropy and thermodynamic properties at ambient conditions respective"y in above

Euations.

Chemica" eergy /based on dry and ash free2 estimation' reuired for the fue" on"y' has

been eva"uated separate"y.

H66666F

H66666F2/

*********

*****

*****

*

CH OO

CH N N

CH OO

CH O H O H

CH COCO

N N OOO H O H COCOOO 34F 34F

CH 34F

e5e5e5e5e5

s5 s5 s5 s5 s5 sT HH! e

−−−−−

−−−−−

−++++

−−−−+−=

/$.32

34F and HH! denote dry and ash free and higher heating va"ue respective"y.

3$


26/67

ut of it the eergy f"o! rate "eaving !ith f"ue gas is9

g 0

g 0

g out e- E ∑=

/$.%2

!here' the summation app"ies over a"" the components of the f"ue gas and superscript g is

for f"ue gas.

A detai"ed eergy ana"ysis inc"udes ca"cu"ating the eergy destruction and "oss in each

component. The eergy ba"ance euation for any component /!ithout decomposing2

∑ ∑+=+e i

' i' 6' ' e E E * E .

'

.

'

..

'

/$.(2

The subscripts e, i, ' and 6 denote eit' in"et' component and heat transfer respective"y.

..

and * E denote the Eergy rate and !or transfer rate in Euation $.(.

The eergy destruction rate in a component is ca"cu"ated from eergy ba"ance

∑ ∑−=i e

' e' i 3 E E E .

'

.

'

.

/$.,2

The eergy destruction ratio ' 3 y ' represents the eergy destruction rate

.

3 E in the t$'

component !ith tota" eergy destruction rate in the system.

∑= .

'

.

.' K ' 3' 3' 3 E E y /$.+2

The genera" definition for eergetic efficiency for a therma" system is

E&ergies %nput 4ll

loss E&ergy E..iciency E&ergetic −=1

/$.02

33


27/67

Appendi 1 sho!s the euation used for ca"cu"ating eergy destruction and eergy

efficiencies for p"ant subsystem.

Tab"e $.1 Pressure' temperature' mass f"o! rate' energy and eergy f"o! rate for the

streams of po!er p"ant at %% 4) /@ase case design2

S#%$!5P%$*%$

T$5"$%!#*%$

F(


28/67

3.6 RESULT AND DISCUSSION

Here both energy and eergy ana"ysis are done on %%4) sing these intensive and etensive properties' program

ca"cu"ates subsystem effectiveness at rated "oad and part "oad conditions. 4ainsubsystems of therma" po!er p"ant are boi"er' turbine' and condenser and feed !ater

heaters.

The re"evant steam operating data for po!er p"ant at 3 and %%4) "oad !ere supp"ied as

an input and the va"ues of entha"py' eergy and effectiveness has been computed as an

output data. Tab"e $.1 sho!s the computed va"ues of energy and eergy of various f"o!s

in the p"ant.

Tab"e $.1 contain re"evant thermodynamic data i.e.' pressure' temperature' energy and

eergy for steam po!er p"ant at %%4). 8imi"ar ca"cu"ations !ere a"so performed for

34). Corresponding energetic and eergetic efficiencies of subsystems and of the

!ho"e p"ant at %%4) is sho!n in 7igure $.*. 7rom energetic point of vie! turbine is

maimum efficient component !ith an efficiency of 0(.%$&. The 7eed !ater heaters'

3(


29/67

7igure $.* Efficiencies of p"ant and sub

*

3

(

+

1

1*

@oi"er

Turbine

Condenser

7eed)ater

Heaters

P"ant

7irst ;a! efficiency

8econd ;a! efficiency

boi"er and condenser are eua""y efficient components !ith the efficiencies of +3.+*'

+3.$% and +3.13& respective"y. The energetic efficiency of p"ant !as estimated as

*3.%*&. 7rom 8econd "a! point of vie!' the turbine remains as the maimum efficient

component !ith eergetic efficiency of ((.*%& and boi"er is the "east efficient

component !ith eergetic efficiency of $,.(,& !hereas the eergetic efficiencies of

feed !ater heaters and condenser are +$.13& and %0.3(& respective"y and "ies bet!een

the eergetic efficiencies of turbine and boi"er. The eergetic efficiency of the !ho"e

p"ant has been estimated as **.*1&.

7igure $.$ sho!s the 7irst "a! efficiency at fu"" and part "oad condition of 34). 7romenergy or the first "a! standpoint vie! the overa"" p"ant efficiency varies *3.%* at %%4)

to **.1& at 34). The component-!ise variation in the 7irst "a! efficiency is a"so

indicated in 7igure $.$. The efficiencies of boi"er' turbine' condenser and feed !ater

3,


30/67

7igure $.$ 7irst "a! efficiency for subsystems and overa"" p"ant

*

3

(

+

1

1*

@oi"er Turbine Condenser 7eed )ater

HeatersP"ant

Efficiency /&2

%% 4)

3 4)

7igure $.3 Eergetic efficiencies for subsystem and p"ant

*

3

(

+

1

@oi"er Turbine Condenser 7eed )ater Heaters P"ant

Efficiency /&2

%% 4)

3 4)

3+


31/67

7igure $.% Eergy destruction /&2 !ithin subsystems

*

3

(

+

1

@oi"er Turbine Condenser 7eed )aterHeaters

%% 4)

3 4)

Eergy destruction /&2

heaters drop to +*.+3' 0*.++' 3$.10 and ,%.*0& respective"y. The condenser operates !ith

"o!est efficiency at 34) as indicated in 7igure $.$. 7igure $.3 sho!s second "a! or

eergetic efficiency of subsystems and overa"" p"ant at rated fu"" "oad and part "oad

condition. The eergetic efficiency of p"ant at designed rated condition' !hich is **.1&

drops to 10.03& at part "oad of 34)' !hich is very "o!. This indicates that tremendous

opportunities are avai"ab"e for the improvement. Ho!ever' part of this irreversibi"ity

cannot be avoided due to physica"' techno"ogica" and economic constraints. The eergetic

efficiency for boi"er varies from $,.(, to $(.%&' for turbine' the efficiency is improved

to (+.*%& at 34)' for the condenser' the second "a! efficiency varies from %0.3(& at

fu"" "oad to 1%.%& at part "oad of 34) and for' feed !ater heaters and the eergetic

efficiency varies from +$.1*& at %%4) to ,%.+& at 34).

7igure $.% sho!s the eergy destruction in percentage /eergy destruction in a component

to the tota" eergy destruction in p"ant2 in subsystems of p"ant at %%4) and 34). This

figure sho!s that maimum eergy destruction taes p"ace in the boi"er and "east eergy

30


32/67

destruction taes p"ace is feed !ater heaters at %% and34). The eergy destruction in

the boi"er increases from ,+.+$& to +.*&. It is observed that maimum eergy

destruction of tota" eergy destruction occurs !ithin the boi"er and destruction rate

increases at part "oad conditions. There are many sources of irreversibi"ity !ithin the

boi"er. The maor sources of eergy destruction first"y' is chemica" reaction in boi"er

combustion chamber !here chemica" reaction is the most significant source of eergy

destruction causing the incomp"ete combustion in a combustion chamber !hich is the

irreversib"e combustion itse"f. Primary source of destruction is that high potentia" fue" is

consumed in the spontaneous combustion. The eergy destruction at part "oad increases

due to improper heating of in"et combustion air. 8econd"y' the eergy destruction in the

combustion chamber a"so significant"y affected by ecess air and in"et temperature of air.

The efficiencies of combustion can significant"y increased by preheating the in"et

combustion air effective"y and contro""ing the air-fue" ratio effective"y. As discussed

ear"ier maimum eergy destruction occurs in the boi"er due to incomp"ete combustion'

ecess air' and poor performance of air pre-heaters and use of "o! grade fue" other than

designed fue". The temperature of air supp"ied to the boi"er at fu"" "oad is $3oC !here as

at 34) part "oads this temperature is $$oC. Third"y and "ast"y' the eergy destruction

a"so caused by the poor heat transfer from f"ue gas to steam !hich is the irreversib"e heat

transfer bet!een the hot combustion products and the f"uid in the boi"er tubes. The coa"

temperature at mi"" out"ets shou"d be in the range of (%-+ oC !here as actua" temperature

is in range of +3-+0oC at the a"" mi""s. A steep fa"" in the condenser efficiency may be

seen at part "oad condition because of the actua" high bac pressure and high termina"

temperature difference against designed va"ues. ;o!ering the condenser temperature'

conseuent"y' "o!ers cyc"e average temperature. Essentia" effect is that' the eergy "ost

through condenserMambient heat transfer decreases. Sua"ity and uantity of ra! !ater

supp"ied to coo"ing to!er is poor. Euiva"ent minera" acidity and G4


33/67

in the course of heating the feed !ater. 7eed heating sho!n in 7igure 1 derives its

irreversibi"ity from t!o main sources' first' the miing of sub coo"ed "iuid !ith a

saturated miture of higher temperature' and' in the case of the "ater feed heating stages

and second' the miing of superheated steam !ith a saturated miture of "o!er

temperature. The thermodynamic data provided for of regenerative system !ere

insufficient for ca"cu"ation purpose. Ho!ever based on some assumed data' ca"cu"ation

for eergetic efficiency has been made. It is observed from the data that at part "oad' ;P1

is not in the service as there is no temperature gain in the heater. In turbine eergy

destruction drops from 1(., & to 13.%3& indicating that turbine performance improves

at part "oad condition from second "a! point of vie! !hereas in the condenser the eergy

destruction increases from $.1& to 3.*& and for the feed !ater heaters eergy

destruction increases from 1.3%& to *.%&.

According to 7irst ;a! ana"ysis turbine and feed !ater heaters are most efficient parts

!hereas the boi"er and condenser are eua""y efficient but comparative"y not efficient as

turbine. n comparing the 7igure $.$ and 7igure $.3' it is observed that boi"er

performance is not as good as from the eergetic efficiency point of vie! and same

conc"usion may be dra!n from other subsystems a"so. In this sense first "a! ana"ysis is

mis"eading. 8econd ;a! Ana"ysis serves to pinpoint the true po!er generation

inefficiencies occurring throughout the po!er p"ant.

3.7 CONCLUSIONS

In this !or an energy and eergy ana"ysis has been performed on a %%4) actua"

therma" po!er p"ant at 34) and %%4) output to find the "osses taing p"ace in the

p"ant. Eergy and percent of destruction a"ong !ith energetic and eergetic efficiencies

have been eva"uated. In the considered po!er cyc"e' maimum energy "oss !as found in

the condenser. 7eed !ater heaters and boi"er !ere the net. In the terms of eergy

destruction' it !as found that eergy destruction rate of boi"er is dominating over a"" other

irreversibi"ities in the p"ant.


34/67

in the condenser and feed !ater heaters is very "o!. Ca"cu"ated eergetic efficiency of

p"ant is **.1& at %%4) !hich is very "o! as compared to modern po!er p"ants.

7ina""y eergy based ana"ysis provides a measure of approach to idea"ity or deviation

from idea"ity.

%*


35/67

CHAPTER-3

EXERGOECONOMIC ANALYSIS OF COAL FIRED

NON;REHEAT THERMAL POWER PLANT

6.1 INTRODUCTION

In chapter III of this thesis' the energy and eergy ana"ysis of coa" fired non-reheat

therma" po!er p"ant has been performed. Eergy ana"ysis usua""y predicts the

thermodynamic performance of an energy system F;o=ano 4 A et a". /100$2 and 8=argut

? et a". /10++2. 7urthermore' eergoeconomic ana"ysis combines the eergy ana"ysis and

economic princip"es' estimates the unit cost of products and uantifies monetary "osses

due to irreversibi"ity F@ean A et a". /100(2 and Gotas T ? /10+%2. At present' such

ana"ysis is in great demand because proper estimation of production cost is essentia" for

companies. Eergoeconomics that integrates the eergy and economics inc"udes the

determination of9

• the appropriate a""ocation of economic resources

• the economic feasibi"ity and profitabi"ity of a system

A"" techniues have the fo""o!ing common characteristics9

• they combine eergy and economic princip"es

• they recogni=e that eergy' not the energy ' is the commodity of the va"ue

in a system' and they conseuent"y assign the costs and Kor prices to

eergy re"ated variab"es

In present study' eergetic and thermoeconomic ana"ysis has been performed for %%4)

non reheat therma" po!er p"ant. In this ana"ysis' mass and energy conservation "a!s !ere

app"ied to each component. Suantitative ba"ance of eergies and eergetic costs for each

component and for !ho"e system !as considered carefu""y. The eergy- ba"ance and cost

ba"ance euation mentioned in @ean et a". /100(2 has been used in these ana"yses.

%$


36/67

Ca"cu"ation resu"t sho!s that unit cost of e"ectricity increases !ith decrease in "oad. In

this !or certain eergy-re"ated variab"es a"so has been ca"cu"ated to study the various

components of po!er p"ant.

6.2 THE NON REHEAT THERMAL POWER PLANT

A schematic of a %%4) non reheat therma" po!er p"ant is sho!n in 7igure $.1 and

sho!s main !or and eergy f"o!s and state points !hich !e accounted in these

ana"yses. The system consist of a boi"er' "o! and high pressures steam turbines'

condenser and feed !ater heaters. The mass f"o! rate of steam to the turbine is ,*.**

gs-1 at %$oC and 0$.1, bar !hen p"ant operates at %%4). The temperature and pressure

of ehausted steam from ;P turbine is 3(oC and .0+ bars respective"y. )ater enters to

economi=er at 103oC raising its temperature from %*oC through feed !ater heaters. The

incoming air to air pre-heater has a temperature of *% oC and pressure 1.1$ bars. The

temperature of incoming air increases to $3oC by air pre-heaters. Temperature of f"ue

gases "eaving air pre-heaters is 1%oC.Tota" cost of coa" consumed by the p"ant is Rs

(*,.$$ mi""ion in a year and *00 mega units of e"ectricity have been generated. The unit

has been designed for a ca"orific va"ue of *$1 G?Kg !ith ash content of **& and a

vo"ati"e matter of $+&. Ho!ever during recent years the average ca"orific va"ue of fue" of

about 10$$, G?Kg !ith ash content of $.(%& and vo"ati"e matter of *%.,$& is beingsupp"ied but in the ca"cu"ation the va"ue :CO of *$+ G?Kg has been used.

6.3 FORMULATION OF EXERGO;ECONOMIC BALANCE

EUATION

A genera" eergy- ba"ance euation' app"icab"e to any component of a therma" system is

formu"ated in chapter $.1 and is as fo""o!s9

∑ ∑+=+e i

' i' 6' ' e E E * E .

'

.

'

..

'

/3.12

Assigning a unit eergy cost to every eergy stream' !e can !rite the cost ba"ance

euation corresponding to euation /3.12

%%


37/67

...

''

.

'

.

2/2/ ' ' ii

i' 6' 6' ' w' e

e

e ( E c E c* c E c ++=+ ∑∑ /3.*2

!here c denotes the unit eergy cost and term

.

'

( inc"udes a"" financia" charges

associated !ith o!ning and operating the t$'

p"ant component. Euations /3.12 and

/3.*2 are t!o main euations used in this ana"ysis. This eergy costing is simi"ar to that

suggested by ;o=ano and Oa"ero /100$2. The productive structure of the system can be

obtained by app"ying Euation /3.*2 to each component.

The other eergoeconomic variab"es are re"ative cost difference ' r

and eergoeconomic

factor ' .

. .The re"ative cost difference is as in @ean et a". /100(2.

.

''

..

1

' P ' F

O)

'

C%

'

'

'

'

E c

( ( r

++

−=

ε

ε

/3.$2

!here ' F c ' cost per unit fue" eergy'

.C%

' ( 9 cost rate associated !ith capita" investment'

.O)

' ( 9 cost rate associated !ith operating and maintenance. This revea"s the rea" cost

associated !ith t$' component.

The eergoeconomic factor ' .

is as in the @ean et a". /100(2.

2/.

'

.

''

.

.

' 7' 3' F '

'

'

E E c (

(

.

++=

/3.32

The

.

' ( is tota" cost rate associated !ith t$'

component !hereas

..

and 7 3 E E represents the

eergy destruction rate and eergy "oss rate respective"y. The eergoeconomic factor

%,


38/67

epresses as a ratio the contribution of the non-eergy-re"ated cost to tota" cost increase.

A "o! va"ue of the eergoeconomic factor ca"cu"ated for a maor component suggest that

cost saving in the entire system might be achieved by improving the component

efficiency even if the capita" investment for this component !i"" increase.

6.6 ECONOMIC ANALYISIS FOR THE POWER PLANT

COMPONENTS

The aim of economic ana"ysis in this thesis is to provide sufficient inputs to be used in the

eergoeconomic ana"ysis. These inputs are initia" investment or purchased euipment

cost' operation and maintenance cost and annua"i=ed cost for the p"ant components and

for !ho"e p"ant.

7o""o!ing steps has been app"ied in this ind of economic ana"ysis9

I. Purchased euipment cost shou"d be estimated and there are severa" !ays to

obtain purchased euipment costs of euipments. @est source is vender#s

uotations. ther !ays are cost estimates from past purchased orders' uotations

from eperienced professiona" cost estimates. Cost databases maintained by

companies. In this thesis' purchased euipment cost has been obtained from the

stoc register of cost database of po!er p"ants. A"" costs due to o!ning have been

taen from the stoc register and !ere purchased during year 10,( as "isted in

Tab"e 3.* in *nd co"umn.

II. ;eve"i=ed costs shou"d be ca"cu"ated as the costs of components vary significant"y

!ithin the economic "ife of the p"ant. In genera"' carrying charges decreases !hi"e

fue"' ra! materia" and D4 costs increase !ith increasing years of operation.

Therefore' "eve"i=ed annua" va"ues for a"" cost components shou"d be used to

simp"ify the eergoeconomic ana"ysis.

III. ;eve"i=ed annua" costs for a"" components shou"d be ca"cu"ated. In this thesis' the

annua"i=ed /"eve"i=ed2 cost method of 4oran /10+02 has been used.

The amorti=ation cost or present !orth for a particu"ar component may be !ritten as

%0


39/67

( )ni P*F C P* ni '−= /3.%2

C i' i.e. initia" capita" investments or purchased-euipment costs /PEC2 / #s.2 for the

components and has been taen from stoc register of the company. n and P*F denotes

the sa"vage va"ue and present !orth factor !hereas i and n denotes interest rate and

component "ife in years.

The present !orth of a component is converted to annua"i=ed cost by using the capita"

recovery factor C#F 8i, n9' i.e.

.

C / #s. : year 2 2'/6 niC#F P* /3.(2

ividing "eve"i=ed cost by +,( annua" operating hours' !e obtain the fo""o!ing capita"

cost for the t$'

component of the p"ant.

2+,(6$(K/..

' ' ' C ( φ = /3.,2

The maintenance cost can be taen into consideration through the factor(.1=

'

φ but in

the ca"cu"ation this va"ue has taen as unity for each p"ant component !hose epected "ife

is assumed to be *% years.

6.7 COST BALANCE EUATIONS FOR NON REHEAT THERMAL

POWER PLANT

The cost ba"ance euations for each component in the po!er p"ant' sho!n in 7igure $.1'

can be derived from the genera" cost-ba"ance euation given in Euation /3.*2. These cost

ba"ance euation may be so"ved for the cost per eergy unit of eiting steam !ith the

need of aui"iary re"ations. As a ru"e' n/1 aui"iary re"ations are reuired for the

component !ith n e&iting eergy streams F;o=ano 4.A et a" /100$2' @ean A et a" /100(2

and G!a H et a". /*$2.

(1


40/67

3.%.1 @I;ER

The function of boi"er is to raise the temperature and pressure of feed !ater. The cost

ba"ance euation for boi"er is

3$

.

3$1

.

1

.

*0

.

*0.

..

3+ E c E c ( E c E c E c bbau&wCHE +=+++

/3.+2

c;


41/67

3.%.* T>R@I


42/67

.

1+1+

.

*0*0

...

*1*11(

.

1(

.

1$1$

.

11

.

,

.

,33 E c E c ( E c E c E c E c E c E c E c $trs$tau&w +=+++++++ /3.132

The $trs$tau& ( E

..

and denote aui"iary eergy to feed !ater heaters and the sum of charges

associated !ith feed !ater heater#s capita" investment and operating D maintenance

respective"y and aui"iary re"ations are

11+*11(1$1,3 cccccccc ======= /3.1%2

3.%.% OERA;; P)ER P;A


43/67

for turbine unit is highest and "o!est for feed !ater heaters. The Tab"e 3.$ sho!s the

va"ues of eergy' cost rates associated !ith f"o!s and average unit costs of f"o!s for base

case design at %%4). These costs have been obtained by app"ying the cost euations

from /3.+2 to /3.1(2. The average unit cost va"ue of fue" /coa" on"y2' .0% Rs per 4?' has

been used in this ca"cu"ation. In this ana"ysis' the highest eergy unit cost !ith a va"ue of

.$0(0 Rs per 4ega ?ou"es is achieved at turbine-generator eit !here a"" eergy is

avai"ab"e at eit in e"ectrica" po!er' !hich is the most epensive product in the system. It

is a"so noted that cost per eergy unit is considerab"y higher for stream % and stream *0.

The monetary "osses associated !ith eergy "oss of stream 3$ and streams % are

,%%3.( Rs per hr and 0,1+*. Rs per hr respective"y. The cost of fina" product is

depends on the cost of input fue".

In Tab"e 3.3' thermoeconomic variab"es are summari=ed. These variab"es inc"ude average

costs per unit of fue" eergy F c ' product eergy P c ' cost rate f"o! rate of various streams

.

C ' investment and D4 cost rate.

( '..

( C 3 + /RsKhr2' re"ative cost difference BBr and

eergoeconomic factor BB . ' the boi"er and turbine have the highest va"ues of..

( C 3 + and

are' therefore most important components from the thermoeconomic vie!point. The "o!

va"ue of variab"e BB . for boi"er suggest that cost associated !ith boi"er is ec"usive"y due

to eergy destruction and cost saving might be achieved by improving the component

efficiency. n the other hand' the va"ue of BBr revea"s the rea" cost source associated

!ith any component. The high va"ue of BBr for the boi"er suggests that !hi"e optimi=ing

the component' this va"ue has to be minimi=ed instead of minimi=ing the cost per eergy

unit of the products for the component. Therefore the .1*& va"ue of BB . for boi"er

suggest to increase the eergetic efficiency' even if the capita" investment increases and

1(%.%,& va"ue or BBr suggest that this va"ue has to be reduced so that rea" cost

associated !ith boi"er decreases. Turning net' re"ative"y high va"ue of BB . for the steam

turbine suggests that capita" investment and D4 costs dominates but this va"ue of BB .

suggest that by reducing the eergy destruction' the eergetic efficiency of turbine can be

(0


44/67

improved further and cost saving in the system may be achieved by improving the

eergetic efficiency of component.

Tab"e 3.1 Pressure' temperature' mass f"o! rate and eergy f"o! rate at %% 4)

Tab"e 3.*Initia"

,1

P('# P%. T$5" F(


45/67

investment costs' annua"i=ed costs and corresponding monetary f"o! rates of each

component in po!er p"ant

C(5"('$'# I'#!

I'-$#5$'#

+(#

A''*!$)

+(#

M('$#!%0

4( %!#$

@oi"er *1.0$1 *.31( *0*.$(

Turbine ,(.3+1 +.3*% 110.%(

Condenser 3.3+ .33( %$.0(

7eed !ater

heaters

.3+% .%$ (.3,

ther

euipments

1*+.1* 13.113 1,+.1%

P"ant *$1.3, *%.3%3 $+.%

Tab"e 3.$ Eergy' cost rates associated !ith f"o!s and unit costs of f"o!s at %% 4)

S#%$!5

N(.

.

E c

.

C

1 1%.0 .*%3$ 0(*0*.+

3 3.1+, .*%3$ $+$(.%*

, $.%*1 .*%3$ $**(.(1

1 1.%( .*%3$ 0(+.

1$ 1.3($ .*%3$ 1$3.%*

1( $.+0 .*%3$ $30.((+

1+ .*1( .*%3$ 10+.1

10 +.1% .*%3$ ,$33.$(

* .13+ .*%3$ 1$%.($

*1 .31* .*%3$ $,,.1,*

*0 11.,0, .$$(* 13*+.1*

C! %%. .$0(0 ,+%+(.*

3$ **.% .0% ,%%3.(

3+ *3,.(( .0% +3+%%.(

30 . . .

% ,.1+ .$,( 0,1+*.

%1 . . .

,$

C(5"('$'# U'# C(# (4

F*$ E$%/0

F c

U'# C(# (4

P%()*+#

E$%/0 P c

C(# 4(

R!#$ (4

S#%$!5

.

C

C(# (4

$$%/0

)$#%*+#('<

R@%>

3C .

.

(

..

( C 3 +

/&2r .

@oi"er .1(1 .*%3$ 001$%.,* %%30.3 *0*.$( %%,1.,( 1(%.%,

Turbine .*%3$ .$0(0 0(*0*.+ *%((3.+ 110.%( *((+3.$( %*.00

Condenser .*%3$ .$,( ,$33.$( 3(*0.0% %$.0( 3(+$.01 1+.+

7eed )ater

Heaters

.*%3% .$$(* 1$*$0.3, **$1.(+ (.3, **$+.1% *.*0

P"ant .0% .$0(0 +3+%%.( %$,0$%.+ $+.% %311%.+% $((.(3


46/67

Tab"e 3.3 Oa"ues of PEC and thermoeconomic variab"es at %% 4)

,%


47/67

7urther' the condenser and feed !ater heaters are net components having the "o! va"ue

of ..

( C 3 + . 7or condenser and feed !ater heaters these va"ues are 3(+$.01 and **$+.1% Rs

per hr respective"y' !hereas the va"ues of BB . are .,% and .%& respective"y. This

suggest that by improving the performance' cost saving might be achieved by improving

the eergetic efficiency of these components even if the cost of capita" investment

increases. The va"ue of BBr for the condenser !hich is 1+.+&' is considerab"y on higher

side' therefore condenser can be optimi=ed by reducing this va"ue. 7or the overa"" p"ant

the va"ue of eergoeconomic factor BB . is 3.3(&' !hich is "o! and suggest that in

overa"" p"ant eergy destruction dominates and therefore cost of eergy destruction and

therefore cost saving can be reduced by improving the eergetic efficiency of the p"ant'

even if the capita" investment increases. )hi"e optimi=ing po!er p"ant' the re"ative cost

difference BBr ' !hich is $((.(3&' has to be reduced instead of minimi=ing the cost per

eergy unit of the fina" product. The co"umns $ rd and 3th of Tab"e 3.3 sho! the cost per

unit eergy for fue" and products respective"y for the various components. The average

unit cost of fue" eergy for the feed !ater heaters is s"ight"y higher !ith a va"ue of .*%3%

Rs. per 4? than the turbine and condenser !hose va"ue is .*%3$ Rs per 4? for both

components. The average unit cost of fue" eergy for the boi"er is "o!est !ith a va"ue of .1(1 Rs per 4?.

Tab"e 3.% Ca"cu"ated production rates of e"ectricity' eergetic efficiency at various "oadconditions

L(!)

C(')#('

M! 4( %!#$


48/67

7igure 3.1 Average unit cost of fue" eergy /Rs. per 4?2 for subsystems and p"ant

.%

.1

.1%

.*

.*%

.$

.$%

%% 4) 3 4)

@oi"er

Turbine

Condenser

7eed !ater heaters

P"ant

>nit cost of fue" eergy

/Rs. per 4?2

been "isted in this tab"e. :enera""y' unit cost of e"ectricity produced by coa" based non

reheat po!er p"ant increases at part "oad conditions because fu"" capita" ependitures are

uti"i=ed at part "oad conditions. At the fu"" "oad condition i.e. at %%4) the unit cost of

product at turbine generator eit is Rs .$0(0 per 4? and at 34) part "oad the unit cost

of product is Rs .3,($ per 4?. The average unit cost of product eergy for the boi"er'

turbine' condenser and feed !ater heaters are .*%3$' .$0(0 .$,( and .$$(* Rs per

4? respective"y at %%4). This cost is minimum for the boi"er and maimum for turbine

generator. The 7igure 3.1 compares the average unit cost of fue" eergy in Rs per 4? for

the subsystems and overa"" p"ant at %% and 34). >nit cost of fue" eergy for the feed

!ater heaters remains s"ight"y high at %% and 34) having the va"ues of .*%3% and

.$133 Rs per 4? respective"y !hi"e unit cost of fue" eergy for the turbines and

condensers are same at both the "oads !ith the va"ues of .*%3$ and .$13* Rs per 4?

respective"y. >nit cost of fue" eergy for boi"er is .1(1 and .1*+* Rs per 4? at %%4)

and 34) respective"y and is the "o!est among a"" components.

,,


49/67

7igure 3.* Average unit cost of product eergy /RsK 4?2 for subsystems and p"ant

.*

.3

.(

.+

1

%%4) 3 4)

>nit cost of product eergy/Rs per 4?2

@oi"er Turbine

Condenser

7eed !ater heaters

P"ant

7igure 3.* compares the average unit cost of product eergy for subsystems and overa""

p"ant at %%4) and 34). It has been observed that unit cost of product eergy for the

boi"er has increased to .$13* Rs per 4? from .*%3$ Rs per 4? !hen p"ant operates at

part "oad of 34). Thus unit cost of product eergy is higher at part "oad because eergy

destruction at part "oads increases and more than that because at part "oad product cost

has to bear the fu"" capita" ependiture for its process. >nit cost of product eergy for

turbine' condenser' and feed !ater is .3,($' .$0(0 and .+$(+ Rs per 4? respective"y

at part "oad of 34). The cost of product eergy for a"" subsystems increases at part "oad

as discussed ear"ier. It is a"so observed that rea" cost associated for the product i.e.

difference of unit cost of product eergy and unit cost of fue" eergy increases at part

"oad as sho!n in 7igure 3.$. At %%4) this va"ue is highest for boi"er and minimum for

the condenser !ith va"ues of .13+* and .,0, Rs per 4? respective"y. 7or the turbine

and condenser rea" cost for the products eergy is .13*( and .1*1, Rs per 4?. 7rom

this ana"ysis boi"er and turbine are most critica" component and reuires the more

attention. At 34) rea" cost associated !ith the product eergy is highest for the feed

,+


50/67

7igure 3.$ Rea" cost associated for products for subsystems and p"ants

.1

.*

.$

.3

.%

.(

%%4) 3 4)

Rs per 4?

@oi"er Turbine

Condenser

7eed !ater heaters

P"ant

!ater heaters !ith a va"ue of .%**3 Rs per 4? and reuires the more attention' !hereas

for the condenser' this va"ue is again "o!est !ith a va"ue of .+*, Rs per 4?. 7or the

other components boi"er and turbine at 34)' rea" cost is on higher side !ith the va"ue

of .1+( and .1(*1 Rs per 4? respective"y.

7igure 3.3 and 7igure 3.% sho!s the thermoeconomic variab"es !hich are re"ative cost

difference BBr and eergoeconomic factor BB . respective"y. Higher the va"ue of BBr in a

component' more attention is reuired for the component. At the fu"" "oad as !e"" as at

part "oad conditions boi"er and condenser is most critica" component. At part "oad of

34) the va"ue of BBr for boi"er increased to 1,3.$& from 1(%.%,& at %%4) and for

condenser this increases to111.1*& at 34) from 1+.+& at %%4). 7or the turbine this

va"ue drops to 3+& !hen p"ant operates at 34) and for the feed !ater heaters the va"e

of BBr becomes a"most doub"e !hen operates at 34). 7or the overa"" p"ant the va"ue of

BBr increased by 1(& !hen p"ant operates at 34).

,0


51/67

7igure 3.3 Re"ative cost difference r /&2 for subsystems and p"ant

*

3

(

%% 4) 3 4)

r /&2

@oi"er Turbine

Condenser

7eed !ater heaters

P"ant

7igure 3.% Eergoeconomic factor f /&2 for subsystems and p"ant

1

*

$

3

%

(

%%4) 34)

@oi"er

Turbine

Condenser

7eed !ater heaters

P"ant

f /&2

The "o! va"ue of BB . "ess then 1 & for a"" components ecept for the turbine' as pointed

out ear"ier' suggests that cost associated !ith these components is ec"usive"y due to

eergy destruction and cost saving might be achieved by improving the component

efficiency.


52/67

6.9 CONCLUSIONS

The eergoeconomic techniues presented here seems to be po!erfu" and systematic too"

for identifying a"" cost sources in any therma" system. An eergoeconomic ba"ance

app"ied to a process or !ho"e p"ant assesses the cost f"o! rates to the various f"o!s in the

system. This techniue a"so assesses the cost of consumed resources' money and system

irreversibi"ities in the terms of the overa"" production processes. Assessing the cost of the

f"o! streams and processes in a comp"e system he"ps to understand the process of cost

formation from input resources to the fina" products. @y using the eergoeconomicana"ysis in this thesis many conc"usions can be made. The unit cost of eergy product

increases from fu"" "oad condition to part "oad condition and unit cost of product eergy is

highest for feed !ater heaters at 34) !hereas the turbine unit cost of eergy is highest

at %%4). @oi"er is the main source of eergy destruction and therefore maimum cost of

eergy destruction goes to boi"er' ho!ever the average unit cost of fue" eergy is "o!est

for the boi"er. The maimum rea" cost associated for product goes to boi"er. The Rs

.$0(0 per 4? unit cost of the product eergy at turbine generator has been obtained at

%%4). These resu"ts are very c"ose to cost of e"ectricity estimated by company !hich is

.*$$$ Rs per 4? to .$++0 Rs per 4?. These costs are based on fied cost of the p"ant

on"y and D4 cost has not been considered. 7urther the re"ative cost difference and

eergoeconomic factor for the subsystems and for the !ho"e p"ant has been obtained at

%%4) D 34) and it !as observed that performance of the subsystems can be

improved by improving the eergetic efficiencies even if the capita" investment increases.

The ana"ysis sho!s that eergy and the eergoeconomic ana"ysis presented here can be

app"ied to any energy system systematica""y. If the correct information of initia"

investment' sa"vage va"ues and maintenance costs for each component can be supp"ied'

the unit cost of production can be estimated.

+1


53/67

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gas turbine based po!er generation system' Energy' *3' *0' 11+$-1*%.

0,. 8=argut ?. and 4orris .' Cumu"ative eergy consumption. Energy Research

10+,5 11' *3%-(1.

0+. 8=argut ?.' 4orris .R. and 8te!ard 7.R.' Eergy ana"ysis of therma"' chemica"

and meta""urgica" processes' Hemisphere'


61/67

1(. Tsatsaronis :.' Invited papers on eergy economics' Energy Int ?.' 1003' 10' *,0-

$+1.

1,. Tsatsaronis :.' Thermoeconomic ana"ysis and optimi=ation of energy systems'

Progressive Energy Comb.' 100$' 10' **,-*%,.

1+. Tsatsaronis :.' ;in ;. and Pisa ?.' Eergy costing in eergy economics' ?ourna" of

Energy Resources Techno"ogy' 100$' 11%' 0-1(.

10. Tsatsaronis :. and 4oran 4.?.' Eergy aided cost minimi=ation' Energy

Conversion and 4anagement' 100,' $+' 1%$%-1%3*.

11. Tsatsaronis :. and Par 4.H.' n avoidab"e and unavoidab"e eergy destructions

and investment costs in therma" systems' Energy Conversion and 4anagement'

**' 3$' 1*%0-1*,.

111. Tsatsaronis :. and Pisa ?.' Eergy economic estimation and optimi=ation of

energy systems5 app"ication to C:A4 prob"em' Energy' 1003' 10' *+,-$*1.

11*. Tsatsaronis :.' Ta!fi T.' ;in ;. and :a""aspy .T.' Eergetic comparison of t!o

GR) based I:CC po!er p"ants' ?ourna" of Engineering for :as turbine and

Po!er' 1003' 11(' *01-*00.

11$. Tsatsaronis :.' Ta!fi T.' ;in ;. and :a""aspy .T.' Eergetic comparison of t!o

GR) based I:CC po!er p"ants' ?ourna" of Engineering for :as turbine and

Po!er' 1003' 11(' $-$(.

113. Tsatsaronis :.' Recent deve"opments in eergy ana"ysis and eergy economics.

Internationa" ?ourna" of Eergy' *+' %' %-(.

11%. Tsatsaronis :. and )inho"d 4.' Eergy economic ana"ysis and estimation energy-

conversion p"ants-1. A ne! genera" methodo"ogy' Energy' 10+%' 1' (0-+.

11(. Oa"ero A. and Torres C.' n causa"ity in organi=ed energy systems9 II. 8ymbo"ic

eergy economics' >niversity of arago=a' 8pain.

11,. Oa"ero A.' ;erch 7.' 8erra ;. and Royo ?.' 8tructura" theory and thermoeconomic

diagnosis9 Part II' App"ication to actua" po!er p"ant' Energy Conversion and

4anagement' **' 3$' 1%10-1%$%.

11+. Oa"ero A. ;o=ano 4.A. and 8erra ;.' C:A4 prob"em9 efinition and

conventiona" so"ution' Energy' 10' 1003' *,0-*+(.

00


62/67

110. Oa"ero A. ;o=ano 4.A.' 8erra ;. and Torres C.' App"ication of the eergetic cost

theory to the C:A4 prob"em' Energy' 1003' 10' 0$0-0(.

1*. Oerda O.' 8erra ;. and Oa"ero A.' The effects of contro" system on

thermoeconomic diagnosis of po!er p"ants' *3' *0' $$1-$%0.

1*1. )a"" :.' Eergy f"o!s in industria" processes' Energy' 10++' 1$' 10,-*+.

1**. )a"" :. and :ong 4.' n eergy and sustainab"e deve"opment-Part19 Conditions

and concepts' Eergy Internationa" ?ourna"' *1' $' 1*+-13%.

1*$. Ories @. and


63/67

APPENDIX I

2./ plant power t$er-al re$eat nonbased Coal plant o5erall

and subsyste- plant .or e6uationse..iciencye&ergeticand ratendestructio E&ergy

−

8ubsystem Eergy destruction rate Eergy efficiency

@oi"er ...'

.

out in .uel o. e&ergyC$e-ical 1oil er 3 E E E E −+=.

..

'

.uel o. e&ergyC$e-ical

ininboiler %%

E

E E −=η

Turbine

Turbineout inTurbine 3 * E E E

....

'

.

−−=..

.

'

.

' 1

out in

Turbine 3

Turbine %%

E E

E

−−=η

Condenser out inCondenser 3 E E E ..

'

.

−=

out

inCondenser %%

E

E

.

.

' =η

7eed !ater

heaters

out in$eaterswater Feed 3 E E E ..

'

.

−=

.

.

'

.

' 1

in

$eaterswater Feed 3

$eaterswater Feed %%

E

E −=η

P"antco-ponents 4ll 3

Plant 3 E E '

.

'

.

∑= .uel o. e&ergyC$e-ical

out Net

Plant %%

E

* .

'

.

' =η

1$


64/67

APPENDIX;II

Plant Turbine=asCycleOpen .or Plant and co-ponents

plant .or #ation 3estructio E&ergyand #aten 3estructio E&ergy E..iciency E&ergetic '

.

'

.

.

'

.

.

.

'

.

.

.

'

..

'

.

..

'

.

'

.

sup'

.

.

'

.

plant .uel

inco-pout co-p

co-p 3

inco-pout co-pco-p 3

co-p

inco-pout co-p

pco-p

co-p P

co-p

E

E E y

#ation 3estructio E&ergy

E E E

n 3estructio E&ergy

*

E E

E

E

E..iciency E&ergetic

CO)P#EO#

−=

−=

−==ε

pla nt .uel

out co-bin .uel inco-b

co-b 3

out co-bin .uel inco-bco-b 3

in .uel inco-b

out co-b

pco-b

co-b P

co-b

E

E E E y


E E E E

n 3estructio E&ergy

E E

E

E

E


CO)1"TO#

'

.

'

.

'

.

'

.

'

'

.

'

.

'

.

'

.

'

.

'

.

'

.

sup'

.

'

.

−+=

−+=

+==ε

(*


65/67

plant .uel

net out turbinturb

turb 3

net out turbinturbturb 3

out turbinturb

net

pturb

turb P

turb

E

* E E y


* E E E

n 3estructio E&ergy

E E

*

E

E


T"#1%NE

'

.

.

'

.

'

.

'

.

'

.

'

.

'

.

'

.

'

.

.

sup'

.

'

.

−−=

−−=

−==ε

turb 3co-b 3co-p 3 plan t 3

plan t .uel

net

plan t

E E E E

n 3estructio E&ergy

E

*


P74NT

'

.

'

.

'

.

'

.

'

.

.

++=

=ε

(*


66/67

APPENDIX;III

1*

1$

6

1*

6

1$

1

6

1

1

6

1

6

1$

6

1*

6

%

6

3

6

3

6

1

6

*

6

1*

6

*

6

1

cos

E

E

E

E

E E

E E

E E E E

E E E

E E E

plant power

turbine gascycleopen .or tse&ergetict$e g calculatin .or used E6uations

=

=

==

=−−−

=−+

=+−

(3


67/67

APPENDIX;IV

plant power turbine gascycle

open .or PEC tse6uip-ent purc$ased t$e g calculatin .or E6uations 2/cos

Co-pressor 0.CWK/gKs2'1.,1

"n

1*11

1

*

1

*

1*

.

111

==

−=

C

p

p

p

p

C