This document describes a computer-aided energy and exergy analysis (EEA) program developed to evaluate the performance of steam power plants. The program can analyze all main systems of a power plant, including the boiler, turbine, condenser, and feedwater heaters. It calculates the energy and exergy destruction of each system as well as the overall plant efficiency. The program was validated using data from previous studies and found to have errors less than 3%. Analysis of a 350 MW power plant in Egypt showed that the condenser accounts for most energy destruction while the boiler has the highest exergy destruction. Operation at full load and in later years showed improved efficiencies. The program provides a more detailed and flexible analysis compared to previous

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‫ه‬‫الر‬ ِ‫ن‬َ‫م‬ْ‫ح‬‫ه‬‫الر‬ ِ ‫ه‬‫اَّلل‬ ِ‫م‬ْ‫س‬ِ‫ب‬ِ‫يم‬ ِ‫ح‬
"‫ا‬ً‫م‬ْ‫ل‬ِ‫ع‬ ‫ي‬ِ‫ن‬ْ‫د‬ ِ‫ز‬ ِِّ‫ب‬َّ‫ر‬ ‫ل‬ُ‫ق‬َ‫و‬"
‫طه‬114
In The Name Of Allah, The Most Beneficent, The
Most Merciful
“And say: My Lord! Increase me in
knowledge”
Ta-Ha' Verse 114

2. 2
Computer - Aided Evaluation of Steam
Power Plants Performance Based on
Energy and Exergy Analyses
‫الطاقة‬ ‫أساس‬ ‫على‬ ‫البخارية‬ ‫ارية‬‫ر‬‫الح‬ ‫المحطات‬ ‫تقييم‬
‫اآللى‬ ‫الحاسب‬ ‫بمساعدة‬ ‫اإلتاحية‬ ‫و‬

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4. 4
Eng. AHMED Noaman Ahmed
Kamal
Operation Engineer
Cairo Electricity Production
Company
Cairo West Thermal Power Plant
Units (7 & 8)
Mechanical Engineering
Department
Shobra Faculty of Engineering
Benha University

5. 5
Supervisors

6. 6
Prof. Dr.
EED A. ABDEL-HADI
Professor
Mechanical Engineering
Department
Shobra Faculty of Engineering
Benha University

7. 7
Prof. Dr.
SHERIF HADY TAHER
Professor
Mechanical Engineering
Department
Shobra Faculty of Engineering
Benha University

8. 8
Ass. Dr.
ISLAM HELALY ABDEL-AZIZ AFIFI
Associate Professor
Industrial Engineering
Department
Faculty of Engineering
Fayoum University

9. 9
Introduction

10. 10
• Energy is the cornerstone of the economic
development
Growing Energy Consumption
Depletion of Energy Resources
Energy Crisis
Electricity Shortage

11. 11
Solutions to Energy Crisis
Management of Energy
Production
Transmission
Usage
Alternative Energy
Solar Energy
Wind Energy
Geothermal Energy
Biofuel and Ethanol

12. • Countries pay money for
less power.
• Increasing the efficiency
will save resources and
money.
12
• Significant part of power is lost without any
benefit.
Management of Production Energy

13. 13
Main Objective
Solving Energy Problem
Increase Power Plant
Efficiency

14. 14
Indicate systems responsible for destruction
Calculate Main Systems Energy and Exergy
Efficiency Destruction
Possible ways to
Increase Efficiency Reduce Destruction

15. Energy and Exergy Analyses
Exergy is the maximum shaft work
It is used to analyze thermodynamics systems
15
Law of Thermodynamics
First
Quantity of
Energy
Second
Quantity of
Energy
Quality of Energy

16. Energy and Exergy Analyses for
Power Plants
Traditional Method
Computer Application
Method
16
Manual
Calculations
Write Codes
Calculations Graphs

17. 17
Author Energy and Exergy Analyses
Aljundi, 2009 Al-hussein Power Plant in Jordan
Ameri, 2009 Hamedan Power Plant in Iran
Erdem, 2009 Coal-fired Power Plants in Turkey
Rashad, 2009 Shobra El-Khima Power Plant
Traditional method
• Condenser: responsible for energy destruction
• It is thermodynamically insignificant.
• Boiler: responsible for exergy destruction
Results

18. 18
Author Computer Application
Ahmadi and Toghraie,
2016
EES (Engineering
Equation Solver)
Ahmadi and Dincer , 2011 Matlab Code
Singh et al., 2012 C++ Code
Al-Bagawi, 1994 Fortran Code
Fungtammsan, et al.,
1990
Turbo Pascal Code
Computer Application Method

19. 19
• Neglect fuel volumetric analysis
• Some mechanical systems are not
mentioned (De-superheat)
• Specified for the studied power plants
• Require source code modification
• Not interactive
From previous work we can
conclude that:

20. 20
Visual C# EEA
Crystal
Reports
EEA creation steps
• Applicable for all Steam Power Plants
• Cover the shortage in the earlier programs
• Overcome the problems of these programs
• Energy and Exergy Analyses (EEA)
Therefore the proposed computer
program aimed to:

21. • Determine energy and exergy analysis of the
power plants in detail.
• Determine systems and cycle energy and
exergy:
Destruction
Efficiency
• Determine main components responsible for
energy and exergy destruction.
• Cover many systems existed in power plants
21
EAA Specifications

22. • Add more details for each system
• Cover a wide range of hydrocarbon fuels
• Fuel volumetric analysis
• Introduce the results in tables and charts.
22

23. 23
EAA validation

24. 24
Study (kW) EEA (kW) Error %
Total Energy
Destruction
856 831.8 2.9
Exergy Destruction
Heater 1 438 442 0.9
Heater 2 359 356.63 0.66
Deaerator 355 351.06 1.12
Heater 4 377 377.45 0.12
Heater 5 295 294.46 0.18
• Feed-water heating system
Aljundi, 2009

25. 25
Study EEA Error %
Condenser Energy
Destruction
306.9
kW
308.81
kW
0.62
LHV of fuel
volumetric analysis
49433.96
kJ/kg
49427.307
kJ/kg
0.01
• Condenser
• Fuel volumetric analysis
Ameri et al., 2009

26. • Cairo West Thermal Power Plant (Units 7 & 8)
• 2 X 350 MW
• Boiler : Babcock-Hitachi
Drum type natural circulation
Natural gas / Heavy Fuel Oil fired
Forced draft fans
• 3 stages turbine : Mitsubishi Heavy Industries
• Water cooled condenser
• 8-Stage regeneration system
• Water pumping system : Termomeccanica Pompe
26
Power Plant Description

27. 27
Power Plant Layout

28. 28
Governing Equation
• Energy equation
• Exergy equation

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I. Energy balance for steady flow
through control volume
• 𝑸 = 𝑾 + 𝒆 𝒎 𝒉 − 𝒊 𝒎 𝒉
• 𝒉 = 𝒉 + 𝑽 𝟐
𝟐 + 𝒈𝒁

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II. Exergy balance for adiabatic
steady flow through control
volume
• 𝑾 + 𝒆 𝒎. 𝒆𝒙 − 𝒊 𝒎. 𝒆𝒙
+ 𝑬𝒙 𝒅𝒆𝒔 = 𝟎

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• Boiler
• Turbine
• Condenser
• Condensate pump
• Feed-water pumps
• Feed-water heaters
Thermodynamics model of the main
systems of the power plant

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Boiler’s thermodynamics model

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•Ql,B =
•(m. h)f + (m. h)air + (m. h)33
•+(m. h)11 + (m. h)27 + (m. h)29
•−[(m. h)9 + (m. h)12 + (m. h)AH,eg]
•ηΙ,Boiler =
•m9. h9 + m12. h12 −
•
(m34.h34+m11.h11+m27.h27+m29.h29)
mf.CV
Energy analysis

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•Fuel = WB,i + Exf + Exair
− ExAH,eg
•Product =
•Ex9 + Ex12 −
•(Ex33 + Ex11 + Ex27 + Ex29)
•Destruction = Fuel
− Product
Exergy analysis

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𝑰 = WB,i + Exf + Exair + Ex33
+Ex11 + Ex27 + Ex29 −
(Ex9 + Ex12 + ExAH,eg)
𝜼𝚰𝚰,𝑩𝒐𝒊𝒍𝒆𝒓 =
Product
Fuel
= Ex9 + Ex12 −
(Ex33 + Ex11 + Ex27 + Ex29)
WB,i + Exf + Exair − ExAH,eg

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• Boiler has the lowest exergetic efficiency
Results at 175 MW

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Condenser is the main source of energy
destruction with 81%.
Boiler is the main source of exergy destruction
with 88.1%.

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Exergy destruction in boiler is due to:
Combustion process
Boiling and super-heating process

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Comparison between design
data at 175 MW 350 MWI

40. 0
5
10
15
20
25
30
35
40
45
50
Thermal Efficiency Exergetic Efficiency
34.575
45.32
38.53
48.049
Power Plant Efficiency Comparison
175 MW 350 MW
40
Operation at full load is more efficient

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Boiler is responsible for efficiency increment
0
10
20
30
40
50
60
70
80
Boiler Efficiency Combustion Efficiency
49.54
74.65
51.36
76.47
175 MW 350 MW

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Boiler is responsible for efficiency increment
0
5
10
15
20
175
MW
350
MW
Air / Fuel 19.24 16.66
1800
1900
2000
2100
2200
175
MW
350
MW
AFT 1944 2153
°C

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Comparison between
recorded parameters in
2011, 2013 and 2015
II

44. 39.517
33.87
37.919
45.952
41.798
44.423
0
5
10
15
20
25
30
35
40
45
50
2011 2013 2015
Efficiency(%)
Power Plant Efficiency in Different Years
Thermal Efficiency Exergetic Efficiency
44
Cycle thermal and exergetic efficiency
decreased in 2013

45. 45
Boiler
99%
Boiler
Turbine
Condenser
Heaters
Deaerator
Destruction increment in 2013 = 56.6 MW

46. 2011 2013 2015
Gross Energy Efficiency 76.991 69.29 75.308
Fuel Energy Efficiency 86.966 78.375 85.076
Exergetic Efficiency 51.049 45.757 49.921
20
30
40
50
60
70
80
90
100
Boiler Efficiencies
46
Thermal and exergetic efficiencies of
the boiler decreased in 2013

47. 2011 2013 2015
Boiling and Superheating
Process Destruction (MW)
82.16 126.42 89.83
Combustion Process
Destruction (MW)
108.47 120.44 113.31
Fuel Flowrate (t/h) 30.61 35.73 32.04
20.00
40.00
60.00
80.00
100.00
120.00
140.00
Destruction(MW)
Exergy Destruction in Boiler Processes
47
• Boiling and super-heating process
• Combustion process
Exergetic destruction

48. 48
Using the fuel oil number 6 (Mazout) led to:
1. Corrosion occurs in the burner impeller and
gas spuds.

49. 49
2. Ashes and deposits:
Fouled the boiler tubes
Clogged the spaces between the tubes

50. 50
• Damaged parts are replaced
• Chemical cleaning
Major Overhaul In 2015

51. Old Programs EEA
Specified to the studied
power plants
General and applicable to
any steam power plant
Some mechanical
systems are not
mentioned
Cover a wide range of
systems
Neglect fuel volumetric
analysis
Consider fuel volumetric
analysis
Source code should be
edited to be used
No need for source code
editing
Not interactive
work line by line
Interactive program
Edit any system at any time51
Advantages of EAA

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• Condenser is the main source of energy
destruction with 81%.
• Boiler is the main source of exergy
destruction with 88.1%.
• Boiler has the lowest exergetic efficiency
with 51%
• Operation at full load is more efficient.
• Exergy destruction in boiler is due to:
• Combustion process
• Boiling and super-heating process
Conclusion

53. 53
• Further thermodynamic analyses of the
Cairo West Thermal Power Plant at
mixed firing.
• Upgrade the EEA to cover more systems:
• Gas Turbine system
• Combined Power Plants
• Geo Thermal Power Plants
• Solar Power Plants
Recommendations

54. 54
Thank you for your
attention
Ahmed Noaman Ahmed Kamal ElZayati
P.G. Student,
Dept. of Mechanical Engineering Department
Shobra Faculty of Engineering
+201113610115
Eng.pow.ahmed@gmail.com