Steam power plant cycle design

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Best Practices for Cycle Improvement
in Fossil-Fuel Steam Power Plants
1

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Best Practices for Cycle Improvement
in Fossil-Fuel Steam Power Plants
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 Current state of electricity production by fossil-fired power plants
 Steam power units improvement by high pressure turbine superstructure
 Reconstruction of steam power units into combined
 Replacement of the motor driven feed pumps with steam turbine driven
 Improvement of the regeneration system of a steam power plant
 AxCYCLE™ as tool for steam power plant cycle improvement implementation
 Demonstration of cycle redesign using AxCYCLE™
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Fuel Electricity Generation (1990-2040)
Source: U.S. Energy Information Administration – Annual Energy Outlook 2014 Early Release Overview.
http://www.eia.gov/forecasts/aeo/er/pdf/0383er(2014).pdf
18

Power Plant Improvement
 The important tasks in response to fuel resource depletion and the growth of
electricity consumption are efficiency improvement and capacity increase of fossil-
fuel steam power plants.
 The implementation of reconstruction projects and upgrading of available capacities
is a more optimal option of electricity generation development than the
construction of new energy generating capacities of thermal power plants.
 Improvement in the performance of existing power plants can be obtained by
modifying their thermodynamic cycles.
19

HR Improvement Projects
Source: National Energy Technology Laboratory (2008).
20

Power Plant Capacity & HR Improvement
1. Exclusion of additional losses and bringing the plant operation to
design conditions
2. Improvement of characteristics of separate cycle components and
systems
3. Cycle modification
21

The regional growth of energy demands requires greater electric generation. The increase in the power of an
individual power plant is the most expedient solution to the issue.
Steam Power Units Improvement
by Superstructure
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Superstructure consists of the addition of a new high pressure turbine to an existing power unit. Live steam at
first expands in the new turbine to a backpressure level that is slightly higher than the initial pressure of the old
turbine.
Assumed application effects:
 Increase in power generation without additional losses in the condenser
 Increase in cycle efficiency
High Pressure Superstructure
23

High Pressure Superstructure
Superstructure
PartialTotal
All steam MFR passes through
the new high pressure turbine.
Only part of steam MFR passes through
the new high pressure turbine.
Existing
Equipment
Additional
Equipment
Existing
Equipment
Additional
Equipment
24

Enlargement Based on Turbine K 100-90-7
Main parameters of K 100-90-7
Electrical power – 118 MW
Mass flow rate – 420 t/h
Live steam pressure – 8.8 MPa
Live steam temperature – 535 C
Condenser pressure – 3.5 kPa
Feed water temperature – 210 C
Process of Steam Power Plant Cycle in t-s
coordinates
25

Examined Cycles
Embodiment 1: Steam Power Plant with Total Superstructure
Embodiment 2: Steam Power Plant with Total Superstructure and Reheat
Embodiment 3: Steam Power Plant with Total Superstructure, Reheat and HP FWH
Embodiment 4: Steam Power Plant with Partial Superstructure
26

Embodiment 1
Processes of Initial Cycle (1-6) and Modified Cycle (1a-7a) in t-s
coordinates
Existing Equipment
New HP Turbine
with Generator
New SG
HP FWH operate under higher
FW pressure
Parameters of Superstructure:
Live steam pressure 19 MPa
Live steam temperature 535 C
Backpressure 8.8 MPa
Outlet steam temperature 411.8 C
Steam MFR 420 t/h
Electrical power 23.6 MW Feed
water temperature 210 C
Assumed parameters of new components:
HP turbine efficiency 0.9
SG efficiency 0.88
FW pump efficiency 0.8
Generator efficiency 0.98
Steam Power Plant with Total Superstructure
27

Processes of Initial Cycle (1-6) and Modified Cycle (1a-
8a) in t-s coordinates
Existing Equipment
New HP Turbine
with Generator
New SG and
Reheat
Steam MFR 420 t/h
Electrical power 21.7 MW Steam
temperature after reheat 535C
Steam pressure after reheat 8.8 MPa
Feed water temperature 210 C
Steam Power Plant with Total Superstructure and Reheat
Embodiment 2
28

Embodiment 3
Additional
Extraction
Additiona
l HP FWH
Steam MFR 448.8 t/h
Electrical power 23.2 MW
Steam temperature after reheat 535C
Steam pressure after reheat 8.8 MPa
Feed water temperature 245 C
Processes of Initial Cycle (1-6) and Modified
Cycle (1a-9a) in t-s coordinates
Steam Power Plant with Total Superstructure, Reheat and Additional FWH
29

Splitter
Existing SG
Live steam pressure 1 9 MPa;
Live steam temperature 535 C;
Backpressure 9.4 MPa;
Steam MFR 210 t/h;
Electrical power 10.9 MW; Steam
temperature after reheat 535 C;
Steam pressure after reheat 8.8 MPa;
Feed water temperature 213 C.
Processes in t-s coordinates for modified cycle:
0.5 steam MFR operates according to initial process 1-7; the other
steam MFR operates by process 1a-2a-3a-4a/5-…-3
Steam Power Plant with Partial Superstructure
Embodiment 4
30

Type of scheme
Electrical
Power, MW
Net power, MW
Outlet steam
quality
Heat
consumption,
kJ/s
Heat Rate,
kJ/kWh
Thermal
Eff
Original SPP K-100 118.791 117.736 0.88 353310 10836.25 0.332
Embodiment 1
(Total superstructure)
125.066 122.05 0.82 332475 9806.72 0.367
Embodiment 2
(Total superstructure
with Reheat)
140.507 137.483 0.88 359785 9421 0.3821
Embodiment 3
(Total superstructure
with Reheat and FWH)
141.997 138.767 0.88 361279 9372 0.3841
Embodiment 4
(Partial Superstructure)
129.649 127.367 0.88 356476 10075.72 0.3573
Calculated Performances
31

Reconstruction of Existing Steam Power Plants Into
Combined Power Plants
Power generation via combined-cycle plants is one of the most effective techniques of rational energy
conversion, as it involves a more complete energy use.
32

Addition of Upper GTU
Transformation of the existing steam turbine plant into a combined power plant with the addition of upper GTU
allows the increase of their power production and thermodynamic efficiency.
Main tasks:
 Selection of a means of flue gas heat recovery
 Selection of a suitable upper gas turbine (power, flue gas parameters)
FG Heat Utilization
HRSG FW Heating
+ High efficiency;
+ Thermal scheme of steam
cycle is unchanged;
- SG replacement is required.
+ SG left unchanged;
+ Increased power of steam turbine;
- FWH replacement by FG/water
heaters is required;
- Increased condenser load;
- Decreased efficiency of bottoming
steam cycle.
33

Examined Combined Cycles
Embodiment 1: Upper GTU and Steam Power Plant with discharge of the gas turbine exhaust to HRSG
Embodiment 2: Upper GTU and Steam Power Plant with use of the gas turbine exhaust for heating of
feedwater
34

Initial Steam Turbine
Parameters of Steam Power Plant:
Electrical power 39.3 MW
Mass flow rate 40 kg/s
Live steam pressure 80 bar
Condenser pressure 0.085 bar
Pumps efficiency 0.8
FW temperature 165 C
Boiler efficiency 0.85
Process of the steam cycle in t-s coordinates
35

Embodiment 1
Performances of the upper GTU (Alstom
GT11N2):
Electrical output 113.7 MW
Electrical efficiency 33.3 %
Exhaust gas flow 400 kg/s
Exhaust gas temperature 524 C
GT Exhaust Discharged to HRSG
36

Performances of the upper GTU (GE 10):
Electrical output 11. 7MW
Electrical efficiency 32%
Exhaust gas flow 47.216 kg/s
Exhaust gas temperature 483 C
GT Exhaust is Used for Heating of the Feedwater
Embodiment 2
37

Addition of Upper GTU
Type of scheme
Electrical
Power, MW
Net Power,
MW
Heat
Consumption,
kJ/s
Heat Rate,
J/Wh
Thermal Eff
Initial Steam Power Plant 39.35 38.909 107374 9934.65 0.36
Embodiment 1: GT Exhaust
Discharged to HRSG
153.048 152.607 330059 7786.86 0.462
Embodiment 2: GT Exhaust
for FW Heating
53.331 52.890 137375 9350.43 0.385
38

Replacement of the Motor Driven Feed Pumps by Steam
Turbine Driven
39

The history of turbine construction around the world shows that the replacement of the motor driven feed
pumps with the steam turbine driven pump allows an increase of up to 0.7 % in fuel economy.
Main task: Definition of the location of steam extraction from the main turbine to supply turbine drive and the
Replacement of the Motor Driven Feed Pumps with Steam Turbine Driven
Feed Pump Replacement
40

Advantages:
 Reduction of the auxiliary power consumption
 Fuel economy due to exception of few intermediate members
in the process of energy transfer from steam to feedwater
pump.
Field of Application:
 Powerful steam plants (when power production exceeds 200-
250 MW)
 Power plants with high live steam pressure.
Feed Pump Replacement
41

Improvement of the Regeneration System of a Steam
Power Plant
42

Regeneration System Improvement
Addition of drain coolers and superheated steam
coolers to feedwater heaters
Modification of drain system with cascade condensate
drain
Advantages:
 Increase in the feedwater temperature
 Reduction of the amount of heat discharged into the condenser
 Full utilization of the extracted steam heat
43

240 MW Power Plant (Initial Scheme)
Main parameters of Steam Power Plant:
Mass flow rate 740 t/h
Live steam pressure 150 bar
Live temperature 537C
Back pressure 0,1033 at
FW temperature 242 C
44

Efficiencies new components:
Driving steam turbine efficiency 0.85
Feedwater pump efficiency 0.8
Drain pump efficiency 0.8
Parameters of steam coolers and drain coolers:
FW underheating to hot steam saturation
temperature in SC1 and SC2 -0.36 C
Temperature difference between inlet FW
and outlet drain in DC1 and DC2 5 C; 9 C
DC1
DC2
SC1SC2
240 MW Power Plant (Modified Scheme)
45

Initial vs. Modified Schemes
Parameter Initial Design Modified Cycle
1 Electrical Power Production (EPP), MW 246.365 240.85
2 Total Power Consumption, kW 6475.19 403.843
3 Net Power Production (NPP), MW 239.890 240.446
4 Heat Consumption, kJ/s 623640 618692
5 Thermal Efficiency, % 38.47 38.86
6 Heat Rate by EPP, kJ/kWh 9112.92 9247.63
7 Heat Rate by NPP, kJ/kWh 9358.89 9263.166
8 Gain in Thermal Efficiency, % - 0.39
9 Gain in Net Power Production, MW - 0.556
10 Heat economy, kJ/s - 4948
11 Heat Rate decrease (NPP), kJ/kWh - 95.724
46

AxCYCLE™ as Tool for Steam Power Plant Cycle Improvement Implementation
Analysis and redesign of the thermodynamic cycle of a steam power unit are the first and most important
phases of the unit performance improvement process. Solving these tasks with minimal time and financial costs
is impossible without the use of reliable and effective tools. Today, a wide range of software products for the
thermodynamic simulation of cycles is available for engineers and researchers, but not all of the software is
universal. Additionally, not all of them contain the necessary tools and features for the cycle redesign.
AxCYCLE is best suited for solving the tasks of analysis and redesign of steam power plant cycles. All
mentioned embodiments of improvement of steam turbine cycles were realized with the AxCYCLE program
without any essential efforts.
47

AxCYCLE™ as Tool for Steam Power Plant Cycle Improvement Implementation
AxCYCLE advantages for cycle redesign problems:
 Easy to use
 All necessary components are included
 AxCYCLE allows to solve simulation tasks in different statements with minimal set of initial data
 AxCYCLE includes a lot of useful tools, that facilitate and accelerate the solution of the cycle redesign
problem.
48

Technical Demonstration

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Contact
Europe Contact:
switzerland@softinway.com
Phone: +41 44 586-1998
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Switzerland
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Phone: +1‐781‐685‐4942
15 New England Executive Park
Burlington, MA 01803
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Steam power plant cycle design

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