Pergamon

Heat Recovery Systems & CHP Vol. 15, No. 7, pp. 619-630, 1995
Copyright 1995. Elsevier Science Lid
0890- 4332( 94) 00085- 9 Printed in Great Britain. All rights reserved
0890-4332/95 $9.50 + .00
COMPUTER SI MULATI ON OF A COMBI NED CYCLE POWER
PLANT
B. SEYEDAN, P. L. DHAR, * R. R. GAUR and G. S. BI NDRAt
Depar t ment of Mechanical Engineering, Indi an Institute of Technology, New Delhi-110016, India;
and l"Bharat Heavy Electrical Ltd, New Del hi - l l 0409, India
(Received 26 September 1994)
Abst ract --Thi s paper presents the simulation procedure developed to predict the performance of a
combi ned cycle power pl ant from given performance characteristics of its mai n components. In order t hat
the procedure could be validated, the simulation technique has been applied to a typical combi ned cycle
power pl ant (having a dual pressure bot t omi ng cycle) manufact ured by a promi nent company. The
characteristics of the st andard equipment like the air compressor, steam and gas turbines, various pumps,
etc. have been t aken from the manufact urer' s catalogues and converted into appropri at e equations based
on theoretical understanding. The performance of various heat exchangers (like economizers, super-
heaters, evaporators, etc.) has been determined by using the effectiveness concept after evaluating t he
overall heat transfer coefficient by using appropri at e correlations from literature. The strategy of system
simulation is obt ai ned by judiciously interlinking the i nformat i on flow diagrams of various component s
and t hus the task is finally reduced to t hat of solving nine non-linear equations for nine variables. The
predicted performance of the system is seen to be in good agreement with its rated performance.
a, b
A
A f
Aft
Arr
DPB
f
G
g
h
hr
hrg
HP, LP
Ja
k
L
M
n
nf
Nu
P
Pr
Q
Re
Rr
S
SD, SL, ST
tr
T
U
U
NOME NC L AT UR E
relative transverse and longitudinal pitch
surface area, m 2
fin area, m 2
free flow area in compact heat exchanger, m 2
heat exchanger front al area, m 2
specific heat at const ant pressure, J/ kg. K
t ube diameter, m
boiler gas side pressure drop, bar
friction factor
gas mass velocity, kg/s. m 2
gravitational acceleration, m/ s 2
convective heat transfer coefficient, W/ m 2. K; specific enthalpy, J/ kg. K
height of fin, m
l at ent heat of vaporization, J/kg
hi gh and low pressure
Jakob number
t hermal conductivity, W/ m. K
length, m
mass flow rate, kg/s
number of moles
compressor speed
number of fins/m
number of t ube in longitudinal and transverse directions
Nusselt number
pressure, bar
Prandt l number
heat transfer rate, W
Reynolds number
fouling factor, m2. K/ W
fin pitch, m
diagonal, longitudinal and transverse pitch of a tube bank, m
thickness of fin, m
absolute temperature, K
overall heat transfer coefficient, W/ m 2. K; fluid velocity, m/s
mass average fluid velocity, m/s
*Aut hor t o whom correspondence should be addressed.
619
620 B. SEYEDAN et al.
v s p e c i f i c v o l u me , m3 / k g
variable assumed in the simulation procedure
W work, J
x mole fraction
Greek letters
~/o o v e r a l l e f f i c i e n c y
Z correction factor
heat exchange effectiveness
p mass density, kg/m 3
~r Stefan-Boltzman constant; surface tension, N/m
iz viscosity, kg/s. m
Subscripts and superscriFts
c c o m p r e s s o r
e. i e x i t , i n l e t
f formation, fin, free stream(main flow)
g dry saturated steam, gases
m mean value over tube cross section
o outside, across
p pump
s surface condition
sat saturated
t turbine
V valve
A difference
l compressor inlet
2 compressor delivery
3 turbine inlet
4 turbine exit
I NT RODUCT I ON
With the twin crises of energy resources depl et i on and pol l ut i on increasingly engulfing our
civilization, it has become very crucial t o devel op mor e efficient and less pol l ut i ng t hermal power
plants, which are capabl e of effectively utilizing fuels like coal and nat ural gas, etc.
Gas t urbi nes ( GT) have, by now, pr oven t o be very compact and reliable types of power plants
having a very small gest at i on peri od and low capital cost. However , because of low efficiency due
to high exhaust t emperat ures, these plants did not hi t hert o find wide application. Despi t e this, by
using the exhaust heat of this gas t urbi ne cycle t o generate steam for a bot t omi ng Ranki ne cycle,
it is now possible to achieve much hi gher t hermal efficiency t han convent i onal st eam power plants.
Such combi ned cycle power plants are now clearly emerging as the most f avor ed t echnol ogy for
electric power generat i on, not onl y because of t hei r increased efficiency but also due to many ot her
operat i onal and envi ronment al advant ages discussed in t he l i t erat ure [1].
The design of such combi ned cycle (CC) power plants is obvi ousl y much mor e involved,
especially because of the coupl i ng between t wo different types of power - pr oduci ng cycles and the
need t o identify the opt i mal di st ri but i on of power pr oduct i on bet ween them. Ther e is t herefore a
need for devel opi ng comput er si mul at i on techniques which woul d enabl e eval uat i on of vari ous
possible design opt i ons and also permi t predi ct i on of off-design per f or mance of the system.
Thi s paper presents the details of a si mul at i on pr ocedur e which has been devel oped for predicting
the per f or mance of a typical CC power pl ant involving a gas t urbi ne coupl ed to a dual -pressure
bot t omi ng cycle t hr ough a waste heat recovery boiler. The pr ocedur e has been val i dat ed by
compar i ng its predi ct i on to the rat ed per f or mance of a typical 800 MW, t wo modul e combi ned
cycle power plant, each modul e of which consists of t wo gas turbines with t wo waste heat recovery
boilers feeding a single steam t urbi ne (Fig. 1).
COMP UT E R S I MULATI ON S TRATEGY
The task of comput er si mul at i on involves predicting the operat i ng condi t i ons of the system
(pressures, t emperat ures, energy and fluid flow rates) at which vari ous mass and energy balances,
all equat i ons of state of worki ng substances and the per f or mance characteristics of the individual
component s are satisfied [2]. Therefore, the availability of per f or mance characteristics of the
various component s const i t ut i ng the system is a pre-requisite f or system simulation. The st rat egy
Simulation of a combined cycle power plant 621
Z
L~
r j
L~
~ ~
g
LC
<
t - -
HRS 15/7--B
622 B. SEYEDAN et al.
of system simulation is strongly dependent on the manner in which the characteristics of various
component s are available. For the purpose of system simulation, these characteristics are best
represented by an i nformat i on flow diagram, which is essentially a block diagram indicating t hat
the out put variables are known functions of the input variables. Often, it is possible to re-arrange
the functional relationships and therefore the choice of input and out put variables is to some extent
arbitrary. It is therefore possible (and necessary) to choose the input and out put variables
judiciously to arrive at an optimal simulation strategy.
COMPONENT SI MULATI ON
The main component s of a combi ned cycle power plant system are the compressor, turbines,
l i qui d/ vapour heat exchangers, pumps, throttling valves and the condenser. The simulation of a
component implies prediction of the desired out put i nformat i on given the input i nformat i on and
physical dimension of the component .
C o m p r e s s o r
The characteristics of a gas-turbine compressor are usually given in the form of a graphical
relationship between three dimensionless numbers, namely the compressor mass paramet er (CMP),
compressor pressure ratio (CPR) and the efficiency (~/c). Knowi ng the mass flow rate handl ed by
the compressor and air inlet temperature, and the characteristic curves (or the equat i on representing
these), the work input to the compressor, the compressor discharge pressure (P2) and temperature
(7"2) can be comput ed as follows by using basic t hermodynami c relationships [3]:
Wc = C M P c p a x / ~ t p , ( c P a ~, L,~_ 1). (4)
T h e c o m b u s t i o n p r o c e s s
The fuel used in the combust i on chamber is nat ural gas composed of different constituents.
According to the first law for a steady-state steady flow, adiabatic combust i on process, the total
ent hal py of product s and the reactants is equal [4], i.e.
n~[h + A~]~ = ~ ne[h + AJ~]e. (5)
R p
The adiabatic flame temperature (TIT) is determined iteratively so t hat the above equat i on is
satisfied.
T u r b i n e s
The characteristics of turbines are also given by three dimensionless numbers, namely the turbine
mass paramet er (TMP), turbine pressure ratio (TPR) and its efficiency (~/,). The simulation of a
turbine implies det ermi nat i on of TMP, Or, exhaust gas temperature and the power out put , for
specified values of TPR and turbine inlet temperature (TIT). The basic t hermodynami c relations
used in the turbine calculation are [3]:
Mxxf~3 - A TPR, ~ (6)
r/t =f 4 ( TPR, ~ T 3 ) (7)
AT34=n, T3 1 \ T - - ~ / A (8)
Simulation of a combined cycle power plant 623
' Y-'q
\TIp-~f j . (9)
Pumps
The pumps mass parameter (PMP) and its efficiency (r/p) are primarily functions of the pump
pressure ratio (PPR). Using pump characteristics, the work input and outlet temperature are
computed from basic thermodynamic equations:
PMP = f5 (PPR)
r/p =f6(PPR)
Wp =fT(vr, PPR)
h2=ht + Wp
Condensate/feed water control valves
(10)
(11)
(12)
(13)
(14)
The steam cycle is fitted with a number of control valves to maintain the liquid levels in various
drums and the pressure in the deaerator constant under varying load conditions. The pressure
drop/flow rates through these valves under steady state conditions are therefore determined so as
to ensure the mass and energy balance of the drums downstream. Thus the pressure drop across
the condensate feed control valve (APvj) should be such as to ensure the mass balance of the
deaerator. Similarly, the pressure drop APv2 and APv3 are calculated so that the mass balance of
HP- and LP-drums are satisfied. The pressure drop APv4 is estimated on the basis of the energy
balance across the deaerator tank, so as to ensure a constant pressure in it.
Economizer~superheater heat exchangers
Economizers and superheaters are basically cross-flow heat exchangers of different configuration
provided at various sections of the boiler to raise water temperature and superheat the steam before
entry into the HP- and LP-turbines. The simulation of these heat exchangers involves determination
of the pressures and temperatures of outgoing streams for given pressures, temperatures and flow
rates of incoming streams. This is most conveniently done using the effectiveness concept:
Q = C m i n ( T g i - Two). (15)
Now the effectiveness of any heat exchanger can be determined once the NTU and heat capacity
ratio of the two fluids are known. The main task involved in heat exchanger simulation is thus,
the estimation of overall heat transfer coefficient U, which determines the value of NTU. This, in
turn, requires estimation of the gas-side and water/steam-side heat transfer coefficients, the
efficiency of fins employed on the gas-side and various fouling factors. The heat transfer
correlations used for simulation are given in Appendix A, and the procedure for calculation of
various pressure drops is given in Appendix B.
THE SYSTEM SIMULATION PROCEDURE
The system simulation strategy is obtained by suitably combining the information flow diagrams
of individual components of the system. This combination is effected through the interlinking
variables which appear as the output from one component and are used as the input in the other
component. The information flow diagram for the complete system, obtained by combining these
component information flow diagrams, is shown in Fig. 2.
It is obvious from the multinested nature of Fig. 2, that an iterative solution strategy would be
imperative. This necessitates assumption of suitable initial values to start the simulation. The best
strategy, as identified from the information flow diagram is to assume appropriate values of the
following variables and then the simulation of various components can be carried out sequentially:
(1) air flow rate through air compressor (Ma~f);
(2) gas-side pressure drop across boiler (DPB);
624
PF'r ('FIT)
B. SEYEDAN e l L l ] .
T C O N D [-
PCPH[
V A L V E
APvI
M a s s
M a s s
b a l a n c e
CONDENSATE
FEED PUMP
I
T 1
D
T c m p c r s t u r c
c o m p a r a b i l i t y
M a s s
b a l a n c e
TIT ( T ~ )
M a s s
c o m p a r a b i l i t y
I IP-TURB INE
PeOND (TcoND)
Q
V a r i a b l e s a s s u m e d
f o r t h e s y s t c m
I n p u t t o t h e s y s t e m
Q C o n s t a n t s
[ ] O u t p u t s u s e d f o r
c a l c u l a t i o n i n
other section
Fig. 2.
(3) HP- p u mp exi t pressure ( P r l P E I 1 ) ;
(4) LP- pump exi t pressure (PLPEI);
(5) HP- dr um pressure ( P D ~ ) ;
(6) HP- e c o no mi z e r II i nl et t emperat ure (THPEI2);
(7) LP- drum pressure (PD2)
(8) c onde ns e r pressure (Pcor~o);
(9) c o nde ns a t e c ont r ol val ve pressure dr op (APv~).
As i ndi cat ed, as s umi ng M,~r(V~), and kno wi ng t he c o ndi t i o n o f air at i nl et t o t he compres s or
and its charact eri st i cs, t he c ompr e s s or pressure rati o ( CPR) and its di scharge t emperat ure (T2) and
pressure (P2) are c o mput e d f rom t he s i mul at i on procedure. Thes e are t he i nput c o ndi t i o ns t o t he
c o mbus t i o n chamber. Fr om t he heat bal ance across t he c o mbus t i o n chamber, kno wi ng t he heat
o f f or mat i on o f each c ons t i t ue nt , t he t emperat ure o f gases at t he i nl et t o t he t urbi ne is i terati vel y
c o mput e d, s o t hat t he t ot al e nt hal py o f t he product s equal s t he e nt hal py o f t he react ant s. The
pressure dr op across c o mbus t i o n chamber is t aken as 2. 5% o f compres s or out l e t pressure. Thus
t urbi ne i nl et pressure can al so be cal cul at ed. As t he pressure dr op across t he boi l er is as s umed (V2),
S i mu l a t i o n o f a c o mb i n e d cycl e p o we r p l a n t 625
the pressure ratio across the turbine can be calculated and using it the turbine mass parameter
(TMP) and exhaust temperature (T4) are determined.
Since the deaerator pressure is kept constant, assuming HP- and LP-pump exit pressures
(1"3, V4), their mass flow rates (MNpp, MLpp) and efficiencies can be determined from the pump
characteristics. The WHRB calculations are now started from the HP-superheater, since that is the
first piece of equipment which meets the hot gases leaving the gas turbine in the system under
consideration (Fig. l). Knowing the pressure, temperature and the mass flow rates of incoming
streams and the design of the superheater, the pressures and temperatures of streams going to
the HP-turbine (PMsT, TMST) and the HP-evaporator (Tx~) and the pressure drop inside and
across the superheater [(APHPs)0 and (APHps)~] are determined using heat exchanger simulation
procedure.
The analysis of the HP-evaporator is carried out by assuming the drum pressure (V~). The
condition of liquid-vapour mixture (vapour quality xr), hot gases leaving the evaporator (Tp~) and
the pressure drop across tube bundles [(AP.PB)0], can then be found. The HP-economizer 2 is next
analyzed, by assuming economizer inlet temperature (1/6) and using the information already
available, as indicated in the information flow diagram (Fig. 2).
Similarly, the simulation of the LP-superheater (bare-tubes) and the LP-evaporator are carried
out using the effectiveness concept after evaluating the overall heat transfer coefficient by using
appropriate correlations. The HP-economizer-1 and the LP-economizer are arranged in parallel.
The outgoing gas condition are therefore determined by writing the heat balance of these two
together. The condensate preheater, which is placed at the rear section of WHRB, receives hot
water from the condenser at condensate temperature (TcoND). The preheater outlet temperature
(TcPHO), stack temperature (TsTACK) and the pressure drops inside and across the preheater
[(APcPH)0, (APcpH)d are determined from the simulation procedure. The pressure of water at the
inlet to the condensate preheater (PcPHt) can also be calculated, as indicated in the information
flow diagram.
The analysis of the HP-turbine is then carried out using the pressure and temperature conditions,
as calculated in the HP-superheater simulation, which are the inlet condition to the turbine and
the outlet pressure of steam leaving the LP-superheater, which forms the exit condition of the
HP-turbine. The turbine mass flow rate and exit temperature (MMsr, THPEX) c a n now be calculated
from the turbine characteristics. Using the basic mixing rule of thermodynamics, the condition of
steam at the entry to the LP-turbine is calculated. As the condenser pressure (I/8) is assumed,
LP-turbine analysis is conducted and the mass flow and steam exit conditions (MssT, TLPEX) are
determined.
The condenser simulation can also be carried out once the condensate pressure (1/8) and the flow
and temperature of the cooling water (Mcw~, Tcw~) are specified. The heat transfer in the condenser
(Qi) is thus calculated.
The pressure drop across the condensate feed control valve (V9) is also an assumed variable.
Using this along the value of condensate preheater inlet pressure (PcPm), the pressure at the exit
of the condensate feed pump can be determined. The performance (MFp , WFp ) of this pump can
now be determined as the inlet pressure, PCOND, had already been assumed.
The analysis of all the components of the system is thus computed, and checks are made to ensure
that the values of various assumed variables satisfy the following compatibility conditions:
(l) Mass balance across compressor and turbine.
(2) Energy balance of HP-drum.
Tabl e I .
Condenser Power out put
Fuel flow Compressor cooling wat er (MW)
rate inlet temp. inlet temp. Gas cycle Steam cycle Combi ned cycle
(kg/s) ( ' C) ( ' C) comput ed rated comput ed rated comput ed rated
6.23 27 32 139.06 139.24 109.0 108.73 248.06 247.97
7.76 27 32 199.8 199.2 128.5 131,1 328.3 330.3
9.01 50 36 236.9 235.6 156.5 158.83 393.4 392.0
9.43 27 32 259.9 260.4 150.9 151,0 410.8 410.0
10.0 27 32 281.0 279.0 158.6 162,4 439.6 441.4
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Simulation of a combined cycle power plant 627
(3) Mass balance across HP-pump and HP-turbine.
(4) Energy balance of LP-drum.
(5) Temperature matching at HP-Econ 2 inlet with HP-Econ 1 outlet.
(6) Mass balance of various streams at exit of HP-turbine and inlet to LP-turbine.
(7) Energy balance across condenser.
(8) Mass balance of deaerator tank.
(9) Pressure drop balance across boiler.
Consequently, the whole task of system simulation reduces to that of obtaining appropriate
values of nine variables so that the nine compatibility equations are satisfied.
S OL UT I ON T E C HNI QUE
It is obvious that these equations are highly complicated functions of the variables and, therefore,
it is extremely important to adopt an appropriate solution technique to achieve convergence to the
correct solution in the minimum computation time.
A review of various methods available shows that Warner' s method [5] is best suited for such
complicated non-linear equations. The most important feature of this method is that only one set
of error values needs to be calculated to determine the successive approximations to the correct
solution.
VAL I DAT I ON OF P R OGR AM
The validity of the procedure developed has been tested by comparing the predicted performance
of the system with the rated performance for a system designed by a reputed power plant
engineering company. Table 1 shows the comparison of power out put at various loads.
It is observed that the predicted and rated values of both the gas and steam cycles match to
within 1%.
A comparison of the corresponding operating conditions is given in Table 2.
C ONC L US I ONS
The present work describes the general procedure for the simulation of a dual pressure gas-steam
combined cycle power plant. The method has been tested by comparing its predictions with data
of a typical combined cycle; a very good correspondence between the predicted and the actual
performance has been obtained. With a slight modification, this approach can be adopted to suit
similar configurations encountered in practice.
R E F E R E NC E S
1. B. Seyedan, R. R. Gaur, P. L. Dhar and G. S. Bindra, Underst andi ng the characteristics and potential of combined
cycle power plants. 8th ISME Conf. New Delhi, March, 1993.
2. W. F. Stoecker, (editor), Proposed Procedure for Simulating the Performance of Components and Systems for Energy
Calculations. ASHRAE, New York, 1971.
3. H. Cohen, G. F. C. Rogers and H. I. H. Saravanamut t oo, Gas Turbine Theory, revised and enlarged edition. Longman
Group, UK, 1989.
4. G. J. Van Wylen and R. E. Sonntag, Fundamentals of Classical Thermodynamics. John Wiley & Sons, New Delhi,
1989.
5. P. L. Dhar and G. R. Saraf, Computer Simulation and Design of Refrigeration Systems. Khanna Publishers, Delhi,
1987.
6. F. P. Incropera, D. P. DeWitt, Fundamentals of Heat and Mass Transfer. John Wiley & Sons, New York, 1990.
7. Bejan Adrian, Heat Transfer. John Wiley & Sons, New York, 1993.
8. J. G. Collier, Convective Boiling and Condensation. McGraw-Hill, UK, 1972.
9. A. Zukauskas and J. Karni, High-performance Single-phase Heat Exchangers. Hemisphere, New York, 1989.
10. A. Zukauskas and R. Ulinskas, Heat Transfer in Tube-banks in Cross-flow. Hemisphere, New York, 1988.
11. R. H. Shah, E. C. Subbaro and R, A. Mashelkar, Heat Transfer Equipment Design, revised and enlarged edition.
Hemisphere, New York, 1988.
12. W. M. Kays and A. L. London, Compact Heat Exchangers. McGraw-Hill, New York, 1964.
628 B. SEYEDAN et al.
AP P E NDI X A
The effectiveness of cross-fl ow exchangers can be calculated f r om t he st andar d expressi on [6]:
For bot h fluids unmi xed
1
, = l - e x p [ ( c ~ ) ( NTU) 2 2 { e x p [ - C~ ( NTU) . 7 8 ] - I }] ; ( AI )
For C ..... (mixed) and Cm, . (unmi xed)
~ = [ 1 - e x p { - C r [ l - e x p ( - NT U) ] } ; (A2)
For all exchangers when C r = 0
e = 1 - e x p ( - NTU) ; (A3)
where NTU is number of t ransfer uni t s and C~ is t he heat capaci t y rat i o and t hese are given by
Cmi, UA
C~ = NTU . . . . .
l 1 R~ l n( do/ di ) R~'.h 1
~- ' + - - - - - + .... + - - (A4)
UA (qohA )~ (qoA )c 2rckL (qoA )h (rt0hA)h'
where c and h refer to col d and hot fluids, and Rr is t he foul i ng factor.
He a t t r ans f er coef f i ci ent f o r c onf i ne d f l o ws
For confi ned flow inside the t ubes, Nussel t number can be cal cul at ed by t he Gnielinski correl at i on [7]:
- - ( f / 8 ) P r [ R e o - 1000] F d0] 2/3
Nu - L I ~ I IA5)
I + 1 2 . 7 v / ( f / 8 ) ( P r 2~3- 1) + L ~
pUma,
ReD --
where Um is t he mean fluid velocity over t he t ube cross-sect i on and d i is t he t ube di amet er. Its range of validity is
0.5 < Pr < 106
2 3 0 0 < Re D < 5 106.
The fri ct i on fact or for s moot h t ubes is cal cul at ed by using t he equat i on r ecommended by Fi l oneko:
f =( 1 . 8 2 1 Og t o Re D - 1.64) 2.
Er apor al or
In t he evapor at or t he wat er is sat ur at ed at ent r y and onl y partially evapor at ed (typical vapour fract i on ~0. 2) when it
leaves it and re-ent ers t he evapor at or dr um. The cor r el at i on of Chen [8], whi ch has been widely r ecommended in t he
l i t erat ure for such si t uat i ons, has been used. Thi s cor r el at i on suggests t hat t he t ot al heat t ransfer in boi l i ng is cont r i but ed
by t wo component s:
hlp = he + hNs, (A6)
wher e he, t he convect i ve boi l i ng component , can be cal cul at ed as
- x ) d i o.s #c 0.4 kr
= 0"023IG(1L ~ ] [ k J r ' - pq [ , ~ ] [ "~(F), (A7) hc
where F is a funct i on o f the Mart i nel l i par amet er ( 1/ X. )
l ( x ~ 9 ( v ~ ' ( , g ~ "
x , , - \ ~; ~/ \ ~/ \u,7
and hy s , t he nucl eat e boi l i ng component , can be est i mat ed as
. ! F k079C o,4s 049 7
f Pf Pf 024 o . 7 5
hNc B = 0 . 0 0 1 2 2 / ~ , ~ 4 ] AT ~ , AP~t (S). (A8)
L a #r , , r g eg d
Chen suggest s t hat S can be r epr esent ed as a funct i on of t he local t wo- phase Reynol ds number . Chen gives graphi cal
rel at i onshi ps for est i mat i ng t he values of F and S as funct i ons of X~, and ReTp, respectively The fol l owi ng equat i ons have
been fitted to t hese gr aphs for use in t he comput er :
F = 1.361 + 0. 7788( ~u)
S = 0. 7194- 0. 8081 10-7Rerp,
where Revp = R e f F t25 ,
S h e l l - a n d - t u b e condenser
To cal cul at e t he shell-side heat t ransfer coefficient in t he condenser, t he well known Nussel t equat i on has been used [6]:
~D N = 0 799/gpl- (p' --P~)k~hf sl l l 4" - (A9)
- L ~ Y ~ - - T - S ~ j '
S i mu l a t i o n o f a c o mb i n e d cycl e p o we r p l a n t 629
wh e r e 1 a n d v r ef er t o t he l i q u i d a n d v a p o u r pha s e , N i s t he n u mb e r o f r o ws o f t ube s a n d Ts i s s ur f a c e t e mp e r a t u r e . Th e
c o r r e c t e d l a t e n t h e a t i s c a l c u l a t e d as f ol l ows :
h~g = hfg(1 + 0 . 6 8 J a )
J a c p ' ( T ~ t - Ts)
hrs
Gas - s i de he at t r ans f e r coef f i ci ent
Th e h o t ga s e s f l ow a c r os s t he t u b e b a n k s f o r me d b y t he v a r i o u s h e a t e xc ha nge r s . To e s t i ma t e t he he a t t r a n s f e r coef f i ci ent
a c r os s t he s e bundl e s , t he l a t e s t c o r r e l a t i o n s s ugge s t e d b y Z u k a u s k a s [9, 10] h a v e be e n used.
Fi nne d t ubes
Nuf = O. 192(a / b ) 2(s / do) l S( hf / do) - A' Re~65 pr~36( Pr r / Prw) 25
1.102 < Re < 2.104 ( AI 0 )
Nur = 0. 0507( a / b) ' 2( s / d0) ' n( hr / d0) - ' t 4Re ~Se r ' ( e r f / Pr , ) ' 25
2 . 1 0 4 < Re < 1.4 x 106
1.1 < a < 4 . 0
1.03 < b < 2 . 5
0. 07 < h / d < 0. 715
0. 06 < s / d < 0. 36 ( Al l )
Nuf = 0. 0081 ( a/ b ) 2( s / d o) l s( hr/ d o) - o t4Re 0.95pr 0.4 (prf/prw)0.25
2.105 < Re < 1.4 x 106
2. 2 < a < 4 . 2
1. 27 < b < 2 . 2
0. 125 < h / d < 0 . 6
0. 125 < s / d < 0. 28. ( A12)
Bar e t ubes
- - C R e m prO.36f P r ~ 1/4
Nu = ~, . . . . ~ P r J ( A13)
1000 < ReD.ma x < 2 106
0. 7 < Pr < 500.
Th e v a l u e o f c o n s t a n t C f or s t a g g e r e d t ube s i s gi ve n as
C = 0 . 3 5 ( S T/ S L) 1'5 m = 0. 60 f or S r / S L < 2
C = 0 . 4 m= 0 . 6 0 f o r S r / S L > 2 .
Th e v a l u e o f Re y n o l d s n u mb e r f or t he f o r g o i n g c o r r e l a t i o n i s b a s e d o n t he ma x i mu m ve l oc i t y o c c u r r i n g wi t h i n t he t u b e
b a n k . F o r s t a g g e r e d c o n f i g u r a t i o n , t he ma x i mu m ve l oc i t y ma y o c c u r a t e i t he r t r a n s v e r s e o r d i a g o n a l pl a ne . I t wi l l o c c u r
a t d i a g o n a l p l a n e i f t he r o ws a r e p l a c e d s uc h t h a t
2( S D - do) < ( S r - do) ,
whe r e
I- / S \ 2 q l n S _t_d
= S2L+ ~T < r ' _ O.
I n thi s case max i mum vel oei t y is gi ven by
ST
Urea x - - u.
2( S o - - do)
I f U~a ~ oc c ur s a t t r a n s v e r s e p l a n e f or s t a g g e r e d c o n f i g u r a t i o n , i t ma y be c o mp u t e d as
ST
Urea x - u.
S T - - d o
Fi n ef f i ci ency
Th e fi n ef f i ci ency i s de f i ne d as t he r a t i o o f a c t u a l he a t t r a n s f e r r a t e t o t he ma x i mu m h e a t t r a n s f e r r a t e t h a t wo u l d o c c u r
wi t h a fi n o f i nf i ni t e t h e r ma l c o n d u c t i v i t y . Th e ove r a l l ef f i ci ency o f a f i nned s ur f a c e i s c a l c u l a t e d as
Af
t/0 = 1 - - ~- (1 - t/r), ( A14)
whe r e t/f i s t he fi n ef f i ci ency a n d i s di s c us s e d i n r ef er ence [6].
HRS 15~7~C
630 B. SEYEDAN et al.
AP P E NDI X B
Estimation of pressure drop
The pressure dr op inside t he t ube [I 1] is given as
(Ap)lo~ = (Ap)r, ctio . + (Ap),.r,i,g. ( Al 5)
Frictional pressure drop. Fri ct i onal pressure dr op is cal cul at ed f r om t he convent i onal Dar cy equat i on [11]:
4 f L { 1 z \
(Ap)ffiction = ~ } p U ) , ( Al e)
where D h is t he hydraul i c di amet er and f is t he f anni ng fri ct i on fact or whi ch can be expressed as
16
f = Ree (for l ami nar flow)
0.046
f = ~ (for t urbul ent flow).
Pressure drop due to flow turning. The pressure dr op associ at ed wi t h flow t urni ng is expressed in t he f or m of
here k is t urni ng loss coefficient, whi ch consi st s o f t wo factors: K~ and Ko, K = K~ "K o, wher e K~ = loss coefficient for
90 and Ko = cor r ect i on fact or for t ur ni ng angle; bot h o f whi ch are cal cul at ed f r om reference [1 l].
Pressure drop outside unfinned tubes. The mos t recent and reliable cor r el at i on t o calculate pressure dr op across a bundl e
o f unfi nned t ubes, as r ecommended by Zhukauskas [7], is
y, iAlSi
wher e f is t he fri ct i on fact or, X is t he cor r ect i on fact or, whi ch are bot h eval uat ed f r om gr aphs given by Zhukauskas [7],
and N, is t he number o f rows.
Pressure drop outside finned tubes. The t ot al pressure dr op on t he fin-side across a heat exchanger core [12] can be
cal cul at ed as
Ap = G- ' . __ +( 1 +o ' 2 _ _ p i n - 1 . ( AI 9)
2Pi, L A~rp~, \ Pout
In this equat i on p is t he average densi t y eval uat ed bet ween inlet and out l et values
1 t / l 1 )
2 p in P o u t
P. , + Poo,
The maxi mum mass velocity, G, is given by
pUAfr rh
G = p U~ . . . . . .
Arf aAf~
In this equat i on cr is t he rat i o o f mi ni mum free-flow area of finned passage (cross-sect i onal area perpendi cul ar to flow
di rect i on), Aft, t o t he front al area, Aft, o f t he heat exchanger:
free flow area (ST -- do) -- (2trnrhr)
front al area Sr