“En busca de una generación térmica eficiente y sostenible.

Mejores prácticas y
alternativas”

To Convert a Simple Cycle Power Plant

into a Combined Cycle

Uirajara Vieria Jr, MSc Mech Eng - FAE

GE Energy

Uirajara.vieira@ge.com
1
What is a “Combined Cycle” Power Plant?
Uses 2 thermodynamic cycles to generate
electricity… Brayton - Gas Turbine & Rankine -
Steam Plant

The Brayton cycle gets its heat from burning the fuel.
The Rankine cycle uses heat rejected from the Brayton
cycle. 2
 Ideal Brayton Cycle

Fuel Combustion 3
q in
q in t .p
2 3 ns
1 o

Temperatur
Pressure
C
2 23 3
Co
ns 2

Co s
t. Generation 4
s

e
Work

ns
Compressor Turbine 4

t.
Out 1 4 st. p
1 Con
1
q out Heatq out
4 Rejected
Fresh Exhaust
Specific Volume Entropy S
Air
v
A Brayton Cycle is an all gas cycle where combustion
and exhaust take place at different, but constant
pressures.

Efficiency Area of Generation

= Total Area
3
 Ideal Brayton Cycle Efficiency
The theoretical maximum Brayton Cycle 3
p
thermal efficiency is a function of: q in nst
.
Co

Temperature
2
• The Compressor ratio - Ratio of Generation 4
Combustion to Atmospheric Pressure
• The maximum temperature achieved 1 st. p
Con q out
or the maximum temperature that the Heat
Rejected
machine can withstand Entropy S
• Ambient temperature

Expressed as: ηth = 1 - rp (1-k)/k

Where:
rp = Compressor Ratio
k = specific heat ratio of the working
fluid

4
 Rankine Cycle (Steam Side)

g
in

g
at

n
he
A Rankine Cycle is a condensing

ati
er

he
HPT

p
Su

Re
cycle. In our case, steam is Boiling

g
in
at
Absolute Temperature
condensed.

He
Electrical LPT

FW
Generation

Heat is added independent of Pump Condensation

pressure. LPT Exhaust

enters

(degF)
Heat Rejected condenser
to Condenser

Entropy (Btu/#/degF)

Efficiency =Area of Generation 5

Total Area
 Ideal Rankine Cycle Efficiency

g
in

g
at

n
he
The theoretical maximum

ati
er

he
HPT

p
Su

Re
Rankine Cycle thermal efficiency Boiling

g
in
at
is a function of:

He
Electrical LPT

Absolute Temperature

FW
Generation

• Boiler pressure Pump Condensation

• The max. temperature LPT Exhaust

enters
achieved (the max. Heat Rejected
to Condenser
condenser

(degF)
temperature the machine can
withstand)
Entropy (Btu/#/degF)
• Ambient temperature
Expressed as: ηth = (Wout - Win) / Qin
Where: Wout = work done by the system,
Win = work done on the system, and
Qin = heat added

6
Combined Cycle

7
8
Because it increases overall efficiency!
Fuel Energy In
GT Gen. GT Waste Heat (HRSG
Energy
ST Gen. In) ST Waste Heat
Total
Gen. Out the Stack
GT Gen.
GT Efficiency = Fuel Energy In ~
35% ST Gen.
ST Efficiency = HRSG Energy ~
35% In
Total
Overall Efficiency =Total
Gen.energy ~
58% ηOA = ηCT + ηSTIn - ηCT ηST
9
 Why use a Combined Cycle?

Let’s put in numbers…

907 MW (3 Billion BTU/Hr)
Fuel
GT
330 MW 577 MW
190 MW 349 MW
ST
520 MW
Total 38 MW
330 MW
GT Efficiency = 907 MW ~
36% 190 MW
ST Efficiency = 577 MW ~
33% 520 MW
Overall Efficiency = 907 MW ~
57% η = .36 + .33 - .36 x .33 = .57 = 57% 10
OA
 Combined Cycle
349
38 MW
MW
190
907 MW
MW

330
577
MW
MW

11
 GT/ST Combined Cycle

Advantages:
• Short Project Schedules ~ 24 Months
• High Thermal Efficiency ~ 50%
• Uses multiple fuels - Oil or Gas
• Quick Startup - 1 to 5 hours
• Low Environmental Emissions per
kW
• Operating Flexibility – Run CT’s
alone
• Easier to Operate and Maintain
Disadvantages:
• High Availability ~ 90%
• Burns “expensive” fuel.

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Things to take into account !
To convert your simple cycle power
•plant...
Fuel cost The higher, the more
likely!
• Dispatch profileThe higher, the more
likely!
• Enviromental permits
206FA needs ~ 250 m3/h
• Water Do you have water?207FA needs ~480 m3/h

• Footprint Do you have land?207FA needs ~ 180 x 330

m2
•Extra backpressure
• GT modificationsControl upgrade • Bottoming cycle
control
• Grid connectionIs it possible?~ 57% power increase
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Economics
• Fuel price: $3.00 to $6.00 /MM BTU-HHV
• Interest rates:
• Fixed charge: 18%
• Discount rate: 12%
• Escalation: 3%
• Costs
• STG ~USD 160/kW (reaheat) / ~USD 205/kW (non-
reheat)
• BoP ~USD 350/kW (SC) Æ USD 670/kW (CC)
• Schedule: HRSG ~14 month / STG ~18 month

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Steam Turbine Products

50% -

48% -
G12 3500# G3 3500#
46% -
Steam Turbine Efficiency (%)

44% - G9 2400#
D5 2400#
42% -
A15
Fossil ST
40% - D10

A14
38% -
D11 50Hz
36% -
D11 60Hz Combined Cycle ST
N2
34% - Nuclear ST
SC4
32% -
SC5
Small
ST 160 USD/kW
30% -| | | | | | | | |
0 100 200 300 400 600 1000 1400 1600
Output

205 USD/kW
15
3x6FA – vs- 206FA
200 MW power plant
example

16
3x7FA – vs- 207FA
500 MW power plant
example

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What can GE does for you, right now?
To support your decision...

• Perform specific heat balances for your

project...
• How much extra power can I get?
• How much water will I consume?
• What are my emissions?
• What is my best configuration? Which Steam
turbine?
• Provide preliminary cost estimatives ...
• Steam turbine
• HRSG & BoP (with ECP support)
• Lay out information
• Schedule planning
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• Others
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