Professional Documents
Culture Documents
Prepared by
Bradley R. Schaffer
Drexel University
Philadelphia, PA 19104
Submitted to:
Dr. William J. Danley of MEM 310 - Thermodynamic Analysis I
on
May 28, 2004
Abstract
With today’s soaring energy demands and continually increasing fuel costs, it is
plant’s efficiency. Companies that have high efficiencies in their plants are given an
upper hand in the market. Companies that don’t utilize the latest advancements in power
We’ve studied and simulated your system using our proprietary software that
utilizes the renowned Danley transfer functions and have concluded that the highest
efficiency obtainable is 41.06%. This was the optimal efficiency value that met all of
In addition to testing the system that you specified, we also did further research
and analysis on improving this efficiency. These improvement options range from
simple additions to your current cycle to scaling up projects to meet future demands
greater than 550 megawatts. The end result of these improvements has the potential to
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Table of Contents
Abstract……………………………………………………………………………………2
Solution……………………………………………………………………………………7
References………………………………………………………………………………..14
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Table of Figures
Table 1: Design Specifications………………………………………….........................15
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System Problem Statement
The objective of this project was to produce a 550 megawatt vapor power plant
that meets certain criteria yet maintains a high efficiency. To begin this problem, a
complete analysis of the Rankine cycle must be completed. The simplest form of this
isobaric condenser.
The cycle analysis starts with the condenser. The condenser is a heat exchanger
that acquires exhaust steam from the turbine and then removes heat from the exhaust until
it becomes a saturated liquid. This saturated liquid is then sent to the pump. The pump
then pressurizes the saturated liquid up to the turbine inlet pressure. After the liquid
leaves the pump, it is routed through a boiler which adds heat to the liquid, converting it
into a superheated vapor. At the final stage, the superheated vapor is sent through the
turbine which internally expands the steam and in return, the output shaft of the turbine
rotates. This mechanical energy is then used to turn the input shaft of a generator,
This is the simplest form of the Rankine cycle. This cycle will meet the output
requirement. However, it doesn’t meet the desired efficiency. The first attempt at
increasing efficiency was seen in the early 1920’s by implementing regeneration by the
use of feedwater heaters (See Appendix A). Feedwater heaters are heat exchanges that
use superheated steam bled from the turbine to heat the feedwater before it enters the
boiler. This increases the average temperature of heat addition which increases the
overall efficiency of the cycle (Cegel, 522). Feedwater heaters come in two types: open
and closed. The open feedwater heater mixes the superheated steam directly with the
5
feedwater. The advantage of this type is its simplicity and its high efficiency of heat
transfer. Conversely, the closed feedwater heater does not mix the two streams. The
advantage of this type is the superheated steam and the feedwater can be at two different
The second attempt at increasing efficiency was introduced in the late 1920’s by
using a reheat cycle (See Appendix A). The reheat cycle sends the exhaust from the high
pressure turbine back through the boiler before it enters the low pressure turbine. This
allows for greater high-pressure turbine inlet pressures without encountering moisture
problems. Higher boiler pressures mean higher feedwater temperatures entering the
boiler. This leads to a higher average temperature of heat addition which, in turn,
The given specifications for the cycle dictate a maximum temperature of 600 oC, a
maximum reheat temperature of 460 oC, a maximum feedwater heater exit temperature of
210 oC, and a maximum pressure of 20 Mpa. The problem also states a minimum
condenser temperature of 55 oC (See Table 1). Using these values and accounting for the
turbine and pump inefficiencies, the absolute overall maximum efficiency can be
calculated. However, the major problem lies in the quality of the low pressure turbine
a quality less than this. Variables must be adjusted to raise this quality yet maintain a
high efficiency.
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Solution
Once the transfer functions were properly connected, any changes made to the
variables instantly showed changes in both efficiency and the quality of the low pressure
turbine exhaust (See Appendix F). Knowing that the minimum quality was 98.5%,
variables could be changed one at a time until the desired quality was obtained.
The first variable that was experimented with was the maximum temperature.
When the maximum temperature was decreased, the efficiency dropped substantially but
no effect on quality was seen. The next variable that was modified was the condenser
acceptable quality levels. This reduced efficiency by 5.01%. After the condenser
temperature was tested, changes in maximum pressure were explored. This produced the
same results that were seen when the maximum temperature was decreased. Efficiency
was decreased but no effect on quality was seen. The maximum reheat temperature was
the next variable that was modified. As this temperature increased so did the quality of
the steam. The final variable that was manipulated was the temperature of the open feed
water heater exit. When temperature was decreased, quality increased sharply yet
variables were manipulated. The only combination that had the desired outcome of
higher quality was the minimum temperature and the open feedwater heater exit
temperature. The best combination that met all specifications was a lowered open
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The combination of lowered feedwater heater temperature and increased
efficiency could have been increased further if the open feedwater heater temperature had
been lowered below 165 oC and the condenser temperature kept at 55 oC. However, this
165 oC (See Table 3). Therefore, the condenser temperature had to be increased to
8
Discussion and Conclusion
efficiency of the cycle was 42.97%. When the quality requirements are taken into
account, the efficiency only dropped by 1.91%. This was the lowest possible drop in
Upon analysis of the variables and their impact on the cycle, the choice to modify
the temperatures of the feedwater heater and the condenser becomes clear. The following
analysis demonstrates how each variable impacts the cycle: The problem with the cycle
using the variables as given was that it didn’t meet the minimum steam quality upon
exiting the low pressure turbine. The factor that affects this quality was the entropy at
state 8 (See Appendix B). For a given condenser pressure, the quality increases
The first variable that was modified was the maximum temperature of the cycle.
Decreasing this value likewise causes a decrease in efficiency but does not affect quality.
The decrease in efficiency was due to the lowering of the average temperature at which
heat was transferred to the steam in the boiler. However, the maximum temperature has
no effect on the quality of the steam because it doesn’t affect the entropy of the steam
entering the low pressure turbine. The reheat cycle heats the steam that enters the low
previous components.
The second variable that was modified was the condenser temperature. This had a
substantial effect on efficiency and also had an effect on quality. The efficiency
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decreased because the average low temperature increased. However, the quality
increased due to the fact that as the condenser temperature rises, the decrease in sfg is
greater than the increase in sf. This produces an overall increase in the denominator that
is greater than the decrease in the numerator of the quality equation, thereby producing a
higher quality.
The third variable that was modified was the reheat temperature. As this
temperature decreased, both the efficiency and the quality also decreased. The reheat
cycle allows higher boiler pressures without causing moisture problems in the low
pressure turbine. The reheat cycle reheats the high pressure turbine exhaust before it
enters the low pressure turbine. This increase in temperature increased the entropy of the
superheated steam. The efficiency also increases due to the fact that as the maximum
pressure increases, the temperature of liquid entering the boiler increases which means a
The final variable that was modified was the open feedwater heater exit
temperature. As this temperature decreased, efficiency also dropped, but quality went up.
The efficiency declined due to the fact that as this temperature decreases, the feedwater
entering the boiler decreases as well which produces a lower average temperature of heat
addition in the boiler. However, the quality of the steam rises because as the temperature
of the feedwater heater decreases, the pressure of the steam entering the reheat cycle
superheated vapor after the reheat process is inversely proportional to its pressure.
In conclusion, there are only three variables that affect the quality of the low
pressure turbine exhaust. The first variable-- reheat temperature-- affects quality and
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efficiency in an adverse way. The only two variables that will increase quality are
these two variables lowered efficiency, they were modified in such a way that limited this
decrease. This system’s efficiency was only reduced by 1.91%. This decrease in
efficiency can be recouped along with a gain in overall efficiency through the use of
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Recommendations for Future Analysis
One addition that could be added to the original cycle is an additional feedwater
heater (See Appendix C). This type of addition could be done during a routine
heater could boost efficiency as high as 42.89% (See Table 4). This is gain of 1.83%
The cycle that was chosen for this additional analysis was based on the original
system with the addition of a closed feedwater heater. The open feedwater heater was
designed to heat the feedwater to a mid temperature between the condenser and the
closed feedwater heater. The closed feedwater heater was designed to heat the feedwater
to the original systems feedwater heater temperature of 165 oC. The first feedwater
heater was chosen to be an open type for its secondary purpose as a feedwater deaerater.
This prevents any air that may have leaked into the lines through the condenser from
entering the boiler which would otherwise cause internal corrosion. The second
feedwater heater was chosen to be a closed type. The advantage of a closed feedwater
heater is the ability to have the steam that heats the feedwater at a different temperature
than the feedwater itself. This means that the third pump only has to pressurize the
saturated liquid produced by the steam, which means a smaller pump will be suitable for
this task. This is advantageous for two reasons: the pump can be smaller which will save
Using the same values calculated in the first system, the increase in efficiency was
1.83%. This idea of increasing the number of feedwater heaters will continue to increase
the efficiency. However, with each additional feedwater heater, the change in efficiency
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continually decreases. A cost-benefit analysis must be done to decide how many
feedwater heaters will optimize the cycle. Some of today’s larger power generation
demand exceeds the wattage that the original cycle was designed to supply, a second
generation system may need to be implemented to increase the overall net output of the
power plant. A combined cycle, which is a combination of the Rankine cycle and the
Brayton cycle is a valuable cycle to consider (See Appendix D). This cycle can produce
efficiencies in the 50 percent range (See Appendix E). This is a greater efficiency than
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References
2. Kutz, Myer. Mechanical Engineers' Handbook (2nd Edition). New York: 1998
3. “Combined Cycle Plant Ratings,” [Internet]. Siemens. (2004 [cited 20 May 2004]);
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Table 1
Design Specifications
Design Specifications
Maximum feedwater heater temperature 210 oC
Maximum pressure entering the High pressure turbine 20 MPa
Minimum condenser temperature 55 oC
High pressure turbine adiabatic efficiency 89 %
Low pressure turbine adiabatic efficiency 93 %
Low pressure pump adiabatic efficiency 87 %
High pressure pump adiabatic efficiency 89 %
Minimum steam quality entering the condenser 98.5 %
Maximum steam temperature 600 oC
Maximum steam temperature exiting reheater 460 oC
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Table 2
Optimized Specifications
Maximum feedwater heater temperature 165 oC
Maximum pressure entering the High pressure turbine 20 MPa
Minimum condenser temperature 60.5 oC
High pressure turbine adiabatic efficiency 89 %
Low pressure turbine adiabatic efficiency 93 %
Low pressure pump adiabatic efficiency 87 %
High pressure pump adiabatic efficiency 89 %
Minimum steam quality entering the condenser 98.5 %
Maximum steam temperature 600 oC
Maximum steam temperature exiting reheater 460 oC
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Table 3
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Table 4
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Table 5
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Table 6
qin 3327.963
qout 1961.626
nth 0.410563
wnet 1366.337
y 0.175819
x8 0.9853
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Table 7
y 0.087954
z 0.073751
Qin 3410.247
Qout 1947.5
nth 0.428927
x 0.984997
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Appendix A
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Appendix B
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Appendix C
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Appendix D
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Appendix E
26
Appendix F
Low T to h fg hfg1
sf1
Low T to s f
T1
Low T to s fg sfg1
Low T to v f vf1
Low T to P P1 P8
T8
27
Mid T to h f hf3
Mid T to v f vf3
T3
Mid T to P
Mid P & T P6
P3
to s g
P2 P7
28
High T & P
to h g h5
T5 & P 5
Reheat
T&P s g7 sg8
to sg
T7 & P 7
Reheat
T&P hg7
to h g
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Appendix G
State 5: P4 = P5 T5 = 600oC
h5 = 3537.6 kJ/kg s5 = 6.5048 kJ/kg K
State 7: T7 = 460 oC
h7 = 3395.7 kJ/kg s7 = s8 = 7.8167 kJ/kg K
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State 8: P1 = P8 = 20.406 kPa
hf = 253.23 kJ/kg hfg = 2357.4 kJ/kg
sf = 0.8375 kJ/kg K sfg = 7.0661 kJ/kg K
s8 - s f
x = = 0.985 = 98.5%
s fg
h8 = hf + x hfg = 253.23 + 0.985 * 2357.4
h8 = 2575.9 kJ/kg T8=60.5 oC
ws h i - h os
ηP = = For Pumps/Compressors
wa h i - h oa
wa h i - h oa
ηT = = For Turbines
ws h i - h os
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High pressure turbine nT = 89 % = 0.89
.89 = (h5 – h6a)/(h5 – h6s)
h6a = 2775.22 kJ/kg
q out
η Th = 1 − = 0.4106 or 41.06%
q in
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Appendix H
Rankine Cycle
T (K)
s (kJ/kg K)
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