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M2 IGCC HRSG Enhanced Modeling and Simulation in Power Plant DR R R Joshi
M2 IGCC HRSG Enhanced Modeling and Simulation in Power Plant DR R R Joshi
BY
Dr RATNADIP R JOSHI
ratnadip.joshi@gmail.com
Cell Number: 09423332754
INTRODUCTION
Process Synthesis and Optimization
3
Origin of the Research Problem
4
Origin of the Research Problem Contd.
5
Enhanced Modeling and Integrated
Simulation of Gasification in Power Plant for
Capacity Enhancement and Clean Power
Production
6
Overview of a gasifier for power production with relevant processes 7
Process Flow Diagram for simulation of the power plant
8
Overview of HE skid for power production developed using HYSYS 9
Stages In Process Simulation
Apart from design considerations, IGCC performance depends on
numerous integration options and can be improved by process
optimization. These considerations include
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Model of Power Plant
Gas stream
•As gas turbines were modeled, gas streams had to be
considered. These contain:
•Air (as N2, O2 mixture).
•Gas fuel (containing CH4, C2H6, C3H8,
•n-C4H10, n-C5H12)
•Gas turbines
•This is a complex model consisting of three sections:
• a compressor;
• a combustion chamber with a pre-mixer for air and fuel;
and
• an expansion section
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Model of Power Plant
•Heat exchangers
•The exhaust gas of a gas turbine is hot enough to
generate steam at different pressure levels, for use as
process steam, in de-aeration or in steam turbines for
additional power generation. A fundamental model was
developed for the waste heat recovery section, consisting
of a series of heat exchanger models.
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Model of Power Plant
•Combustion reactions
•This model assumes the use of natural gas with the first 5
alkanes (methane, ethane, propane, n-butane and n-
pentane), identified as Cl,…,C5, respectively. The
combustion in air of each of these 5 hydrocarbons, is
described by an extent of reaction εi, i=1,…,5.
3i 1
C H
i 2i 2 O 2
iCO 2 (i 1) H O
2
2
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Methodology
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SIGNIFICANCE OF THE STUDY
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Analysis on the basis of
process simulation study and calculations
•2. The flow and pressure drop analysis of the system direct to
suction header indicates that under condition of bypass of tanks
is controlled solely by the orifice. An effective model was
developed when the same was controlled by a combination of an
orifice and a control valve.
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Analysis on the basis of process simulation
study and calculations
3. The maximum available fuel gas quantity is 55630 Nm3 / hr The
full amount of fuel gas available can not be utilised with the
existing gas conditioning skid in circuit.
4. Diesel Oil System :As per pressure drop calculation with a
recycle flow of 50m3/hr from tank back to pump ,the pressure
drop across the orifice under conditions of 1GTG to 4GTG’s
operating is from 48.432 m to 51.122 m i.e. within narrow range.
Therefore this scheme is practical to operate.
5. Gas hydrate formation is shown as possible scenario by the
simulation. Same is the case for FSNL condition at GTG4 inlet.
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Effect of humidity on power generation-
winter conditions
18
19
Complete Optimized PFD of Four Gas Turbines 20
21
Existing design capacities and design modifications in the system
Modified
Present Power generation, MW
Components Actual usage Design
Design
of Fuel Gas in practice, usage
Capacity, Existing
System Nm3/hr capacity, Modified Plant
Nm3/hr Plant
Nm3/hr
Fuel Gas
49517 27400 35630
System
High Pressure
Knockout 47400 27400 35630
Vessel
Fuel Gas
Conditioning 47400 27400 35630
Skid
Fuel Gas
93 131
Filter 47400 27400 35630
Separator
Fuel Gas
Super Heaters
16600 9130 11900
(Each of
Three Units)
Pressure
58000
Control 29000 27400
(Two sets)
Valves
22
Simulation of fuel gas and high pressure knockout vessel
along with scrubbers
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Simulation of heat conditioning skid
24
Simulation of gas turbine section with PRVs for
capacity augmentation
25
Comparison of Flow sheets with
3 GTGs and 4 GTGs
•Objective: 100 MW Power Generation:
•FDP-1 Fuel, 17% WC conditions:
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1. Analysis - With 3 GTGs:
•Maximum power that can be generated: 105 MW (35MW each)
•Required fuel supply: 35,630 Nm3/hr (31,000 kg/hr)
•Bottlenecks:
•1. The present High Pressure Knockout Vessel, Gas Conditioning
Skid, Filters are able to process a maximum of 27,400 Nm3/hr.
•2. Fuel Gas Super Heaters with 2 heaters are not sufficient. Third
Heater should be brought in operation. Three will operate partially
and this will hamper the efficiency by around 12%. In this case
there is no stand bye heater in the system, and 4th heater may
have to be provided as a stand bye
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2. Analysis - With 4 GTGs
• Maximum power that can be generated: 112 MW (28MW each) or
Not Not
GTG-4 Not present 5518 23.22
present present
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THANK YOU
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