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Gas Turbine Direct Integration in the Context of Pinch

Technology
By K. Sarabchi* and G. T. Polley

Gas-turbine-based cogeneration systems have been widely used in different applications in recent years. Although the most
common method of using gas turbine exhaust energy is through the generation of steam in a heat recovery boiler, there are some
applications where the exhaust energy has been directly used for drying or process fluid heating. In this work, direct integration
of a gas turbine with a process was fully investigated in the context of pinch technology. This investigation includes simple gas
turbine and gas turbines equipped with recuperator and afterburner. It was found that the best thermodynamic efficiency in a
direct gas turbine system is achieved when two conditions are met: first, turbine inlet temperature is maximized, second,
optimum pressure ratio is that which yields the maximum specific network. Two total cost optimization methods were also
introduced. The first method is based on the assumption that power produced equates to power demand. In the second approach
the power export opportunity was also considered. Finally, illustrative examples have been presented to show how approaches
can be applied in practice.

1 Introduction 2 The Process Utility Interface

The most common method of integrating a gas turbine into
an industrial facility is through the use of exhaust energy for
steam generation. Yet, there are other applications where the
exhaust energy has been directly used for drying or process
fluid heating, as well as a source of preheated combustion air
for process heaters and boilers.
The use of gas turbines to produce power is an attractive
option for ethylene plants, since, by utilizing the exhaust gas as
combustion air for the cracking furnaces, the energy required
per unit of ethylene produced can be reduced [1,2]. The power
produced by the gas turbine can be utilized either for
mechanical drives or to produce electric power for in-plant
use or export.
In this work gas turbine direct integration (GTDI) with a
process plant will be investigated in the context of pinch
technology.
In the pinch analysis approach the grand composite curve
(GCC) [3] is used to identify the appropriate placement of a
single utility or multiple utilities in order to achieve an energy-
efficient system.
Townsend and Linnhoff [4] have used GCC to identify a
ªthermodynamic bestº appropriately placed heat engine.
Later on, Linnhoff and De Leur [5] have used GCC for
simultaneous design of processes and furnaces as a unified
thermal system.
Balanced GCC [6,7] as a complement to GCC has been used
to target more complex utility mixes, such as a furnace and
multiple steam level [8].
Processes generally need an external source of heat and an
external sink for heat rejection in order to operate efficiently.
These are provided by the factory's utility system.
Utilities do not always have to be provided at the
temperature extremes of the process. It is often found that
heat can be added to the process over a range of temperatures
down to the pinch point and rejected from the process over a
range of temperatures starting at the pinch point.
The scope for using utility at different temperature levels
can be identified using the process grand composite curve
(Fig. 1). The construction of this curve is described in the
Process Integration User Guide [3]. It is a graphical
representation of the process heat cascade and shows where
heat demand can be satisfied by heat recovery and where it
needs to be satisfied using utility. In doing so it shows the
distribution of the utility needs across the whole temperature
span of the process.

±
[*] K. Sarabchi, Mechanical Engineering Department, Faculty of Engineer-
ing, University of Tabriz, Tabriz, Iran; G. T. Polley, www.pinchtechnolo-
gy.com Figure 1. General features of GCC.

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With directly integrated gas turbines the hot utility takes the
form of hot gas coming from the gas turbine exhaust. If the
effect of temperature on the specific heat of the gas is ignored,
the utility profile is a straight line of slope equal to the
reciprocal of the heat capacity flow rate of the gas.
Now consider the two utility lines shown in Fig. 2. Both
profiles release the same quantity of heat to the process. Both
systems have the same stack temperature. However, one of
the lines has a much higher heat capacity flow rate than the
other. What are the implications of this higher heat capacity
flow rate?

Figure 3. GCC is cut by hot gas line.

Figure 2. Use of GCC for matching exhaust gas.

If the lines are extrapolated to ambient temperature, the

quantity of heat being lost in the exhaust can be determined. It
is seen that the higher the heat capacity flow rate (the lower Figure 4. Introducing a second utility.
the slope of the utility line) the greater the exhaust losses. So,
for a fixed stack temperature, the exhaust losses are
minimized if the heat capacity flow rate is minimized.
Stack temperature also plays a significant role in controlling
exhaust losses. Ideally, the designer should aim to take the hot
gas down to its acid dew temperature. However, if the pinch
point is at a temperature higher than the acid dew
temperature, nothing is to be gained by taking the hot gas
below the pinch temperature, for below this point the process
only requires cold utility.
Now, consider the situation illustrated in Fig. 3. Hot gas is
available at an initial temperature and flow described by the
line GD. This line is seen to cut the grand composite curve at
point I. This means that the demand made by the process over
span IB cannot be satisfied by the hot gas. What options are
open to the designer? One option is to introduce a second
utility (e.g. steam). This is illustrated in Fig. 4. A second option Figure 5. Increasing gas flow rate results in increased exhaust losses.
is to increase the heat capacity flow rate of the gas. This is
illustrated in Fig. 5. Of course, the result is increased exhaust
losses.
The third option is to increase the temperature at which the 3 Gas Turbine Analysis
hot gas is first available. This is illustrated in Fig. 6. Here, the
heat demand of the process is satisfied without incurring Having identified that the most efficient cogeneration
unnecessary increase in exhaust losses. system is that which employs the smallest possible gas flow

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At a fixed turbine inlet temperature the specific network

varies with turbine inlet pressure (which can be characterized
by the compressor pressure ratio). A typical relationship is
shown in Fig. 8 [9]. The specific network is seen to initially rise
as the pressure ratio increases. It reaches a maximum, then
declines with further increase in pressure ratio. Thus, for
minimum gas flow, the gas turbine should operate at a pressure
ratio, which provides the maximum specific network.

Figure 6. Increasing gas supply temperature, but flow rate remains constant.

the next question that must be addressed is ªhow can this gas
flow be determined?º
A flow diagram of a simple gas turbine equipped with
afterburner is given in Fig. 7.

Figure 8. Specific network variation with pressure ratio for a given turbine inlet
temperature.

Operation at a pressure ratio greater than this optimum

value results in both lower turbine exhaust temperature and
higher gas flow rate. The result (as illustrated in the T-Q plot
presented in Fig. 9) are increased exhaust losses and reduced
system efficiency.
Operation at a pressure ratio less than this optimum value
results in increased turbine exhaust temperature. This may at
first sight appear an advantage. However, the gas flow needed
Figure 7. Flow diagram of simple gas turbine for direct integration. for the required power generation increases. So, the slope of
the exhaust gas line on the T-Q plot decreases. Again, exhaust
The gas flow in a gas-turbine-based cogeneration system is losses increase and efficiency falls (Fig. 9).
controlled by the required power generation. The higher the
required power generation, the greater the flow of gas through
the turbine has to be. The two gas turbine parameters which
dictate the gas flow requirements are the turbine inlet
temperature and the compressor pressure ratio.
The gas flowing through the turbine consists of air and
combustion products. The quantity of fuel burnt is small
compared to the air flow. Consequently, equating the hot gas
flow with that of the air being fed to the combustor is a good
approximation.
The important turbine characterization parameter is the
specific network, which is the ªwork output per unit air flowº.
The objective of minimizing the gas flow is achieved by
maximizing the specific network.
Specific network increases with turbine inlet temperature.
Therefore, a turbine with the highest possible inlet tempera- Figure 9. Deviation from optimum pressure ratio results in increased exhaust
ture should be selected. losses.

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In summary, the best thermodynamic efficiency in a directly
integrated gas turbine system is achieved when two conditions
are met:
± turbine inlet temperature is maximized
± pressure ratio is that which yields the maximum specific
network
The required gas temperature to meet process heat demand
can easily be estimated using the following relationship1):
Rhp : wngt
Tg ˆ Tstack ‡
cpg
The temperature of the gas issuing from a simple gas turbine
is fixed by its operating characteristics. However, it is possible
to adjust the temperature at which this gas is subsequently
passed to the process by using either an afterburner or a
recuperator.
The exhaust gas from the turbine generally contains
sufficient oxygen to support further combustion. So, this gas
can be passed through an afterburner in order to raise its
temperature (Fig. 7).
A recuperator is a heat exchanger placed between the outlet
of the heat engine's air compressor and the primary
combustion chamber (Fig. 10). Heat from the turbine's
exhaust is used to heat the air being fed to the combustor.
The result is a reduction in the fuel consumed by the engine.
The use of a recuperator saves fuel at the cost of reducing the
temperature at which gas is fed to the process. The presence of
a recuperator does not significantly affect the specific network
characteristics of the machine [9] or the relationship between
gas flow rate and power generation.
Figure 10. Flow diagram of a recuperated gas turbine for direct integration.
It should be noted that simple gas turbines together with
turbines equipped with afterburner or recuperator provide a
wide range of heat to power ratios (from slightly less than 1 to
5) and gas temperatures (from 300 to about 1000 C).
Therefore, heat and power requirements of a large number
of process plants can be met by using a suitable configuration
of the gas turbine.
± reduce the turbine fuel consumption. The potential
1) List of symbols at the end of the paper.
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4 Matching a Gas Turbine to Process (Fixed Power
Generation)
4.1 Identification of Process
The first step in matching a heat engine to any part of a
factory site is the determination of the conditions of the gas
issuing from the turbine (flow rate and temperature).
The most efficient cogeneration system is the one in which
(1) this gas is subsequently taken down to its acid dew
temperature.
The designer often has the option of matching the turbine
with a number of different processes on a site (or, with
different component parts of a given process). The ideal'
process can be identified by matching the hot gas line with the
process grand composite curve. The key' is the ability to
extract heat from the gas all of the way down to the acid dew
temperature. So, processes having pinch points at higher
temperatures should, if possible, be avoided. So should those
which impose utility pinches.
4.2 Processes with Fixed Heat Demand
Consider the situation in which the heat demanded by the
process is fixed. The superimposition of the gas line
(associated with the use of a simple gas turbine) on the
process grand composite can yield one of three possible
results:
(a) The line could pass directly through the acid dew
temperature. Here, the heat provided by the turbine
exhaust exactly balances with that required by the process
(Fig. 11).
Figure 11. Exhaust gas heat balances with process heat demand.
(b) The line could cut the vertical axis at a temperature higher
than the acid dew temperature (Fig. 12). This gas contains
more heat than can be taken up by the process. A
recuperator could be used to absorb this excess heat and
savings are easily identified using the construction shown.
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Figure 12. Exhaust gas contains more heat than process demand.
(c) The line could cut the grand composite curve prior to the
vertical axis (Fig. 13). In this case the gas contains
insufficient heat to drive the process. The use of an
afterburner is indicated. The supplementary fuel burning
is easily determined using the construction indicated.
Figure 13. Exhaust gas contains insufficient heat to meet process demand.
The matching procedure described above applies to all
processes including those, which impose utility pinches
(Fig. 14).
5 Total Cost Optimization
In many cases the designer has the opportunity to vary the
utility heat demand made by the process by adjusting the heat
recovery made within the process. This has implications for
the capital cost of the heat recovery network.
The matching procedure described above yielded the fuel
cost/saving associated with matching the turbine exhaust line
at a given heat demand. This can easily be extended to a total
cost optimization procedure based on that currently used for
the targeting of normal heat recovery systems.
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Figure 14. GCC imposes a utility pinch.
The steps involved in the procedure are as follows:
1. From power generation need determine minimum air flow
and gas supply temperature.
2. Set minimum temperature approach for process heat
recovery system and derive grand composite curve.
3. Superimpose turbine exhaust gas line on grand composite
and establish whether or not afterburner or recuperator
should be used.
4. Establish fuel cost (if afterburner) or saving (if recuperator
is used).
5. Incorporate gas into process stream data and derive
balanced composite curves.
6. Determine heat recovery network area requirement and
capital cost from analysis of balanced composite curves.
7. Determine total annual cost of system (from fuel cost/
saving and annualization of network capital cost).
8. Repeat steps 2 to 7 in order to determine total cost profile
and identify optimum condition.
6 Optimal Power Generation
Rather than be faced with a situation in which the power
needs of a project are fixed, the designer may need to examine
how much power can be economically generated against a
given process. That problem is addressed here.
In this situation the gas profile cannot be determined at the
outset of the analysis. It is dependent on both the process and
the amount of heat recovery employed. However, the optimal
turbine operating condition remains that at which the specific
network is maximized. This means that the turbine exhaust
temperature and work efficiency are known. The temperature
at which gas is supplied to the process will depend on whether
or not a recuperator or afterburner is used.
The economic objective will be the minimization of total
annual cost. This cost is made up of three terms: the fuel cost,
the power revenue and the annualized capital cost.
Ctotal ˆ Cfuel Vpower ‡ Cann: capital (2)
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The fuel cost for the cogeneration system is given by: _ ˆ m

W _ g : … wngt †max (6)

_ ‡ m
Cfuel ˆ efuel : ‰W _ g : cpg … Tg
where,
W_ = power generation [KW]
m_ g = gas mass flow rate [Kg/s]
cpg = mean gas specific heat [KJ/Kg C];
taken as 1.14 KJ/Kg C
Tg = gas supply temperature [C]
T0 = ambient temperature [C]
efuel = fuel price [£/KW hr]
T0 †Š (3) 4. Establish fuel cost and power revenue.
5. Incorporate gas into process stream data and derive
balanced composite curves.
6. Determine heat recovery network area requirement and
capital cost from analysis of balanced composite curves.
7. Determine total annual cost of system.
8. Repeat steps 2 to 7 assuming various values for gas supply
temperatures.
9. Adjust minimum temperature approach for heat recovery
and repeat steps 2 to 8 in order to identify conditions for
minimum total annual cost.

The power revenue is given by:

6.2 Process Pinch Constraint
Vpower = epower ´ W (4)
The presence of a process pinch point at a higher
temperature than the acid dew temperature can result in a
epower = power buy-back price [£/KW hr]
substantial reduction in fuel economy. This poses the question
of whether or not power should be raised against the process.
In the context of cogeneration, there are three categories of
Consequently, the above procedure has to be supplemented
process: those in which the process does not impose any
by a determination of the economics of just using a burner to
constraint on the use of heat and thereby allow the hot gas to
satisfy the heat demand of the process.
be taken down to its acid dew temperature; those in which the
Since the fuel economy is fixed by the pinch temperature,
process pinch is at a higher temperature than the acid dew
there is no need to explore supplementary levels of power
point but otherwise the process does not impose a constraint
generation. If power generation is found worthwhile, the power
on the use of heat; and, those in which the process imposes a
generation should be maximized against the process in accor-
utility pinch.
dance with the procedure outlined for unconstrained processes.

6.1 Unconstrained Processes 6.3 Utility Pinch Constraint

With unconstrained systems the initial assumption is that The maximum work that should be set against a process at
the power generation should be maximized for a given heat a specified heat recovery level can be determined from a line
requirement. It is assumed that the tariff for power is such that from the minimum recuperator exhaust temperature point
it can be generated at a profit given full heat recovery. that just touches the grand composite curve (as illustrated in
The procedure is therefore as follows: Fig. 15).
1. Set minimum temperature approach for process heat The mass flow rate of the hot gas is given by:
recovery system and derive grand composite. _ _
Q proc Q u
2. From knowledge of the acid dew temperature and the m
_g ˆ (7)
cpg … Tr; min Tu †
minimum gas supply temperature resulting from the use of
a recuperator (with maximum possible effectiveness where,
(e = 0.90 [10]) determine the maximum possible flow rate Q_ proc = process heat load [KW]
of hot gas: Q_ u = heat co-ordinate of utility pinch [KW]
_
Q Tr,min = minimum recuperator exit temperature [C]
proc
…m
_ g † max ˆ (5) Tu = temperature co-ordinate of utility pinch [C]
cpg … Tr; min Tad †
The stack temperature for this power generation can be
where, computed from the gas mass flow rate and is given by:
Q _
_ proc = process heat load [KW]
Q Tstack ˆ Tr; min
proc
(8)
_
Qg cpg
Tr,min = minimum recuperator exit temperature [C]
Tad = acid dew temperature [C] Reducing the effectiveness of recuperator decreases the
quantity of power generated and the mass flow of the hot gas.
3. Establish power generation from knowledge of gas flow However, this results in a decrease in stack temperature and
and specific network characteristic of turbine: therefore an increase in fuel efficiency.

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the second example the optimum power generation level will

be found for a given process.
Q
The following economic data are used in the solution of
these problems:
T

Utility data
QU Typical electricity and fuel costs [11] are:
TU
Cost of fuel (natural gas) 5.7 £/MWh
Electricity buy-back rate 40 £/MWh
T Electricity purchase rate 70 £/MWh
Cost of Cold utility 7.5 £/(KW yr)

Heat exchanger network

Installed unit cost (£) 437 area0.83 (m2) [12]
Heat transfer coefficient 0.5 KW/(m2 C)
Figure 15. Gas line touches process GCC to maximize power generation. (for all streams)
0.1 KW/(m2 C )
Eventually, further reduction in power generation results in (for exhaust gas)
a need for afterburner. However, this also leads to reduced
stack temperature and increased fuel efficiency (Fig. 16). Plant data
Rate of interest 15 %
Life time 5 years
Operation time 7000 hours/yr
Annualization factor i(i + 1)N/{(i + 1)N ± 1} = 0.298316

The following correlation, based on prices given in [13, 14]

was obtained for assessment of gas turbine equipment price:

GT specific price [£/KW] = 255 ± 0.94 (power)

+ 257/(power) (9)

where, the power (on the right-hand side of the correlation) is

in terms of MW.
This correlation predicts the specific price of gas turbines in
the range of 1 to about 170 MW with a reasonable accuracy
Figure 16. Increase in gas supply temperature results in a decrease in power (within 20 %) which is a good approximation in targeting
generation and exhaust loss.
stage. Tab. 1 compares reported [14] and predicted values
(given by Eq. (8)) for a number of gas turbines.
The economic level of power generation, for a fixed heat
recovery level, can be found by first varying the power
generation and determining the consequent flow of gas and Table 1. Reported and predicted specific cost for a number of gas turbines.
temperature at which that gas is supplied to the process, then
determining the need for supplementary firing and overall Gas turbine model Power Reported cost Predicted cost Difference
[MW] [£/KW] [£/KW] [%]
fuel cost and finally, determining the annualized capital and
GE 7191F 151.3 125.6 114.5 ± 8.8
total annual costs (as outlined above).
100.5 139.9 165.1 + 18
This analysis can be undertaken for different heat recovery ABB GT 13D2
levels until the optimum system is identified.
190.8 202.3 +6
KWU V64.3 60.65
RR RB211 25.25 275.3 241.5 ± 12.3
7 Application of the Approach Ruston Hurcn 1.63 421.8 411.1 ± 2.5

The total cost optimization approach developed for

integrated design of heat exchanger network and gas turbine It should be noted that turnkey installed plant prices can add
utility plant will now be applied to two example problems. In 50 % to 100 % to the equipment price [13]. In this investigation
the first example an attempt is made to find the optimum level the installed price will be assumed 75 % higher than the
of process heat load for a fixed level of power generation. In equipment price.

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7.1 Example Problem 1 4. Required gas temperature can be evaluated from:

Q_
proc
Stream data for a process is given in Tab. 2. The power Tg ˆ ‡ Tstack (10)
_ g : cpg
m
demand of this process is fixed at 6000 KW and the gas turbine
is to solely meet process power and heat demands (power
5. Eq. (3) yields fuel cost.
export is not considered). Assume acid dew temperature of
6. Heat exchangers network area can be calculated by
120 C for exhaust gas. Determine total cost profile and
incorporating exhaust gas into process stream data and
identify optimum condition for this process.
subsequently deriving and then analyzing balanced com-
Table 2. Stream data for example problem 1. posite curve.
7. Finally, total annual cost can be estimated using given
Streams No. Supply Target Heat capacity
economic data. Total annual cost consists of heat recovery
temperature temperature [KW/C]
[C] [C] network, gas turbine system, fuel, and cold utility annual
350 60 costs. It should be noted that in this example gas turbine
1 (cold) 200 cost can be assumed constant as process power require-
200 105 ment is fixed and the power export is not considered.
2 (cold) 100 The results of the calculation are given in Tab. 3.
3 (hot) 100 70 60 Examination of Tab. 3 shows that at approach temperatures
4 (hot) 350 100 70 of below 20 C, gas supply temperature is less than turbine exit
temperature, therefore a recuperative gas turbine is needed.
At approach temperature of about 20 C a simple gas turbine
suffices for the process requirements, and at approach
7.1.1 Solution temperatures of above 20 C a gas turbine equipped with
afterburner should be used (gas supply temperature is higher
The calculation methodology consists of the following steps: than turbine exit temperature).
1. Hot and cold utility requirements can be found by Fig. 17 represents cost profiles for this process. It is observed
constructing process GCC for any assumed approach that the total cost profile is quite flat for approach
temperature. temperatures in the region of 10 C to 25 C with the minimum
2. Stack temperature is determined from consideration of total cost occurring at an approach temperature of about 20 C.
pinch point temperature. It was found that, for approach It should be noted that the total cost also includes the utility
temperatures of 20 C or less, pinch point temperature is plant installed cost.
less than acid dew temperature and therefore stack Now it would be interesting to explore how the economics of
temperature can be set at acid dew temperature. But, for a gas-turbine-based cogeneration system for this process
approach temperature of greater than 20 C, it is higher compares with ªon-site º production of hot utility using a fired
than acid dew temperature and thus stack temperature furnace and purchase of electricity. The total cost, for the latter
equates to pinch temperature. scheme, includes heat recovery network, cold utility, fuel, and
3. Gas turbine characteristics for turbine inlet temperature of electricity annual costs.
1200 C and based on maximization of specific network can We assume a minimum approach temperature of 20 C for
be obtained from analysis of gas turbine cycle [9]. The the process.
respective values are: The actual flame temperature of the furnace is difficult to
Work efficiency 0.317 predict because the combustion is not adiabatic and complex
Turbine outlet temperature 590 C dissociation reactions occur in the flame at high temperatures.
Specific net work 310 KJ/Kg However, a theoretical flame temperature can be used as a

Table 3. Calculated parameters for problem 1.

DTmin H.U C.U Tstack Tg Qf [KW] AHEN CHEN Cfuel CC.U Ctotal
[C] [KW] [KW] [C] [C] [m2] [£/yr] [£/yr] [£/yr] [£/yr]
10 9700 2500 120 560 18025 5155 157148 719197 18750 1810337
20 10400 3200 120 591 18709 3705 119709 747726 24000 1800510
30 11100 3900 130 633 19636 2719 92410 783476 29250 1820378
40 11800 4600 140 675 20563 2176 76809 820463 34500 1847015
50 12500 5300 150 717 21478 1410 53581 856972 39750 1865545
60 13200 6000 160 759 22399 1250 48534 893720 45000 1901894

DTmin = approach temperature; AHEN = heat exchanger network area; H.U = hot utility; CHEN = network annual cost;
C.U = cold utility; Cfuel = fuel annual cost; Tstack= stack temperature; CC.U = cold utility annual cost; Tg = gas supply
_ f = fuel energy rate.
temperature; Ctotal = total annual cost; Q

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Furnace efficiency can be found from the following

equation:
Tflame Tstack
gfur ˆ (11)
Tflame T0
Required fuel energy can be obtained from:
_
Q
_ ˆ
Q proc
(12)
f gfur
The calculated values are given in Tab. 4. Comparison of
total annual costs for both schemes reveals that the annual
gain of the cogeneration scheme is around 1663400 [£/yr]. This
confirms the economic merit of the system for the given
process.

Figure 17. Costs profiles for example 1.

7.2 Example Problem 2

convenient reference since it reflects the actual heat given out
by the combustion. Theoretical flame temperatures are
usually in the region of 1800 C [15] and this value has been
adopted as typical. Fig. 18 shows process GCC superimposed
by flue gas line (for acid dew temperature of 120 C).
The process specifications and economic data used for
problem 1 are again used, but now a directly integrated gas
turbine is needed to satisfy process heat and power require-
ments and export power. Identify optimum level of power
generation.

7.2.1 Solution

The calculation can be done using the approach outlined

above. Minimum gas supply temperature resulting from the
use of a recuperator is determined from Fig. 20. This is found
to be about 400 C for maximum specific network point at
turbine inlet temperature of 1200 C.
Calculations were undertaken for approach temperature
ranging from 10 C to 50 C. The amount of power produced
varied between the maximum possible level and the level at
T =T =T
which gas turbine meets only process power demand. Tabs. 5
and 6 show the results for maximum power generation case.
Figs. 19 and 20 represent respectively the ratio of exported
Figure 18. Process heat (example 1 ) is met by furnace flue gas. power to process power demand and total annual cost both

Table 4. Calculation results for problem 1 for the case of importing electricity.

DTmin H.U C.U Tg Q_f AHEN CHEN Cfuel Celec CC.U Ctotal
[C] [KW] [KW] [C] [KW] [m2] [£/yr] [£/yr] [£/yr] [£/yr] [£/yr]
20 10400 3200 1800 11064 1703 62671 441454 2940000 24000 3468125

Table 5. Thermodynamic results for example 2.

DTmin H.U C.U mg Tg Tstack Pgen Pexp Q_f AHEN

[C] KW KW Kg/S [C] [C] KW KW KW m2
10 9700 2500 38.68 400 180 11990 5990 28967 6485
20 10400 3200 42.43 400 185 13153 7153 31775 4928
30 11100 3900 46.36 400 190 14372 8372 34719 4165
40 11800 4600 49.29 400 190 15280 9280 36913 3828
50 12500 5300 53.49 400 195 16582 10582 40059 1732

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Table 6. Cost results for example 2.

DTmin CHEN Cfuel Cexp Cgt Cc.u Ctotal

[C] [£/yr] [£/yr] [£/yr] [£/yr] [£/yr] [£/yr]
10 190127 1155783 ±1677200 1659771 18750 1347231
20 151382 1267822 ±2002840 1800244 24000 1240608
30 131655 1385288 ±2344160 1946056 29250 1148089
40 122751 1472829 ±2598400 2053720 34500 1085400
50 63555 1598354 ±2962960 2206689 39750 945388

On the other hand, from a capital cost point of view, as the

approach temperature increases the heat exchanger network
cost reduces, but gas turbine capital cost increases. It is usually
the turbine capital cost which dominates.

T = 50 C

8 Conclusion
T = 40 C

In this article direct integration of a gas turbine has been

fully investigated in the context of pinch technology. In
T = 10 C

T = 20 C
T = 30 C
addition to a simple gas turbine system, systems equipped with
afterburner and recuperator have been also examined.
C From matching of an exhaust gas with the process grand
Figure 19. Ratio of power export to process power demand versus gas supply composite curve it has been found that the exhaust losses
temperature for example 2. decrease and, therefore, energy efficiency improves as gas
flow rate reduces. As a consequence, for a given power load,
the objective of minimizing the gas flow is achieved by
T
maximizing the specific network. Gas turbine specific network
T
itself increases with turbine inlet temperature. In conclusion,
the best system is the one to have the highest possible turbine
T

inlet temperature with the maximum specific network.

Two total cost optimization procedures have been intro-
duced:
The first model is for integration of the gas turbine with a
T process subject to fixed power generation. By this method, the
T
process' optimum approach temperature which corresponds
to minimum total cost can be determined.
The second model considers the power export opportunity,
and an attempt has been made to find the optimum level of
C power generation. In this regard it was found that the ratio of
Figure 20. Total annual cost versus gas supply temperature for example 2. electricity buy-back rate and fuel cost determines the
economics of power export.
versus gas supply temperature. It is seen that the higher the Finally, illustrative examples have been presented to show
approach temperature the greater the power export. This is how the approaches can be applied in practice.
because power generation (for a given turbine inlet temper-
Received: December 20, 2001 [CET 1526]
ature and corresponding maximum specific network) is
controlled by gas flow rate. As we know, the higher the
approach temperature the higher the process heat demand
and, consequently, the greater the gas mass flow rate (for a Symbols used
given gas supply temperature).
From an operating cost point of view, an increase in AHEN [m2] heat exchanger network area
approach temperature increases both fuel cost and power Cann.capital [£/yr] annual capital cost
revenue. As a result, the economics of a cogeneration system Cfuel [£/yr] fuel annual cost
designed for power export depends significantly on the ratio of CC.U [£/yr] cold utility annual cost
power buy-back rate to the fuel unit cost. The higher this ratio CHEN [£/yr] heat exchanger network annual
the more economic the power export. capital cost

838 Ó WILEY-VCH Verlag GmbH & Co. KG aA, Weinheim, 2002 0930-7516/02/0808-0838 $ 17.50+.50/0 Chem. Eng. Technol. 25 (2002) 8
 Full Paper

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