BATANGAS STATE UNIVERSITY

Bachelor of Science in Mechanical Engineering

ME 425- Power Plant Design with Renewable Energy

DESIGN OF 300 MW SOLAR-COAL HYBRID COMBINED CYCLE STEAM

POWERPLANT LOCATED AT SIMLONG, BATANGAS CITY

A Technical Re-evaluation of an Existing Power Plant Design Project Study

Using Modified Design Parameters and with Emphasis on the Design of Steam Generator
as a Thermofluid Equipment

Prepared by:

Dullaven, Geraldine P. , 18-54381

Ditan, Lawrence Andrew V. , 18-54902
Magbatoc, Irish Van R. , 14-55000
Mendoza, Carla Shane S. , 18-55010
ME 4108

Mechanical, Petroleum. Automotive and Naval Architecture/Marine Engineering Department

College of Engineering, Architecture and Fine Arts
BatStateU Alangilan
Alangilan, Batangas City

November 27, 2021

 RATIONALE

This design project is based on an existing capstone design proposal entitled “Design

of 300 MW Solar-Coal Hybrid Combined Cycle Steam Powerplant Located at Simlong,

Batangas City” last May 2020. Certain modifications and design options were provided in

order to assess the best method that will make the mentioned proposal feasible and effective.

The first design option required a pure solar power concentrator operated steam generator

with an economizer and superheater. The first design option system employs triple

extractions closed feed water heaters with a deaerator prior to the boiler feed pump (BFW).

The second design option has the same requirements as design option one but the difference

will be the utilization of an open feedwater system and necessary pumps in the design. The

final design option alters the ratio of the power source in operating the economizer and

superheater by making the 30% supplied by SPCs and the remaining 70% will come from

regular combustion from the steam generator. In addition, the third design option shall have a

different steam generator design compared to the two previous design options.

Several design parameters such as mass flow rate, heat added and rejected, turbine work,

efficiencies and others will be evaluated, analysed and compared in order to select the best

design option applicable to the mentioned existing design project proposal. Charts and tables

are to be used in order to evaluate the differences between the given design options proposed.

The main purpose of this design project is to determine the best design option that can be

applied to the existing capstone project proposal in order to make it feasible and effective.
 TECHNICAL DESIGN AND REQUIREMENTS

PART I – THERMODYNAMIC CYCLES

Thermodynamic Cycle

 Design Option 1 using Solar Power Concentrator

Design Calculation
Table 1

Technical Specifications

1 Reheat, 3 Regenerative, 3 Closed Feed Water Heater and 1 Open Feed Water
Heater (Deaerator) with 2 High Pressure Heater and 1 Low Pressure Heater
Parameters Symbol Value Unit Remarks
0
Maximum Temperature Tmax 565 C Based on
Maximum Pressure Pmax 19 MPa Equipment
Maximum Reheat Temperature Tmax 565 0
C Catalogue, Model
Steam Turbine Efficiency et 47.5 % No. GE STF D650
Based on
Condenser Pressure Pmax 0.0084726 MPa
Equipment
0 Catalogue (see
Condenser Temperature Tmax 42.6 C
appendix A)
Based on
Equipment
Generator Efficiency eg 98 %
Catalogue (see
appendix A)
 Extraction Pressure for HP 1 PHP1 10.596696 MPa
Extraction Pressure for HP 2 PHP2 2.978375 MPa
Based on
Extraction Pressure for 1.35964055
PD MPa assumption using
Deaerator 9
Delta T
0.44004546
Extraction Pressure for LP 1 PLP1 MPa
1

Table 1 presents the steam turbine, condenser and extraction pressure, this

data is used to calculate this design option. The steam turbine requirements had an impact

in cycle condensing air. Configuration will vary in different designs. Furthermore, the

extraction pressure and temperature are based on the assumption of Dela T. Design inlet

temperature of steam turbine and design vacuum temperature of condenser is used to

calculate the value of delta T, in order to find the extraction temperatures in each

feedwater heaters.
T-S Diagram

Fig. T-S Diagram of Design Option 1

The figure shows the T-S Diagram for design option 1, red line indicates super-heated

vapor, for blue compressed liquid and for green saturated liquid. State point 7, is

considered as wet mixture. The final T-S diagram is derived after calculation using

refrigeration properties software. The first design option consists of 20 state points, it is

composed of three closed feed water heaters and 1 open feed water heater. Thermal

efficiency was calculated by means of evaluating the work of turbines and pumps and

heat addition in the boiler. Those parameters are manually computed by energy balance,

while the enthalpies, entropy and pressures are evaluated in refrigeration application.
 Table

Summary of Extraction Temperatures of Design Option 1

Parameter Value Unit Remarks

0
Tmax 565 C Based on Equipment Catalogue
0
Tmin 42.6 C Based on Equipment Catalogue
Delta T 3528.471911 kJ/kg Formula: (Tmax-Tmin)/(n+1)
0
T2 460.52 C Tmax-Delta T
0
T3 356.04 C T2-Delta T
0
T4 251.56 C T3- Delta T
0
T5 147.08 C T4- Delta T

The table presents the summary of extraction temperatures of design option 1. The

extraction temperatures are manually computed. The formula used is also stated above.

Higher temperature decreases the wetness of the steam in the later stages of the turbine &

improves the turbine efficiency.

Table

Summary of Enthalpies

Parameter Description Value Unit

h1 Enthalpy entering the steam turbine 3450.287129 kJ/kg
h2 Enthalpy after fist expansion and extraction on HP 3261.997696 kJ/kg
turbine
h3 Enthalpy after entering the re-heater 3533.649781 kJ/kg
h4 Enthalpy after 2nd extraction in IP Turbine 3130.714631 kJ/kg
h5 Enthalpy after 3rd extraction in IP Turbine 2933.059996 kJ/kg
h6 Enthalpy after 4th extraction in IP Turbine 2703.699831 kJ/kg
h7 Enthalpy after 5th extraction in LP Turbine 2124.851485 kJ/kg
h8 Enthalpy after entering the condenser 178.4014433 kJ/kg
h9 Enthalpy after entering condensate pump 179.7646678 kJ/kg
h10 Enthalpy after entering LP1 619.5913898 kJ/kg
h11 Enthalpy entering at steam trap of LP1 619.5913898 kJ/kg
h12 Enthalpy after entering steam trap of LP1 619.5913898 kJ/kg
h13 Enthalpy after entering Deaerator 823.8630977 kJ/kg
h14 Enthalpy after entering Boiler Feed Pump 844.0943485 kJ/kg
h15 Enthalpy after entering HP2 1006.450219 kJ/kg
h16 Enthalpy entering at steam trap of HP2 1006.450219 kJ/kg
h17 Enthalpy after entering steam trap of HP3 1006.450219 kJ/kg
h18 Enthalpy after entering HP1 1433.538395 kJ/kg
h19 Enthalpy entering at steam trap of HP2 1433.538395 kJ/kg
h20 Enthalpy after entering HP1 1433.538395 kJ/kg
 The tables shows the summary of enthalpies for design option 1. The cycle has 20

state points. The values are calculated using refrigeration properties application, it is used to

solve for work, heat addition and rejection and thermal efficiency. Detailed calculation is

shown in the submitted attached excel.

Table

Summary of Fractional Mass Flowrate

Parameter Equation Value Unit

m1 ms(h18-h15)/(h2-h19) 0.233578169 kg/kg
m2 ms(h15-h14)-m1(h20-h16))/(h4-h16) 0.029467799 kg/kg
m3 (ms(h13-h10)-m1(h17-h10)-m2(h17-h10))/(h5-h10) 0.044310112 kg/kg
m4 m4=((m1-m2-m3) (h10-h9))/(h6-h11) 0.033723976 kg/kg

The table shows the fractional mass flowrate in each extraction. The values are

calculated using mass balance, the equation is also stated above for reference.

Table

Summary of Actual Mass Flowrate

Parameter Equation Value Unit

m1 ms = plant capacity / (ng*Wnet); ng = 0.98 based on 441.9483855 kg/s
equipment catalog
m2 ms * m1 fractional mass flow rate 103.2294947 kg/kg
m3 ms * m2 fractional mass flow rate 13.02324618 kg/kg
m4 ms * m3 fractional mass flow rate 19.58278238 kg/kg

The table shows the actual mass flowrate in kg/s. The values are calculated using

mass balance, the equation is also stated above for reference.

Table

Summary of Technical Parameters for Design Option 1

Parameter Description Value Unit

Wt1ideal Isentropic Work of High-Pressure Turbine 419948.5849 kW
Wt2ideal Isentropic Work of Intermediate Pressure Turbine 218121.1321 kW
Wt3ideal Isentropic Work of Low-Pressure Turbine 30425.47509 kW
Wt (ideal) Total Ideal Work of Turbine 668495.1921 kW
Wt Total Actual Work of Turbine 317535.2162 kW
 Table (cont.)

Summary of Technical Parameters for Design Option 1

Parameter Description Value Unit

Wp1ideal Isentropic Work of Pump of Condensate Pump 417.3005536 kW
Wp2ideal Isentropic Work of Work Boiler Feed Pump 8941.168601 kW
Wp(ideal) Total Ideal Work of Pump 9358.469155 kW
Wp Total Actual Work of Pump 11412.76726 kW
Qr Heat Rejected 545747.7702 kW
Qa Total Heat Added 983312.5401 kW
Wnet Difference between t (actual)- Wp(actual) 306122.449 kW
nth Thermal Efficiency 0.311317548 %

The table shows the calculated technical parameters of Design Option. The thermal

efficiency is 31.1% which is considered as high because of the closed feedwater heaters.

Each parameter is computed manually, the detailed calculation is shown in the attached

submitted excel.
 Design Option 2 using Solar Power Concentrator
Design Calculation
Table

Technical Specifications

1 Reheat, 3 Regenerative, 4 Open Feed Water Heaters, Heater (Deaerator) with 2

High Pressure Heater and 1 Low Pressure Heater
Parameters Symbol Value Unit Remarks
0
Maximum Temperature Tmax 565 C Based on
Maximum Pressure Pmax 19 MPa Equipment
Maximum Reheat Temperature Tmax 565 0
C Catalogue, Model
Steam Turbine Efficiency et 47.5 % No. GE STF D650
Based on
Condenser Pressure Pmax 0.0084726 MPa
Equipment
0 Catalogue (see
Condenser Temperature Tmax 42.6 C
appendix A)
Based on
Equipment
Generator Efficiency eg 98 %
Catalogue (see
appendix A)
Extraction Pressure for HP 1 PHP1 10.596696 MPa
Extraction Pressure for HP 2 PHP2 2.978375 MPa
Based on
Extraction Pressure for 1.35964055
PD MPa assumption using
Deaerator 9
Delta T
0.44004546
Extraction Pressure for LP 1 PLP1 MPa
1

Table 1 presents the steam turbine, condenser and extraction pressure, this

data is used to calculate this design option. The steam turbine requirements had an impact

in cycle condensing air. Configuration will vary in different designs. Furthermore, the

extraction pressure and temperature are based on the assumption of Delta T. Design inlet

temperature of steam turbine and design vacuum temperature of condenser is used to

calculate the value of delta T, in order to find the extraction temperatures in each

feedwater heaters.

T-S Diagram
 Fig. T-S Diagram of Design Option 2

The figure shows the T-S Diagram for design option 2, red line indicates super-heated

vapor, for blue compressed liquid and for green saturated liquid. State point 7, is

considered as wet mixture. The final T-S diagram is derived after calculation using

refrigeration properties software. The first design option consists of 17 state points, it is

composed of four open feed water heaters. Thermal efficiency was calculated by means

of evaluating the work of turbines and pumps and heat addition in the boiler. Those

parameters are manually computed by energy balance, while the enthalpies, entropy and

pressures are evaluated in refrigeration application.

Table

Summary of Extraction Temperatures of Design Option 2

Parameter Value Unit Remarks

0
Tmax 565 C Based on Equipment Catalogue
 0
Tmin 42.6 C Based on Equipment Catalogue
Delta T 104.48 kJ/kg Formula: (Tmax-Tmin)/(n+1)
0
T2 460.52 C Tmax-Delta T
0
T3 565 C T2-Delta T
0
T4 356.04 C T3- Delta T
0
T5 251.56 C T4- Delta T

The table presents the summary of extraction temperatures of design option 2. The

extraction temperatures are manually computed. The formula used is also stated above.

Higher temperature decreases the wetness of the steam in the later stages of the turbine &

improves the turbine efficiency.

Table

Summary of Enthalpies

Parameter Description Value Unit

h1 Enthalpy entering the steam turbine 3450.287129 kJ/kg
h2 Enthalpy after fist expansion and extraction on HP 3261.997696 kJ/kg
turbine
h3 Enthalpy after entering the re-heater 3533.649781 kJ/kg
h4 Enthalpy after 2nd extraction in IP Turbine 3130.714631 kJ/kg
h5 Enthalpy after 3rd extraction in IP Turbine 2933.059996 kJ/kg
Table cont.
Summary of Enthalpies
Parameter Description Value Unit
h6 Enthalpy after 4th extraction in IP Turbine 2703.699831 kJ/kg
h7 Enthalpy after 5th extraction in LP Turbine 2124.851485 kJ/kg
h8 Enthalpy after entering the condenser 178.4014433 kJ/kg
h9 Enthalpy after entering condensate pump 178.4014433 kJ/kg
h10 Enthalpy after entering LP1 619.5913898 kJ/kg
h11 Enthalpy entering at steam trap of LP1 621.3514247 kJ/kg
h12 Enthalpy after entering steam trap of LP1 823.8630977 kJ/kg
h13 Enthalpy after entering Deaerator 832.6003443 kJ/kg
h14 Enthalpy after entering Boiler Feed Pump 1006.450219 kJ/kg
h15 Enthalpy after entering HP2 1016.667648 kJ/kg
h16 Enthalpy entering at steam trap of HP2 1433.538395 kJ/kg
h17 Enthalpy after entering steam trap of HP3 1445.923386 kJ/kg
The tables shows the summary of enthalpies for design option 2. The cycle has 17

state points. The values are calculated using refrigeration properties application, it is used to
solve for work, heat addition and rejection and thermal efficiency. Detailed calculation is

shown in the submitted attached excel.

Table

Summary of Fractional Mass Flowrate

Parameter Equation Value Unit

m1 m1 = (ms*(h16-h15))/h2 0.12779615 kg/kg
m2 m2 = ((ms)(h14)-(ms-m1)(h13))/(h4-h13) 0.121949111 kg/kg
m3 m3 = ((ms-m1-m2)(h12-h11))/(h5-h11) 0.065724263 kg/kg
m4 m4 = ((ms-m1-m2-m3)(h10-h9))/(h6-h9) 0.119495556 kg/kg

The table shows the fractional mass flowrate in each extraction. The values are

calculated using mass balance, the equation is also stated above for reference.

Table

Summary of Actual Mass Flowrate

Parameter Equation Value Unit

m1 ms = plant capacity / (ng*Wnet); ng = 0.98 based on 54.51011197 kg/s
equipment catalog
m2 ms * m1 fractional mass flow rate 52.0161184 kg/kg
m3 ms * m2 fractional mass flow rate 28.03399741 kg/kg
Table cont.
Summary of Actual Mass Flowrate

Parameter Equation Value Unit

m4 ms * m3 fractional mass flow rate 50.96958018 kg/kg

The table shows the actual mass flowrate in kg/s. The values are calculated using

mass balance, the equation is also stated above for reference.

Table

Summary of Technical Parameters for Design Option 2

Parameter Description Value Unit

Wt1ideal Isentropic Work of High-Pressure Turbine 258124.7492 kW
Wt2ideal Isentropic Work of Intermediate Pressure Turbine 280124.2762 kW
Wt3ideal Isentropic Work of Low-Pressure Turbine 139508.0887 kW
Wt (ideal) Total Ideal Work of Turbine 677757.1141 kW
 Wt Total Actual Work of Turbine 321934.6292 kW
Wp1ideal Isentropic Work of Pump of Condensate Pump 104.9414886 kW
Wp2ideal Isentropic Work of Work Boiler Feed Pump 424.1855383 kW
Wp(ideal) Total Ideal Work of Pump 12965.98777 kW
Wp Total Actual Work of Pump 15812.18021 kW
Qr Heat Rejected 469113.4161 kW
Qa Total Heat Added 956002.9745 kW
Wnet Difference between t (actual)- Wp(actual) 306122.449 kW
nth Thermal Efficiency 0.32021077 %

The table shows the calculated technical parameters of Design Option 2. The thermal

efficiency is 32.02% which is considered as high because of the closed feedwater heaters.

Each parameter is computed manually, the detailed calculation is shown in the attached

submitted excel.
PART II – THERMOFLUID EQUIPMENT DESIGN – STEAM GENERATOR

The variation of the power source and various design parameters are the key components to

determine the most applicable design option for the existing design project proposal. The

difference between the operation of Solar Receiver Steam Generator and the Coal Fired

Boiler with Solar Power Concentrator will play a huge role in choosing the best design option

for this project.

An article published by GE Renewable Energy last 2016 stated that the mechanism of SRSGs

operate using heliostats which pave way to track the sun on two axes, concentrating the solar

energy onto the SRSG which is located on top of the tower in the heliostat field. Thus, the

reflection of energy enables the heating of water which turns into steam that activates the

steam turbine and produce electricity.

Figure :Molten Salt Solar with Solar Receiver Steam Generator System Diagram
The configuration and components of a Solar Receiver Steam Generator design such as tube

diameters and mass flow rates as well as the ambient temperature of the location are catalysts

of change on the steam energy to be produced by the designed system (Al-Lehyani et al.

2015). The figure below displays the effect of the aforementioned design parameters to the

steam energy produced by the system.

Figure :Effect of Changing Tube Diameters on Steam Energy and Radiation Intensity

(Al-Lehyani et al. 2015)

Figure :Effect of Changing Mass Flow Rates on Steam Energy and Radiation Intensity
 (Al-Lehyani et al. 2015)

On the other hand, a coil fired boiler with solar power concentrator operates on a certain ratio

turning the plant design into a hybrid one. A realistic boiler design must be created in order to

satisfy realistic conditions of the plant condition and location (Conlon and Venetos, 2013). A

hybrid coal fired boiler with SPC typically operates by making use of solar power on air-

preheating and then the boiler mainly operates the system (Amsbeck et al.,2014).

Figure : Schematic diagram of supercritical coal fired power plant

showing solar SPR air-preheating and TBS solarisation points

(Amsbeck et al.,2014)

Various factors such as the air-cycle, recirculation of flue gases, and the incident solar

energy are needed in order to evaluate whether the design hybrid thermal power plant is

effective (Amsbeck et al.,2014). The table below displays the results on a design project

conducted entitled “Hybrid Solar and Coal-Fired Steam Power Plant with Air Preheating

Using a Solid Particle Receiver”.

 Table

Design and Performance Results from Hybrid Solar and Coal-Fired Steam Power Plant with

Air Preheating Using a Solid Particle Receiver

(Amsbeck et al.,2014)

RESULT UNIT AIR AIR AIR AIR TBS TBS

950oC 95oOc 540oC 540oC 335oC 335oC
re-circ re-circ. re-circ

Fuel flow kg/s 39.8 39.4 51.4 51.3 55.7 55.5

Boiler % 94.6 96.8 94.5 95.3 94.2 94.6

Efficiency
(LHV)
Cycle % 45.2 45.2 45.2 45.2 44.5 44.5
Efficiency
(gross)
System % 40.5 41.6 40.5 40.9 39.8 39.9
Efficiency

Table

SUMMARY OF BOILER CALCULATIONS

SEMIRARA COAL
Composition Value Unit Remarks
Total Moisture 19 %
Proximate Analysis
Volatile Matter 20.7 %
Ash 19 %
Fixed Carbon 26.3 %
Gross Heating 20934 kJ/kg
Value
Sulfur 1 %

Table cont.
SEMIRARA COAL
 Ultimate Analysis
Composition Value Unit Remarks
Moisture 19 %
Ash 6.72 %
Carbon 55.34 %
Hydrogen 2.51 %
Sulfur 0.64 %
Oxygen 14.98 %
Nitrogen 0.81 %

INITIAL PARAMETERS
Parameter Value Unit Remarks
o
Fluegas 140 C
Temperature
o
Initial Temperature 27 C
of Air
o
Initial Temperature 30 C
of Fuel

Excess air 25 %

Carbon refuse 10 %

Carbon to Carbon 5 %
Monoxide

Aftheo 6.6115575 kga/kgf

Afactual 8.264446875 kga/kgf

mass of fuel for kg/s

super heater

mass of fuel for kg/s

economizer

Total mass of fuel kg/s

cp of flue gas 0.962964 kJ/kg k

Table
 COMBUSTION GAS PRODUCTS FOR BOILER EFFICIENCY

Parameter Value Unit

GCV 30924.87 kJ/kg
Combustion products on a basis of 1kg with ultimate analysis of semirara coal
CO2 3.362296667 kgco2/kg fuel

CO 0.064563333 kgco/kg fuel

O2 0.604830335 kgo2/kg fuel

N2 6.3551952 kgn2/kg fuel

Humidity ratio of vapor 0.022716489 kgv/kga

H2O 0.438616489 kh20/kgfuel

Dry gas analysis for total 0.324593872 molgas/kgfuel

gas moles
Mass portion of combustion gas per mol
CO2 0.235419828

N2 0.699246896

O2 0.058229528

CO
0.007103749

Carbon in the refuse Crefuse/kgfuel

0.05534

Ash in refuse 0.0672

Weight in refuse 0.12254

Wg 4.798708917 kgdg/kgfuel

BOILER EFFICIENCY USING INDIRECT METHOD

Parameter Value Unit
Percentage heatloss due to 1.688515374 %
dry flue gas
 Table cont.
BOILER EFFICIENCY USING INDIRECT METHOS
Percentage heat loss due to 0.582118646 %
evaporation of water
formed due to H2 in fuel

Percentage heat loss due to 0.489608423 %

evaporation of moisture
present in fuel

Percentage of humidity 0.130803357 %

losses

Stack Losses 2.308927154 %

Unburnt Losses 4 %

Unaccountable losses 0.5 %

Manufacturer Margin 1 %

Total of Losses 10.69997295 %

Boiler Efficiency 89.30002705 %