The Open University of Sri Lanka

Faculty of Engineering Technology

Department of Mechanical Engineering
Study Programme Master of Energy Management (MEM)
Name of the Examination Continuous Assessment Test (CAT)
Course Code and Title DMX 9208 Combined Energy Systems for
Efficient Energy Use (CES)
Academic Year 2021
Date 13th November 2021 (Saturday)
Time 10.00 hours – 12.00 hours (IST)
Duration 02 hours

General Instructions
1. Read all instructions carefully before answering the questions.
2. This question paper consists of four (4) questions. Answer them all.
3. Answer for each question in each space in the OpenLearn LMS web page.
4. Relevant charts/ codes are provided.
5. This is an Opened Book Test (OBT).

QUESTION 01 (25 Marks)

Municipal Solid Waste (MSW) management is a main challengeable task for most countries
due to their exponential growth of accumulation.

a) Name and briefly describe, thermal treatment pathways of converting MSW into
energy.

Incineration – direct combustion of MSW to generate heat

Gasification – gasification of sorted MSW to produce syn gas in conventional
gasification systems or plasma gasification of unsorted for producing syn gas as the
energy carrier.
Pyrolysis – production of biooil (pyrolysis oil) from sorted varieties of MSW, through
high temperature fast pyrolysis.

(Please limit your answer to about 150 words) (5 marks)

b) MSW incineration is a matured thermal conversion technology that is being used to

energise power generation in steam turbine configurations. However, steam power
plants fuelled by MSW are performing less efficiently than their counterparts fuelled
by fossil fuels (ex. Coal). Briefly explain, what are the main reasons for limiting the
efficiency of steam power generation with MSW as fuel.

Boiler efficiency – boiler efficiency is low in MSW boilers as MSW contains

significantly large quantities of moisture in it compare to fossil fuels and dried biomass
components. And combustion temperatures are relatively lower around 1200 - 1400°C
 Significant corrosion issues – MSW boilers are affected by both high temperature
(temperature range around 450 – 700 °C - particularly by halides – chlorin in exhaust
gasses) and low temperature corrosion due to HCl and sulfuric acid condensation on
downstream components (temperatures lower than 300°C).
When temperature range significant for high corrosion is avoided, steam generated will
limit to lower steam parameters; pressure and temperature, resulting lower cycle
efficiency in power generation.

(Please limit your answer to about 150 words) (5 marks)

c) Figure 1 shows the system configuration of MSW fuelled CHP (combined heat and
power) plant situated in Linköping Sweden. Power plant is operational as a base load
plant (operate at constant level, 24/7), providing electricity and heat to the city network.
Table 1 provides few operational data required to complete the exercise in this question.
Calculate the following;
I. If three days of fuel storage is considered, how many tons of MSW should be
stored in feeding bunker. (5 marks).

Hourly feed rate = 24 tons/hr

Storage requirement for 3 days of operation = feed rate x op. hours

= 24 x 24 x 3 tons

= 1728 tons.

II. What is the electrical efficiency of the plant operation (5 marks).

Electrical output = 19 MW

LHV (MSW) given = 11MJ/kg

Feed rate = 24000/3600 = 6.67 kg/s

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑜𝑢𝑡𝑝𝑢𝑡
ŋ𝑒𝑙𝑒𝑐𝑡 =
𝐿𝐻𝑉 𝑓𝑢𝑒𝑙 𝑋 𝐹𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑓𝑢𝑒𝑙

19 𝑀𝑊
ŋ𝑒𝑙𝑒𝑐𝑡 =
11 𝑀𝐽/𝑘𝑔 𝑋 6.67 𝑘𝑔/𝑠

ŋ𝑒𝑙𝑒𝑐𝑡 = 25.89%
 III. What is the total efficiency of the plant (5 marks).

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑜𝑢𝑡𝑝𝑢𝑡 + 𝐻𝑒𝑎𝑡 𝑜𝑢𝑡𝑝𝑢𝑡

ŋ𝑜𝑣𝑒𝑟𝑎𝑙𝑙 =
𝐿𝐻𝑉 𝑓𝑢𝑒𝑙 𝑋 𝐹𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑓𝑢𝑒𝑙

(19 + 49)𝑀𝑊
ŋ𝑜𝑣𝑒𝑟𝑎𝑙𝑙 =
11𝑀𝐽/𝑘𝑔 𝑋 6.67 𝑘𝑔/𝑠

ŋ𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = 92.6 %

Figure 1 - Gärstad CHP plant in Linköping - TVAB, New part (1 boiler)

Table 1 – Operational parameters of the CHP power plant

Parameter Quantity and units

MSW (treated) flow rate to the boiler 24 tons/hour
MSW lower heating value (LHV) 11 MJ/kg
Electricity output 19 MW
Heat output 49 MW
QUESTION 02 (30 Marks)

Natural gas fired combined cycle power plant, schematically shown by figure 2, consisted of
one gas turbine unit (GT) and one heat recovery steam generation unit (HRSG).

Combined cycle power plant is operational as a base load power plant. Fuel combustion is only
inside the gas turbine combustion chamber (that mean there is no secondary combustion at
HRSG/steam cycle).

Power output of gas turbine is 120 MW (electric) and natural gas feeding rate to the gas
turbine is 6 kg/s. Gas turbine combustion is performed at equivalence ratio, ϕ =0.4 (that
means, air supply to combustion process is in gas turbine is 2.5 times of stoichiometrically
requirement amount of air in kg). In this combustion process (ϕ =0.4), one kilogram of
natural gas is combusted with 42.9 kg of air.

Gas turbine 120MW Exhaust to atm

HRSG

Condenser

Steam turbine

Figure 2: Schematic of combined cycle configuration

Table 2 – Operational parameters of the Gas turbine, fuel and exhaust gas properties

Parameter Quantity and units

Gas Turbine Power output (rated, electric) 120 MW
Gas Turbine efficiency (at rated power) 40%
Fuel (natural gas) feeding rate to the 6 kg/s
combustor
Air supply rate to the combustor 257.4 kg/s
Gas turbine exit temperature 680°C
Specific heat capacity of exhaust stream 1.3 kJ/kg. K
 LHV of NG 50 MJ/kg
CO2 generation by NG 55 kg CO2 /GJ fuel

Calculate the following,

a) Fuel power input to the combine cycle (MW). (4 marks)

GT power output =120MW

GT efficiency = 40%

𝐹𝑢𝑒𝑙 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡 = 𝐿𝐻𝑉 𝑓𝑢𝑒𝑙 𝑋 𝐹𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑓𝑢𝑒𝑙

𝑀𝐽 𝑘𝑔
𝐹𝑢𝑒𝑙 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡 = 50 𝑋6
𝑘𝑔 𝑠

𝐹𝑢𝑒𝑙 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡 = 300 𝑀𝑊

b) Mass flow of the exhaust flow (kg/s) (4 marks)

𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑒𝑥ℎ𝑎𝑢𝑠𝑡

= 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑎𝑖𝑟 + 𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑓𝑢𝑒𝑙

𝑘𝑔 𝑘𝑔 𝑘𝑔
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑒𝑥ℎ𝑎𝑢𝑠𝑡 = 257.4 +6 = 263.4
𝑠 𝑠 𝑠

Table 3 – HRGS steam cycle operational data

Parameter Quantity and units

Steam turbine Power output (rated, electric) 42.8 MW
Steam cycle efficiency (at rated power) 25%
HRSG – hot stream inlet temperature 680°C
HRSG – hot stream exit temperature 180°C
Gas turbine exit temperature 680°C
LHV of NG 50 MJ/kg
CO2 generation by NG 55 kg CO2 /GJ fuel

c) Calculate the electrical efficiency of the CC Power plant. (3 marks)

𝐺𝑇 𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 + 𝑆𝑇 𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡

ŋ𝐶𝐶 𝑒𝑙𝑒𝑐𝑡 =
𝐿𝐻𝑉 𝑓𝑢𝑒𝑙 𝑋 𝐹𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑓𝑢𝑒𝑙

120𝑀𝑊+42.8𝑀𝑊
ŋ𝐶𝐶 𝑒𝑙𝑒𝑐𝑡 = 𝑀𝐽 𝑘𝑔 = 54.27%
50 𝑋6
𝑘𝑔 𝑠
d) Estimate the amount of heat rejected by the condenser in HRSG steam cycle (kg/s)
(2 marks)

𝐻𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟𝑒𝑑 𝑎𝑡 𝐻𝑅𝑆𝐺

= 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒𝑒𝑥ℎ𝑎𝑢𝑠𝑡 𝑋 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡𝑒𝑥ℎ𝑎𝑢𝑠𝑡 𝑋 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒𝐻𝑅𝑆𝐺

𝑘𝑔 𝑘𝐽
𝐻𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟𝑒𝑑 𝑎𝑡 𝐻𝑅𝑆𝐺 = 263.4 𝑋 1.3 𝑋 (680 − 180)𝐾
𝑠 𝑘𝑔. 𝐾
= 171.210 𝑀𝑊

Heat rejected by the condenser = Heat received by HRSG – ST Power output

Heat rejected by the condenser (ST cycle efficiency 25%) = 171.21 MW X 0.75 = 128.4 MW

e) Calculate the CO2 emission level in grams/kWh generation by the combine cycle operation
(5 marks)
From fuel (NG) data,
CO2 generation by fuel (NG) = 55 kg/GJ of fuel
LHV of fuel = 50 MJ/kg
Mass of fuel to give one GJ of energy = 1000 MJ/50 MJ/kg = 20 kg of fuel
Now - CO2 generation by fuel (NG) = 55 kg of CO2/from 20 kg of NG fuel
CO2 generation by one kg of fuel = 55/20 = 2.75 kg

From the power generation in CC plant,

Amount of kWh generated per hour = (120 + 42.8) X 1000 = 162,800 kWh
Fuel consumption by the plant per hour = 6 kg/s X 3600 s = 21,600 kg
Fuel consumption per kWh produced = 21,600/162,800 = 0.1326 kg fuel

CO2 emissions - one kWh generation = fuel per one kWh energy X CO2 per one kg of fuel
CO2 emissions - one kWh generation = 0.1326 X 2.75 = 0.3646 kg CO2/kWh of energy
= 365 grams of CO2 /kWh
In order to further increase the overall efficiency of the power plant and to reduce the carbon
footprint per kWh power generation, it is planned to install a tertiary power generation unit
(ORC unit) coupled with a secondary heat recovery system. See figure 3.

Exhaust to atm
Gas turbine 120MW

Condenser

120MW
Sec. HR
ORC turbine X MW

HRSG

Condenser

Steam turbine

Figure 3: Schematic of combined cycle configuration (dashed box – integration of ORC CYCLE)

Table 4 – Secondary heat recovery and ORC cycle operational data

Parameter Quantity and units

Secondary heat recovery – hot stream inlet 180°C
temperature
Secondary heat recovery – hot stream exit 80°C
temperature
ORC cycle efficiency (at rated power) 20%
Specific heat capacity of exhaust stream 1.3 kJ/kg. K

f) Calculate the additional power (MW) can be generated due to the introduction of secondary
heat recovery/ORC cycle (5 marks)

𝑘𝑔 𝑘𝐽
𝐻𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟𝑒𝑑 𝑎𝑡 𝑂𝑅𝐶 𝐻𝑋 = 263.4 𝑋 1.3 𝑋 (180 − 80)𝐾
𝑠 𝑘𝑔. 𝐾
= 34.24 𝑀𝑊

ORC turbine power output = ORC efficiency X 𝐻𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟𝑒𝑑 𝑎𝑡 𝑂𝑅𝐶 𝐻𝑋

ORC turbine power output = 0.2 X 34.24 = 6.85 MW

g) Calculate electrical efficiency of CC/ORC power plant (2 marks)

𝐺𝑇 𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 + 𝑆𝑇 𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 + 𝑂𝑅𝐶 𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡

ŋ𝐶𝐶/𝑂𝑅𝐶 𝑒𝑙𝑒𝑐𝑡 =
𝐿𝐻𝑉 𝑓𝑢𝑒𝑙 𝑋 𝐹𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 𝑓𝑢𝑒𝑙

120+42.8+6.85
ŋ𝐶𝐶/𝑂𝑅𝐶 𝑒𝑙𝑒𝑐𝑡 = = 56.55%
300

h) Calculate the percentage reduction of CO2 footprint per kWh generated with new
configuration including ORC cycle (5 marks)

From the power generation in CC/ORC plant,

Amount of kWh generated per hour = (120 + 42.8 + 6.85) X 1000 = 169,650 kWh
Fuel consumption by the plant per hour = 6 kg/s X 3600 s = 21,600 kg
Fuel consumption per kWh produced = 21,600/169,650 = 0.1273 kg fuel

CO2 emissions - one kWh generation = fuel per one kWh energy X CO2 per one kg of fuel
CO2 emissions - one kWh generation = 0.1273 X 2.75 = 0.3500 kg CO2/kWh of energy
= 350 grams of CO2 /kWh
% of Reduction of CO2 of FP per kWh = 15/365 = 4.11%

Assumptions; No heat losses, specific heat capacity of exhaust is constant within the range of
temperature considered. Dew point of exhaust stream is above 80°C (that means, no water
vapour in exhaust condenses before leaving the secondary heat recovery system)
QUESTION 03 (30 Marks)

Figure 4 describes an arrangement of steam supply systems in a pulp and paper mill. Steam
produces is used for generation of mechanical power and process steam.

Arrangement is consisted of 3 grate fired boilers (P1 to P3), 1 fluidised bed boiler (P7), 1 oil
fired boiler (P8) and 1 electric boiler (Elp).

Figure 4: Schematic Diagram for Steam Supply System of the Process Applications at the
Selected Pulp and Paper Industry

Biomass is used as fuel for P1, P2, P3, P7 and IP (intermediate pressure) and LP (low pressure)
pressure systems for different heating purposes.

The turbine in the system has a maximum power output of 17 MWel but it operates normally
at 10 MWel output. The generator efficiency is 98.4 %. The losses from the turbine are 0.38
MW, which includes mechanical and radiation losses. The high-pressure steam from the boilers
(High pressure header) are at temperature 450°C and the pressure 50 bars. In the low-pressure
system, the steam temperature is 150°C and the pressure is 4 bars. The steam of the intermediate
pressure header is at temperature 250°C and the pressure 12 bars. The incoming feed water to
the boilers, from a feed water tank, has 120°C and the pressure is 80 bars. The normal flow
through the ejector line is 4.3 t/h.
Calculate the following,

a) HP Header Enthalpy at the normal operation. (2 marks)

b) IP Header Enthalpy at the normal operation. (2 marks)

c) LP Header Enthalpy at the normal operation. (2 marks)

d) Boiler Feedwater inlet enthalpy. (2 marks)

e) The input Thermal power to the turbine. (4 marks)

f) The mass flow through the turbine at the normal operation. (5 marks)

g) Mechanical efficiency of the turbine. (2 marks)

h) Assume that the ejector valve is closed for a moment and let the flow enters the turbine
instead. At the same time, the high-pressure steam temperature is increased to 500 °C.

I. What amount of thermal power converted into the mechanical power in the turbine.
(3 marks)
II. What is the electrical output of the turbine at this operation (3 marks)

i) Assume that only 2 boilers are in operation (P2 and P3) with the nominal boiler powers 80
MW (P2) and 125 MW (P3) and feeding steam to HP header at steam temperature 450°C
and the pressure 50 bars. What is the total feed water mass flow rate (= high pressure steam
flow)? (5 marks)
 5 Nov 2021 12:37:13 - Q3.sm

CAT-2021| DMX9208| Model Answer for Q3

Given Data:
Maximum Turbine Output (Electrical): PT_E_Max 17 MW

Normal Operating Turbine Output (Electrical): PT_E_Opt 10 MW

Generator Efficiency: ηG 0.984

Turbine Loss: PT_Loss 0.38 MW

HP Header Condition:
PHPH 50 bar

THPH 450 °C

IP Header Condition:
PIPH 12 bar
TIPH 250 °C

LP Header Condition:
PLPH 4 bar

TLPH 150 °C

Bolier Feedwater Condition:

PFW 80 bar

TFW 120 °C

Normal Flow Through the Ejector Line: tonne

mejector 4.3
hr

P2 Boiler Nominal Power: PB_P2 80 MW

P3 Boiler Nominal Power: PB_P3 125 MW

Calculations:

kJ
HP Header Enthalpy: hHPH 3317.2 (From Superheated Steam Tables)
kg
kJ
IP Header Enthalpy: hIPH 2935.6 (From Superheated Steam Tables)
kg
kJ
LP Header Enthalpy: hLPH 2752.8 (From Superheated Steam Tables)
kg
kJ (From Saturated Steam Tables -
Enthalpy of Inlet Feedwater to Boilers: hFW 503.81
kg Temperature is 120 Deg Cel. )
Normal Operating Turbine Output (Mechanical Power to Generator):
PT_E_Opt
PT_G_Opt 10.1626 MW
ηG
 5 Nov 2021 12:37:13 - Q3.sm

Converted Power to Turbine(Thermal Power to Mechanical Power) at Normal Operational Conditions:

PT_M_Opt PT_G_Opt PT_Loss 10.5426 MW

PT_M_Opt
kg
Mass Steam Flow Through the Turbine: mT_Opt 18.6793
hHPH hLPH s

PT_G_Opt
Mechanical Efficiency of the Turbine: ηT_M 0.964
PT_M_Opt

New HP Header Condition:

PHPH_New PHPH 50 bar

THPH_New 500 °C

kJ
New HP Header Enthalpy: hHPH_New 3434.7 (From Superheated Steam Tables)
kg

kg
New Steam Flow through the Turbine: mT_New mT_Opt mejector 19.8738
s

New Converted Thermal Power to Mechanical Power in the Turbine Due to Closing of the Ejector Valve:

PT_M_New mT_New hHPH_New hLPH 13.5519 MW

New Mechanical Power to the Generator: PT_G_New PT_M_New PT_Loss 13.1719 MW

New Electrical Power Output from the Turbine(Generator):

PT_E_New PT_G_New ηG 12.9612 MW

Only P2 and P3 boilers are working, they feed steam to the HP header with the usual conditions:- PHPH & THPH

Total Operating Boiler Power when the P2 and P3 Working:

PB_Total_P2P3 PB_P2 PB_P3 205 MW

PB_Total_P2P3
Total Feedwater Flow through P2 & P3 Boilers: kg
mFW_P2P3 72.8658
hHPH hFW s
QUESTION 04 (15 Marks)

A 40 MW steam power plant is equipped with an air-cooled condenser. Steam turbine inlet
parameters are; 350ºC temperature, 40 bar pressure. Turbine exit is at 50°C saturated steam.
By changing air-cooled condenser to a water-cooled condenser, turbine exit condition has now
been changed to 30°C saturated steam.

Find out/ Calculate following;

a) Enthalpy of steam at turbine inlet (2 marks)

Enthalpy value read from hs chart (P = 40 bar and T = 350°C) = h T inlet = 3093.3 kJ/kg

b) Enthalpy of turbine exit when it is in air-cooled condenser configuration (2 marks)

Enthalpy value read from hs chart (Saturated steam at 50°C) = h T out at 50C =2591.3 kJ/kg

c) Mass flow rate through the steam turbine (4 marks)

Power = Mass flow X (Enthalpy difference) X (efficiency)

𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 (𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐)

𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =
𝐸𝑛𝑡ℎ𝑎𝑙𝑦 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑋 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
 40 𝑋 1000 𝑘𝑊
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =
(3100 − 2590.4)𝑘𝐽/𝑘𝑔 𝑋 (0.95 𝑋 0.98)

Mass flow rate = 85.587 kg/s

d) Enthalpy of turbine exit when it is in water-cooled condenser configuration (2 marks)

Enthalpy value read from hs chart (Saturated steam at 30°C) = h T out at 30C =2555.6 kJ/kg

e) Increment of power output due to the change of the condenser (5 marks).

Power output when condenser is changes to water cooled condenser. Consequence is

lower condenser temperature, hence lower saturation pressure / enthalpy at steam exit,

Power output (new) = Mass flow X (Enthalpy difference) X (efficiency)

Power output (new) = 85.587 X (3093.3 – 2555.6) X (0.95 X 0.98)

= 42.845 MW.

Increment of power output = 42.845 – 40 = 2.845 MW.

(Mechanical efficiency of turbine is 95% and generator efficiency 98%. Mass flow through the
turbine will not affect condenser change).

ALL RIGHT RESERVED