Power Generation Using Multi Component

Working Fluids

P M V Subbarao
Professor
Mechanical Engineering Department
Indian Institute of Technology Delhi

Synthesis of More Appropriate Working Fluids……

Irreversible Heat transfer process : Rankine Cycle
Flue gases A

External
Irreversibility-1
11

1kg 6
8 Steam
5

7
T

6
4
5 External
Irreversibility-2
2

3 3 f

e
Cooling water
S

External Irreversibilities with Rankine cycle

Working fluid water – Best performance at high pressure Low pressure and low temperature region

4.352 M 7.135
150.0 816.06 A 735.8
777.2 H
639.314 537.0 506.53 310.0
A B C C B
C B A B C B C B C
2.154 M

0.701 M
0.018 M
0.043 M
0.946 M
2.186 M
0.935 M
0.024 M

0.078 M
1.251 M
0.057 M

0382 M

0.382
0.078
G
P=210.061 MW
14.970 M
7.135 735.8 0.854 M
740.70

40.57 740.70 D
61.067 352.2

34.520 310.0
572.218 352.2
0.9069 642.9 0.1033 577.3
36.52 843.89
40.57

16.833 107.1 441.114 46.45

572.156 537.0 2.389 683.2
740.70
61.067 350.4

34.700 423.0
639.314 200.0 15.87 789.9

26.299 195.8 3.068 M

B
16.70 789.9
34.520 309.4
6.564 735.8

34.700 424.5 64.846 M

0.4361 619.8 D

2.269 683.2
26.299 195.5
38.54

0.8616 642.9
16.883 106.8
0.000 M

0.4143 619.8
20.510 77.96 0.1033 46.1

20.510 76.5
509.028 46.4
639.314 164.1
205.5 168.3
205.5

49.2
509.028 49.0

47.0
509.028 46.8
0.299 M

748.8 H
C
0.0 K

2.8 K

3.7 K
0.0 K

2.8 K
D

19.38 46.7
509.028 46.3
256.21
639.314 247.0

509.026 120.8
121.3
6.0 K
210.3 6.0 K

12.0K
D D
61.067 206.0

172.0

124.0
95.766 170.0

26.299 123.8

95.0

76.2
43.183 95.0

63.693 76.3

99.9
0.299 99.9
58.8
63.693 58.8
6.414 162.1
639.314 160.7

HEAT RATE=1985.05 K CAL/KW

92.4 72.7
Radiation losses are Ignored
KCAL/KG 509.026 92.2 509.026 72.6
T/HR CEL
Heat and mass balance program
Fig.1.4 Layout of 210MW Coal Fired Power Plant Optimal bleed pressure &
3
Fig 2 Layout of modern Coal fired power plant
 0.3783 m3/ kg

Exit at higher
velocity

Kinetic
Energy
loss

12.65 m3/ kg

Location of condensation process in a Low pressure steam turbine

Moisture 4
(Source Alstom ) Loss
 For example, a long, full speed rotor blade,
operating in a non-reheat cycle, may
involve wetness levels of about 15% at
exhaust.

Without suitable counter-measures this can

result in extreme tip-erosion (illustrated in
Fig).

Erosion of a long last stage blade

( Source Alstom )
 Source of Energy Vs Working Fluid
• The overall efficiency of a thermodynamic conversion
cycle is a consequence of ;
• the energy potential of the source-sink combination, of
internal inefficiencies (losses in turning machinery, in
regenerators,etc.) and
• of losses from irreversible heat transfer from a source
and to a sink.
• The latter depends mostly on the levels of matching of
the apparent heat capacities of the working fluid, source
and sink.
• In principle, a divergence in the thermal behaviour
between a working fluid and a source or sink can be
counteracted by using complex cycle configurations such
as evaporation at multiple pressure levels in modern
combined cycles or condensation at 2 or 3 decreasing
temperatures in cogenerative systems.
 Energy Recovery from Hot Gas

T 0C
300

250

200

150

100
Two Phase Fluid
50
 Selection of Another Working Fluid along with
Water !!!
• The fluid generally has lower boiling temperature than
water.
• Lower freezing point and high stability temperature.
• Higher latent heat and low liquid specific heat or near
vertical saturated liquid line so that most of the heat is
added during change of phase without the need for the
complexity of regenerative feed heating to ‘Carnotize the
cycle’ to realize high cycle efficiency.
• Small specific volume and low viscosity.
• The fluid should to be non-corrosive, non-flammable,
non-toxic and safe to use.
• Good availability and low cost.
T-S and T-X DIAGRAMS : Binary Components
 Mixtures as Working Fluids
• Any single component working fluid, due to pinch, approach
point limitations and a constant boiling point, cannot cool the
gases to low temperature.
• Single component fluid can recover only about 15-20 % of the
energy is that recovered by a two phase fluid.
• Multiple pressure systems could recover more energy, but
added the complexity of the system and cost.
• The main characteristic is that the boiling of working fluid
occurs over a range of temperatures.
• By virtue of varying boiling point, two component working
fluid is able to "match" or run parallel to the gas (source)
cooling temperature line while recovering energy and hence the
final exit gas temperature can be low.
• The condensation of two component working fluid also occurs
over a range of temperatures and hence permits additional heat
recovery in the condensation system.
• The condenser pressure can be much higher in two component
fluid cycle, and the cooling water temperatures do not impact
the power output of the turbine .
• Thermo-physical properties of mixture can also be altered by
changing the concentration of one component.
• This helps to recuperate or regenerate energy in the
condensation system.
• Modifications to the condensing system are also possible by
varying the mixture concentration and thus more energy can be
recovered from the exhaust gases.
• Expansion in turbine can give a saturated vapor in two
component fluid cycle compared to wet steam.
• Conventional equipment such as steam turbines can be used in
two component fluid cycle.
 Rankine Cycle Vs Novel Cycle

• Binary working fluid -- A mixture of two fluids.

– Variable temperature Boiling.

• Varying concentration of binary fluid in different parts of the cycle.

– Varying thermodynamic properties.

• Internal Recovery of Heat.

– Energy recovery from a one stream of working fluid to another
stream of working fluid.

• 15 -- 25% improvement in efficiency.

– Less Irreversibility.
 Brief History
• The technology is the creation of Dr. Alexander Kalina, a
Russian scientist.
• He left a high position in Soviet Union 30 years ago to
come to US.
• Formed Exergy Inc. to develop and commercialize an
advanced Thermodynamic Cycle.
• 1993, General Electric signed an agreement with Exergy
for a world wide exclusive licensing rights to use the
technology for combined cycle systems in 50 MW to 150
MW range.
• GE and Exergy working on a combined cycle plant that
will operate on an overall efficiency of 62%.
Simple Kalina Cycle
The pump pressurized the saturated liquid (5)
which is leaving from the condenser and it is
sent in to the high temperature recuperator (6).
The liquid takes off the heat from the two phase
dead vapour (3).
The pressurized hot liquid (sub-cooled state)
enters (1) into the vaporizer where the liquid is
converted in to vapor (2) by utilizing the latent
or sensible heat of the hot source (1s-2s).
The saturated vapor (2) from the vaporizer is
expanded in the turbine up to its condenser
pressure.
The two phase mixture after giving a part of
it’s latent heat to the incoming liquid (4) enters
in to the condenser, where cooling water enters
(1w), takes away all the heat available in the
two-phase mixture, and leaves at higher
temperature (2w).
The saturated liquid is pressurized in the pump
and the cycle repeats.
T-S and T-X DIAGRAMS
 Ammonia water cycle modeling

• The mathematical models for Ammonia water cycle are

constructed using the theory of thermodynamics.
• The whole system is divided into many components namely
vaporizer, steam turbine, condenser, high temperature
recuperator etc.
• According to the characteristic construction of each
component, appropriate assumptions are introduced.
• Steady State Steady Flow Models are developed.
Vaporizer
The heat transfer rate QV (W) between the source and the working fluid is
calculated by
 Optimization
• In this case, efficiency of the cycle is considered as the objective function to be
optimized.
• The Ammonia water cycle has four variables.
• Fraction of ammonia (x)
• Turbine inlet pressure (P3)
• Heat source inlet temperature T1S
• Heat source outlet temperature T3S.
• The cycle performance depends on the values for these four variables that are
free to change during optimization.
• Each combination of the eight values represents a unique operating condition of
the cycle.
• Searching for optimum values for these variables are the task of this
optimization work.
• Consequently, the objective function to be maximized can be written as,
The objective function is solved with the help of most power full
optimization methodology ‘Monte Carlo’.

First law efficiency of the cycle is defined as

h2  h3
cycle 
h2  h1
Variation of first law efficiency at different steam inlet conditions of simple

Saturation Pressure of Rankine Cycle (bar)

Effect of variation in fraction of ammonia at the evaporator inlet on first
law efficiency

Condenser pressure in the Ammonia water cycle largely

depends on cooling water inlet temperature and fraction of
Ammonia in the Ammonia water mixture.
For the same cooling water inlet temperature, decreasing
the Ammonia mass fraction at the condenser inlet will
reduce the condenser pressure and it will leads to larger
expansion process in the turbine and hence more power
output and higher efficiency
The Kalina Cycle : Nine Components
Modern Kalina Cycle
 Effect of variation in fraction of ammonia at the evaporator inlet on
first law efficiency

The following modifications are suggested for the proposed Ammonia water
cycle when compared to KCS 34.
1.Super heater is added in the cycle to utilize the superheated steam at low
temperature and pressure.
The saturated vapor from the separator is superheated in the super heater
before entering the steam turbine.
2.The additional feed water is included in the system, which utilize the
sensible heat of low grade to heat the sub-cooled water coming it from the
condenser of an Ammonia water cycle
Kalina Cycle with Subcooler
Effect of turbine inlet pressure on first law
efficiency
The Superheat Kalina Cycle
Comparison of Exergy destruction in various
components of the Ammonia water cycles