Generation of Most Eligible Steam for Rankine

Cycle

P M V Subbarao
Professor
Mechanical Engineering Department

Means to AchieveQualities of Working

Fluid Preferred by Sir Carnot …..
 Reheating : A Means to implement High Live Steam
Pressure
Supercritical
Improvement in Efficiency, %

593/6210C
593/5930C
565/5930C
565/5650C
538/5650C
538/5380C
Classification of Rankine
Cycles
More Bottlenecks to Achieve Supercritical
Steam Cycle
3sup 3sub

2
4sup 4sub
1

s
 Quality and Saturated Liquid-Vapor (Wet)
Mixture
• Now, let’s review the constant
pressure heat addition process for
water shown in Figure.
• The state 3 is a mixture of
saturated liquid and saturated
vapor.
• How do we locate it on the T-v
diagram?
• To establish the location of state 3
a new parameter called the quality
x is defined as
masssaturated vapor mg
x 
mass total m f  mg
 Adiabatic Expansion of Steam

• The liquid in the LP turbine expansion flow field is seen to

progressively appear, with lowering pressure, in four forms,
namely as:
• A fine mist (or fog) suspended in the steam;
• As a water stream running in rivulets along the casing (mainly
OD);
• As a water film moving on the surface of the blades (mainly
stator; not particularly evident on the rotor blades owing to
centrifugal-flinging action);
• As larger droplets created when the water flowing along the
surface of the blades reaches the trailing edge.
More Bottlenecks to Achieve Supercritical
Steam Cycle
3sup 3sub

2
4sup 4sub
1

s
 Ill Effects of High Pressure Cycles

Pressure, MPa
Old Last Stage LP Blade
 Modified Loss Region

 wet
 dry iso
Why should steam condense during Adiabatic
Expansion?????
Thermodynamic Characterization of
Working Fluid
Philosophical Recognition of Working
Fluid

Organic Substances must be selected

in accordance to the heat source
temperature level (Tcr < Tin source)
 Progress in Steam Rankine Cycle
Year 1907 1919 1938 1950 1958 1959 1966 1973 1975

MW 5 20 30 60 120 200 500 660 1300

p,MPa 1.3 1.4 4.1 6.2 10.3 16.2 15.9 15.9 24.1

Th oC 260 316 454 482 538 566 566 565 538

Tr oC -- -- -- -- 538 538 566 565 538

FHW -- 2 3 4 6 6 7 8 8

Pc,kPa 13.5 5.1 4.5 3.4 3.7 3.7 4.4 5.4 5.1

,% -- ~17 27.6 30.5 35.6 37.5 39.8 39.5 40

Reheating of Steam to Enhance Quality at the
Turbine Exit
Single Turbine
drum
 Analysis of Reheat Cycle

• Consider reheat cycle as a combination of Rankine cycle and horn

cycle.
• Cycle 1-2-3-4-5-6-1 = Cycle 1-2-3-4-4’-1 + Cycle 4’-4-5-6-4’.
• Therefore,

qin , RH  qin , Rankine  qin , Horn

wRH  wHP  wLP  w pump

’ 
wRH , net wHP  wLP  W pump
 RH  
qRH ,in q Rankine.in  q Horn,in
 Analysis of the Reheat Cycle

wHP  h3  h4

wLP  h5  h6

qRankine,in  h3  h2

qhorn,in  h5  h4 4’ 6

wRH ,net h3  h4  h5  h6   h2  h1 
 RH  
qRH ,in qRankine.in  qHorn,in
 Clues to Achieve Double Benefit
wRankine,net wRH ,net
 Rankine   RH 
qRankine.in q R.in
wHorn ,net
 Horn 
qHorn.in
Consider the ratio of

 RH  wRH ,net   qRankine.in 

  
  
 Rankine  wRankine,net   qRH .in 

Define Increment in efficiency

 RH
  1
 Rankine
Selection of Reheat Pressure

pmax= 15 MPa
Tmax= 550 0C
Tsat= 342.20C
Effect of Reheat Pressure on New Tm,in

pmax= 15 MPa
Tmax= 550 0C
Tsat= 342.20C
 Effect of Reheat Pressure

0.2 0.4 0.6 0.8 1.0

~0.3
prh/pmax
Optimal Selection of Reheat Point
Reheating : A Means to implement High
Live Steam Pressure

Supercritical
Improvement in Efficiency, %

593/6210C
593/5930C
565/5930C
565/5650C
538/5650C
538/5380C
Super Critical Cycle ~ 1990
Ultra Supercritical Installations of The World
Double Reheat Ultra Super Critical Cycle


 Reheater Pressure Optimization for
Double Reheat Units

97bar
 double  Reheat
 single Reheat 69bar

110bar
Improvement in Efficiency, %
21st century Rankine Cycles
Super Critical Cycle of Year 2005
 Double Reheat Super Critical Plants

Net efficiency on natural gas is expected to reach 49%.

Net efficiency on coal is expected to reach 47%.
Advanced 700 8C Pulverised Coal-fired
Power Plant Project
FUTURE ULTRA SUPERCRITICAL PLANT – UNDER
DEVELOPMENT

EFFICIENCY 55 %
 Steam Generation : Explore more
Causes for Wastage

x=s
Look for More Opportunities to Reduce
Wastage

S  m  s
Follow the Steam Path : Early Stage

S  m  s
Follow the Steam Path : Middle Stage

S  m  s
Follow the Steam Path : End Stage

S  m  s
Follow the Steam Path : The End

S  m  s
Save Wastage thru Recycling !?!?

S  m  s
Regeneration Cycle with Mixer
(Open Feed Water Heater)
 Synthesis of Rankine Cycle with OFWH

S 6  m total  s6  S 5  m total  s5

 
 p2=p6 ’
  s6
S 3  S 2  y  m total S 6 '  S 5  y  m total  s5

ym
 total  s5
S1  1  y   m total  s1  S 2
 
1  y   m total

S
Regeneration Cycle with Mixer
(Open Feed Water Heater)
Analysis of mixing in OFWH
 Analysis of mixing in OFWH

Constant pressure mixing process

y
Consider unit mass
flow rate of steam thru h6
the turbine

h3 h2 (1-y)

Conservation of energy:

y  h6  1  y   h2  h3 y   h6  h2   h3  h2
h3  h2
y
h6  h2
 Analysis of Regeneration through OFWH
h3  h2
y
h6  h2

  h5  h4 
Q in  m

Q Out  m 1  y  h7  h1 
   
W net  W bleed  W cond  W pumps
 
 1  y  h2  h1 
 W pump1 2  m   h4  h3 
& W pump 3 4  m


  y  h5  h6   1  y  h5  h7   1  y  h2  h1    h4  h3  
W net  m
 Optimal Location of FWH

  

 W net
  W net bleed W net cond

Q in Q in

 

 W net bleed
  W net cond

Q in Q in

  bleed   condensing

h3  h2
y
h6  h2
 Performance of OFWH Cycle

0.49 ~ 12MPa
0.485
0.48
0.475
total 0.47
0.465
0.46
0.455
0.45
0 5 10 15 20
pbleed, MPa
 Gross Workoutput of bleed Steam

200 ~ 12MPa
180
160 y   h5  h6 
140
120
wbleed

100
80
60
40
20
0
0 5 10 15 20
pregen, MPa
 Workoutput of bleed Steam

1600
1400
1200
1000
wbleed

800
600
400
200
0
0 0.1 0.2 0.3 0.4 0.5

y, MPa
 More Work output with more bleed Steams

1600
1400
1200
1000
wbleed

800
600
400
200
0
0 0.1 0.2 0.3 0.4 0.5
y pregen, MPa
 Progress in Rankine Cycle Power Plants

Year 1907 1919 1938 1950 1958 1959 1966 1973 1975
MW 5 20 30 60 120 200 500 660 1300

p,MPa 1.3 1.4 4.1 6.2 10.3 16.2 15.9 15.9 24.1

Th o C 260 316 454 482 538 566 566 565 538

FHW -- 2 3 4 6 6 7 8 8

Pc,kPa 13.5 5.1 4.5 3.4 3.7 3.7 4.4 5.4 5.1

,% -- ~17 27.6 30.5 35.6 37.5 39.8 39.5 40

Open (Direct Contact) Feed Water Heater
 An Impractical Efficient Model for
Power Plant
A
Turbine

SG
B
yj, hbj Yj-11,hbj-1 Yj-2,hbj-2
C

OFWH OFWH OFWH C

1 ,hf (j) 1- yj 1- yj – yj-1 1- yj – yj-1- yj-2
hf (j-1)
hf (j-2) hf (j-3)
n number of OFWHs require n+1 no of Pumps…..
The presence of more pumps makes the plant unreliable…
Closed Feed Water Heater (Throttled
Condensate)
Closed Feed Water Heater (Throttled
Condensate)
Control of Entropy Generation due to Liquid
Heating
Effect of no of feed water heaters on thermal efficiency
and work output of a regeneration cycle

40 Thermal Efficiency 1100

W o rk o u tp u t(K J /k g )
39 1050
E ffic ie n c y (% )

38 1000

37 950

36 900

35 850
Specific Work Output
34 800
0 1 2 3 4 5 6
No of Feed water Heaters
Heater Selection and Final Feedwater
Temperature

• In order to maximize the heat rate gain possible with ultra-

supercritical steam conditions, the feedwater heater arrangement
also needs to be optimized.
• In general, the selection of higher steam conditions will result in
additional feedwater heaters and a economically optimal higher
final feedwater temperature.
• In many cases the selection of a heater above the reheat point
(HARP) will also be warranted.
• The use of a separate desuperheater ahead of the top heater for
units with a HARP can result in additional gains in unit
performance.
Typical Single Reheat Heater Cycle with
HARP
Effect of Final Feedwater Temperature and Reheat
Pressure on Turbine Net Heat Rate
Double Reheat Cycle with Heater above Reheat
Point
More FWHs for a Selected Bleed Points
New Circuits of Desuperheater for Preheating
of Feedwater in Steam Power Plants
New Circuits of Desuperheater for Preheating
of Feedwater in Steam Power Plants
New Circuits of Desuperheater for Preheating
of Feedwater in Steam Power Plants
 Efficiency of Danish Coal-Fired Power Plants

Continuous development resulted around the mid 80's in an

average efficiency of 38% for all power stations, and best values
of 43%.
In the second half of the 1990’s, a Danish power plant set a world
record at 47%.
Average efficiency, specific coal usage,
CO2 emissions

Indian Coal Plants:

Efficiency of modern coal power plant = 34-36%
Efficiency of old power plant = 20-30%
Expectations from Modern Steam Generator
for Higher Efficiency

• High Main Steam Pressure.

• High Main Steam Temperature.
• Double Reheat & Higher Regeneration.
• Metal component strength, stress, and distortion are of
concern at elevated temperatures in both the steam
generator and the steam turbine.
• In the steam generator’s heating process, the tube metal
temperature is even higher than that of the steam, and
concern for accelerated corrosion and oxidation will also
influence material selection.