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INTRODUCTION DEFINITION MAIN FEATURES EFFICIENCY OF A POWER PLANT TYPES OF CCPG/CCPP ISCC IGCC SIZE OF CCGT EFFICIENCY OF CCGT BOOSTING EFFICIENCY FUEL FOR CCPP LOW GRADE FUEL FOR TURBINES CONFIGURATION OF CCGT PLANTS ADVANTAGES OF CCPP/CCGT REFERENCES

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ILLUSTRATIONS/DIAGRAMS 1.1 FIG. 1. SIMPLIFIED CCPP 1.2 FIG. 2. COMBINED CYCLE UNIT POWER PLANT 1.3 FIG, 3. INTEGRATED GASIFICATION CPP

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Introduction and Overview of Combined Cycle Power Plant


Power generation is essential to a country's commerce and industry. As the demand for power increases, more efficient power generation systems are developed. The growing environmental concern especially with regards to carbon emission also leads to emphasis on cleaner power generation systems. Combined cycle power generation is one such system that is gaining popularity among nations. Historically successful combined cycles have used hot cycles with mercury vapor turbines, magneto-hydrodynamic generators or molten carbonate fuel cells, with steam plants for the low temperature bottoming cycle. Bottoming cycles operating from a steam condenser's heat are theoretically possible, but uneconomical because of the very large, expensive equipment needed to extract energy from the small temperature differences between condensing steam and outside air or water. However, it is common in cold climates to drive community heating systems from a power plant's condenser heat. Such cogeneration systems can yield theoretical efficiencies above 95%. In automotive and aeronautical engines, turbines have been driven from the exhausts of Otto, Diesel, and Crower cycles. These are called turbo-compound engines. Aside from turbochargers, they have failed commercially because their mechanical complexity and weight are less economical than multistage turbines. Stirling engines are also a good theoretical fit for this application.

In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant, a gas turbine generator generates electricity and heat in the exhaust is used to make steam, which in turn drives a steam turbine to generate additional electricity. This last step enhances the efficiency of electricity generation. Many new gas power plants in North America and Europe are of this type. Such an arrangement used for marine propulsion is called combined gas (turbine) and steam (turbine) (COGAS

Definition
A combined cycle power plant works with the principle of combined cycles. In a simple definition, a combined cycle is an assembly of heat engines that work in tandem off the same source of heat, converting it into mechanical energy, which in turn usually drives electrical generators. The principle is that the exhaust of one heat engine is used as the heat source for another, thus extracting more useful energy from the heat, increasing the system's overall efficiency.
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This works because heat engines are only able to use a portion of the energy their fuel generates (usually less than 50%). The remaining heat (e.g., hot exhaust fumes) from combustion is generally wasted. Combining two or more thermodynamic cycles results in improved overall efficiency, reducing fuel costs. In stationary power plants, a successful, common combination is the Brayton cycle (in the form of a turbine burning natural gas or synthesis gas from coal) and the Rankine cycle (in the form of a steam power plant). Multiple stage turbine or steam cylinders are also common.

Main features

Fig 1

Simplified Combined Cycle Power Plant

Copyright: Phanyessence

Combined cycle power generation combines 2 cycles for operation, namely the gas turbine cycle and the vapor power (or steam turbine) cycle. In a gas turbine power plant, natural gas and compressed air undergo combustion. The resultant high pressure gas drives the gas turbine which in turn produces electricity. Although it is clean and fast in starting up, the gas turbine power plant suffers from low thermo efficiency of about 25 to 30%. Much of the energy is wasted in the form of gas turbine exhaust.

The combined cycle power generation makes use of the merits of the high temperature (1100 to 1650C) gas turbine cycle and the lower temperature (540 to 650C) steam turbine cycle. The hot exhaust gas from the gas turbine, instead of being released as waste, is captured and channeled to the steam turbine where steam is heated by the exhaust to drive the turbine.

For gas turbines the amount of metal that must withstand the high temperatures and pressures is small, and lower quantities of expensive materials can be used. In this type of cycle, the input temperature to the turbine (the firing temperature), is relatively high (900 to 1,400 C). The output temperature of the flue gas is also high (450 to 650 C). This is therefore high enough to provide heat for a second cycle which uses steam as the working fluid; (a Rankine cycle). As already stated above; in a combined cycle power plant, the heat of the gas turbine's exhaust is used to generate steam by passing it through a heat recovery steam generator (HRSG) with a live steam temperature between 450 and 650 C. The condenser of the Rankine cycle is usually cooled by water from a lake, river, sea or cooling towers. This temperature can be as low as 15 C Laying more emphasis on the above, structurally, a combined cycle power plant consists of two main parts: the gas turbine plant and the steam turbine plant. In the gas turbine plant, atmospheric air enters through the compressor and into the combustor (or combustion chamber) where fuel (usually natural gas) is added. Combustion takes place and the hot gas drives the turbine, which in turn drives the generator and produces electricity. The hot flue gas from the gas turbine enters a heat exchanger, sometimes known as heat recovery boiler or heat recovery steam generator, where it is used to heat up the steam. The superheated steam is then used to drive the steam turbine which in turn drives the generator to produce electricity. The exit steam from the steam turbine goes through a condenser and then back to the heat exchanger where the cycle repeats itself.

Fig. 2.

Combined Cycle Unit Power Plant

Copyright: Phanyessence

In its simplest terms, combined cycle, being the combination of two (or more) thermal cycles within a single power plant to increase efficiency has various subsystems in it. (See Figure 2.) There is the topping cycle or high temperature cycle, typically a natural gas turbine-driven generator. Then there is the bottoming cycle or low temperature cycle used for recovering heat from the topping cycle to produce additional electricity through a steam turbine-driven generator. The combustion gas turbine operates on the Brayton cycle. It uses a compressor to compress the inlet air upstream of a combustion chamber. Then the fuel is introduced and ignited to produce a high temperature, high pressure gas that enters and expands through the turbine section. The turbine section powers both the generator and compressor. Combustion turbines are able to burn a wide range of fuels including natural gas and synthesis gas produced by coal gasification. The conventional (fossil) steam plant operates on the Rankine cycle. The steam is created by a boiler, where pure water passes through a series of tubes to capture heat from the firebox and then boil under high pressure to become superheated steam.
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The superheated steam leaving the boiler then enters the steam turbine throttle, where it powers the turbine and connected generator to make electricity. After the steam expands through the turbine, it exits the back of the turbine where it is cooled and condensed back to water in the surface condenser. The condensate is then returned to the boiler through high pressure feed pumps for reuse. Heat from the condenser is normally rejected from the condenser to a cooling tower or a body of water such as a river. In a combined cycle power plant, a waste heat boiler is installed onto the gas turbine exhaust stream. Known as heat recovery steam generators (HRSG), they are used to produce steam from hot gas turbine exhaust to drive a steam turbine which in turn drives an electric generator. The result: a combined cycle power plant increases thermal efficiency by as much as 60%. Efficiency of a Power Plant Thermal efficiency of a power plant measures how effective it can convert heat energy into work which is then converted to electrical output. As such, it is an important measure for power plant. Also, an efficient system uses less fuel, thus incurring lower fuel cost and lower operating costs for the plant.

Types of CCPG
There are various types of combined cycle power generation, some of them are: 1. Combined cycle with supplementary firing, 2. Combined cycle with regeneration, 3. Combined cycle with feedwater heating, 4. Combined cycle with multi-pressure steam cycle, 5. Integrated gasification combined cycle power, 6.Integrated Solar Combined Cycle and 7. Combined cycle for nuclear power plants. Most companies in different countries have already embraced the technology of combined cycle power generation not only for the reason of power efficiency but also to reduce Carbon dioxide and Carbon monoxide emission into the atmosphere. One of such companies topping the list is Siemens. Combined cycle power plants from

Siemens are among the worlds safest fossil-fired plants for the environment and climate. They combine a gas-powered turbine with a steam turbine to make twice the use of the fuel they consume: The exhaust heat from the gas turbine is exploited to power the steam turbine, greatly improving overall power-plant efficiency.
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Todays combined cycle plants already achieve an efficiency of around 58 percent, but raising the combustion temperature could boost this even further. In December 2007, Siemens first ignited a new 375-megawatt gas turbine the most powerful yet most eco-friendly unit of its kind in the world at the Irsching 4 power plant in Bavaria. The Irsching turbines improved efficiency means it not only consumes less fuel per generated kilowatt hour, it also emits less nitrogen oxide (fewer than 15 parts per million) and carbon dioxide. When the turbine goes into combined cycle operation, it is expected to set a new world efficiency record of more than 60 percent and, compared to current combined-cycle plants with the same capacity, it will emit 45,000 tons less carbon dioxide a year. Due to the significant advantages offered by the combined-cycle process, the technology will be adapted to fuels other than gas, including coal, biomass and refinery residue. Integrated gasification combined-cycle power plants (IGCC) in particular look to be a promising way forward.

Integrated solar combined cycle (ISCC)


An integrated solar combined cycle, or ISCC, is a power plant using solar thermal collectors. This is typically in the form of parabolic troughs

Integrated Gasification Combined Cycle


This, as a fact, is an emerging technology. The continued dominance of coal as the fuel of choice for power generating plants may well depend upon clean coal technology, a new generation of energy processes that sharply reduce air emissions and other pollutants compared to older coal-burning systems. Integrated gasification combined cycle (IGCC) is a technology that turns coal into gas synthesis gas (syngas). (See Figure 3.) In a typical IGCC plant, coal is first gasified to synthesis gas hydrogen and carbon monoxide (CO). The synthesis gas is scrubbed to remove acid gases and mercury. The syngas is then burned in the combustion turbine, and hot exhaust is captured in a waste heat boiler or HRSG and used to raise steam to drive a second turbine. As in natural gas combined cycle, both turbines produce electricity while significantly increasing thermal efficiency: 58 to 60% for IGCC operation versus 38 to 42% for a direct-fired coal unit.
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While the IGCC gas plant is far more complex than that of the natural gas combined cycle unit, both the power generating sections and pumping equipment are virtually identical.

Fig. 3.

Integrated Gasification Combined Power Plant

Copyright: Phanyessence

Typical size of CCGT plants


For large scale power generation, a typical set would be a 270 MW gas turbine coupled to a 130 MW steam turbine giving 400 MW. A typical power station might consist of between 1 and 6 such sets. Plant size is important in the cost of the plant. The larger plant sizes benefit from economies of scale (lower initial cost per kilowatt) and improved efficiency. A single shaft combined cycle plant comprises a gas turbine and a steam turbine driving a common generator. In a multi-shaft combined cycle plant, each gas turbine and each steam turbine has its own generator. The single shaft design provides slightly less initial cost and slightly better efficiency than if the gas and steam turbines had their own generators. The multi-shaft design enables 2 or more gas turbines to operate in conjunction with a single steam turbine, which can be more economical than a number of single shaft units.
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The primary disadvantage of multiple stage combined cycle power plants is that the number of steam turbines, condensers and condensate systems - and perhaps the number of cooling towers and circulating water systems - increases to match the number of gas turbines. For a multiple shaft combined cycle power plant there is only one steam turbine, condenser and the rest of the heat sink for up to three gas turbines; only their size increases. Having only one large steam turbine and heat sink results in low cost because of economies of scale. A larger steam turbine also allows the use of higher pressures and results in a more efficient steam cycle. Thus the overall plant size and the associated number of gas turbines required have a major impact on whether a single shaft combined cycle power plant or a multiple shaft combined cycle power plant is more economical. Gas turbines of about 150 MW size are already in operation manufactured by at least four separate groups - General Electric and its licensees, Alstom, Siemens, and Westinghouse/Mitsubishi. These groups are also developing, testing and/or marketing gas turbine sizes of about 200 MW. Combined cycle units are made up of one or more such gas turbines, each with a waste heat steam generator arranged to supply steam to a single steam tubine, thus forming a combined cycle block or unit. Typical Combined cycle block sizes offered by three major manufacturers (Alstom, General Electric and Siemens) are roughly in the range of 50 MW to 500 MW.

Efficiency of CCGT plants


To avoid confusion, the efficiency of heat engines and power stations should be stated HHV (aka Gross Heating Value) or LCV (aka Net Heating value), and whether Gross output at the generator terminals or Net Output at the power station fence are being considered. In general in service Combined Cycle efficiencies are over 50 percent on a lower heating value and Gross Output basis. Most combined cycle units, especially the larger units, have peak, steady state efficiencies of 55 to 59%. Research aimed at 1370C (2500F) turbine inlet temperature has led to even more efficient combined cycles and 60 percent efficiency has been reached in the combined cycle unit of Baglan Bay, a GE H-technology gas turbine with a NEM 3 pressure reheat boiler, utilising steam from the HRSG to cool the turbine blades. Siemens AG announced in may 2011 to have achieved a 60.75% net efficiency with a 578 megawatts SGT5-8000H gas turbine at the Irsching Power Station.
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By combining both gas and steam cycles, high input temperatures and low output temperatures can be achieved. The efficiency of the cycles add, because they are powered by the same fuel source. So, a combined cycle plant has a thermodynamic cycle that operates between the gas-turbine's high firing temperature and the waste heat temperature from the condensers of the steam cycle. This large range means that the Carnot efficiency of the cycle is high. The actual efficiency, while lower than this, is still higher than that of either plant on its own. The actual efficiency achievable is a complex area. The electric efficiency of a combined cycle power station, calculated as electric energy produced as a percent of the lower heating value of the fuel consumed, may be as high as 58 percent when operating new, ie unaged, and at continuous output which are ideal conditions. As with single cycle thermal units, combined cycle units may also deliver low temperature heat energy for industrial processes, district heating and other uses. This is called cogeneration and such power plants are often referred to as a Combined Heat and Power (CHP) plant.

Boosting Efficiency
The efficiency of CCGT and GT can be boosted by pre-cooling combustion air. This is practiced in hot climates and also has the effect of increasing power output. This is achieved by evaporative cooling of water using a moist matrix placed in front of the turbine, or by using Ice storage air conditioning. The latter has the advantage of greater improvements due to the lower temperatures available. Furthermore, ice storage can be used as a means of load control or load shifting since ice can be made during periods of low power demand and, potentially in the future the anticipated high availability of other resources such as renewable during certain periods.

Fuel for combined cycle power plants


The turbines used in Combined Cycle Plants are commonly fueled with natural gas. However, global natural gas reserves are expected to be fully consumed by 2070. Despite this fact, it is becoming the fuel of choice for an increasing amount of private investors and consumers because it is more versatile than coal or oil and can be used in 90% of energy applications. Chile which once depended on hydropower for 70% of its electricity supply, is now boosting its gas supplies to reduce reliance on its drought afflicted hydro dams. Similarly China is tapping its gas reserves to reduce reliance on coal, which is currently burned to generate 80% of the countrys electric supply.
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Where the extension of a gas pipeline is impractical or cannot be economically justified, electricity needs in remote areas can be met with small scale Combined Cycle Plants, using renewable fuels. Instead of natural gas, Combined Cycle Plants can be filled with biogas derived from agricultural and forestry waste, which is often readily available in rural areas. Combined cycle plants are usually powered by natural gas, although fuel oil, synthesis gas or other fuels can be used. The supplementary fuel may be natural gas, fuel oil, or coal. Biofuels can also be used. Integrated solar combined cycle power stations combine the energy harvested from solar radiation with another fuel to cut fuel costs and environmental impact. The first such system to come online is Yazd power plant. Iran and more are under construction at Hassi R'mel. Algeria and Ain Beni Mathar, Morocco. Next generation nuclear power plants are also on the drawing board which will take advantage of the higher temperature range made available by the Brayton top cycle, as well as the increase in thermal efficiency offered by a Rankine bottoming cycle.

Low-Grade Fuel for Turbines


Gas turbines burn mainly natural gas and light oil. Crude oil, residual, and some distillates contain corrosive components and as such require fuel treatment equipment. In addition, ash deposits from these fuels result in gas turbine debatings of up to 15 percent they may still be economically attractive fuels however, particularly in combined-cycle plants. Sodium and potassium are removed from residual, crude and heavy distillates by a water washing procedure. A simpler and less expensive purification system will do the same job for light crude and light distillates. A magnesium additive system may also be needed to reduce the corrosive effects if vanadium is present. Fuels requiring such treatment must have a separate fuel-treatment plant and a system of accurate fuel monitoring to assure reliable, low-maintenance operation of gas turbines.

Configuration of CCGT plants


The combined-cycle system includes single-shaft and multi-shaft configurations. The single-shaft system consists of one gas turbine, one steam turbine, one generator and one Heat Recovery Steam Generator (HRSG), with the gas turbine and steam turbine coupled to the single generator in a tandem arrangement on a single shaft. Key advantages of the single-shaft arrangement are operating simplicity, smaller footprint, and lower startup cost.
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Single-shaft arrangements, however, will tend to have less flexibility and equivalent reliability than multi-shaft blocks. Additional operational flexibility is provided with a steam turbine which can be disconnected, using an synchro-self-shifting (SSS) Clutch, for start up or for simple cycle operation of the gas turbine. Multi-shaft systems have one or more gas turbine-generators and HRSGs that supply steam through a common header to a separate single steam turbine-generator. In terms of overall investment a multi-shaft system is about 5% higher in costs. Single- and multiple-pressure non-reheat steam cycles are applied to combined-cycle systems equipped with gas turbines having rating point exhaust gas temperatures of approximately 540 C or less. Selection of a single- or multiple-pressure steam cycle for a specific application is determined by economic evaluation which considers plant installed cost, fuel cost and quality, plant duty cycle, and operating and maintenance cost. Multiple-pressure reheat steam cycles are applied to combined-cycle systems with gas turbines having rating point exhaust gas temperatures of approximately 600 C. The most efficient power generation cycles are those with unfired HRSGs with modular pre-engineered components. These unfired steam cycles are also the lowest in cost. Supplementary-fired combined-cycle systems are provided for specific application. The primary regions of interest for cogeneration combined-cycle systems are those with unfired and supplementary fired steam cycles. These systems provide a wide range of thermal energy to electric power ratio and represent the range of thermal energy capability and power generation covered by the product line for thermal energy and power systems. by Engr. Bilal Pervez

Advantages of CCPP/CCGT
A combined cycle power generation system offers many advantages. Some of such advantages are as follows:

(1) As most combined cycle generation systems use natural gas as the fuel, the environmental emissions are low. (2) There is less pollution produced compared to conventional steam or gas turbine power plants. As such, complex and expensive environmental control systems are not needed. (3) Transportation of fuel via pipelines is also easier than that of coal and oil.
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(4) The gas turbine portion of the combined cycle system is easy to install. This means a short schedule of about 1 year from order to operation while the steam turbine portion can operate within another year. This can provide the grid with power earlier than with other systems. (5) The combined cycle power generation system also offers quick part-load starting. For example, the GE Model-7000 gas turbine is able to produce maximum output of 198MW within 30 minutes while the steam turbine portion takes about an hour to operate from a cold start. It can operate over a wide range of loads and is suitable for meeting peak power requirement and also base load. Supplementary firing can be used to increase steam turbine output in times of increased output demand. On the other hand, the gas turbine can be stopped when there is a decrease in demand. (6) It is also cheaper to build a combined cycle power plant than coal, nuclear or renewable energy power plant. Its capital cost is lower than that of steam turbine plant. (7) There are many power generation systems available in the world. Although nuclear power plants are clean and efficient, they are expensive and complex. They are also less easily accepted by the population due to the experience of the Three Mile Island and Chernobyl incidents. On the other hand, combined cycle power plants offer flexibility in terms of size and outputs, and are faster to build than nuclear power plants. The ability to increase and decrease output on demand gives combined cycle power plants an upper hand in the competitive power markets. (8) The Earth's supply of natural gas has been estimated to last 70-100 years and as long as natural gas price remains low, combined cycle power generation will have the competitive edge against other forms of generation. (9) Also, with advancement in technology, the capital cost of combined cycle generation has dropped from US$600/ kW in 1990 to less than US$350/kW today. (10) Another advantage of these power plants is that the natural gas they run

on is less carbon dioxide-intense than other fossil fuels. This means that the generators in combined-cycle plants are one of the key power generating technologies in the battle against climate change.

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11. The environmental value of this technology is so much that every country should be encouraged to embrace it. Much lower carbon dioxide emissions per kilowatt hour 345g/kWh for modern combined-cycle plants, compared to 578g/kWh on average for power generating facilities worldwide

Further emissions reductions are anticipated 45,000 tons less carbon dioxide due to efficiency gain of 2 percentage points over earlier plant technologies Studies in the United Kingdom have also predicted that by 2050, 40 - 50% of UK's power supply will be dominated by combined cycle power plants. From these, with continual improvement to the system, we can see that combined cycle power generation will become the mainstay in the power industry for at least the next few decades.

References
1. ^ "Siemens pushes world record in efficiency to over 60 percent while achieving maximum operating flexibility". Siemens AG. 19 May 2011. ^ "Efficiency by the Numbers" by Lee S. Langston 2. ^"The difference between LCV and HCV (or Lower and Higher Heating Value, or Net and Gross) is clearly understood by all energy engineers. There is no right or wrong definition." Claverton Energy Research Group. http://www.clavertonenergy.com/the-difference-between-lcv-and-hcv-or-lower-and-higher-heatingvalue-or-net-and-gross-is-clearly-understood-by-all-energy-engineers-there-isno-right-or-wrong-definition.html. 3. ^ "Natural Gas reserves". BP. Retrieved 19 September 2011. 4. ^ "Yazd Solar Energy Power Plant 1st in its kind in world". Payvand Iran news. 13 April 2007. 5. ^"CCGT Plants in Iran - other provinces". Power Plants Around the World Photo Gallery. 6. ^"SSS Clutch Operating Principle". SSS Gears Limited. http://www.sssclutch.com/howitworks/100-2SSSPrinciples.pdf. 7. ^ "BMW Turbosteamer gets hot and goes" by John Neff, AutoBlog, December 9, 2005

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