Energy 36 (2011) 742e754

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Energy
journal homepage: www.elsevier.com/locate/energy

Prediction of performance, energy savings and increase in protability of two gas turbine steam generator cogeneration plant, based on experimental data
Francisco Jimnez-Espadafor Aguilar*, Miguel Torres Garca, Elisa Carvajal Trujillo, Jos Antonio Becerra Villanueva, Francisco J. Florencio Ojeda
Escuela Superior de Ingenieros de Sevilla, Avda. Camino de los Descubrimientos, s/n, 41092 Sevilla, Spain

a r t i c l e i n f o
Article history: Received 13 April 2010 Received in revised form 10 December 2010 Accepted 16 December 2010 Available online 26 January 2011 Keywords: Cogeneration Combined heat and power GT regulation Legal and market framework

a b s t r a c t
This study analyses three feasible regulation methods of an in-service cogeneration plant. The main task is to study the potential energy savings, CO2 reduction and the increase in protability compatible with the lowest transformation costs. The cogeneration system is composed of two General Electric LM2500 gas turbines and a heat recovery steam generator (HRSG). Two plant localizations in Spain have been considered; San Fernando (Cdiz) where the current plant is located, and Burgos. The latter has been taken into account to analyze the effect of cooler weather on the regulation methods. The paper has been divided into three parts. First, a revision of the current legislation regarding cogeneration in Spain is shown. Second, a description of the power plant and the proposed regulation methods are set out. Then, the cogeneration plant is modelled with the objective of evaluating the effects of the regulation methods in power, generated steam and thermal oil ow. Finally, the model was applied to analyze the prot obtained from different regulation combinations and to compare the benets of those regulation methods in the two locations with different climatic situations. The main conclusion reached is the importance to meet the requirements of Spanish legislation in order to obtain advantages in the sale of electricity; an increased prot of up to 60% was obtained in the simulation. In addition, it is evident that the regulation is more important when ambient temperature is lower. 2010 Elsevier Ltd. All rights reserved.

1. Introduction Cogeneration plants are an excellent way to produce electric energy. These plants reduce emissions, in terms of noxious exhaust gases and also carbon dioxide, and generally are the most protable because they make an increase in energy efciency possible and have lower running costs. Energy analyses reveal that such plants offer a substantial saving in fuel with respect to separate plants for the same power and utility heat [1e3]. Other research demonstrates the reduction of exhaust emissions [4]. The advantages of cogeneration from the point of view of energy and exergy efciencies applied to steam turbine, gas turbine, diesel engine and geothermal systems for water heating is evaluated by Mehmet Kanoglu [5]. Carcasci et al. [6] studied cogeneration uses in district heating applications and indicate that the most frequently used are cogeneration gas turbines. One of the reasons for this is the

* Corresponding author. Tel.: 34954487245; fax: 34954487243. E-mail address: fcojjea@esi.us.es (F. Jimnez-Espadafor Aguilar). 0360-5442/$ e see front matter 2010 Elsevier Ltd. All rights reserved. doi:10.1016/j.energy.2010.12.049

high ratio heat energy/electric energy of this prime mover, in the range of 1.8e2.2, if compared to reciprocating internal combustion engines where the ratio is in the range 0.8e1.1. Gas turbines work in open cycle using ambient air so any change in ambient conditions can cause changes in the gas turbine performance, modifying mass ow, power, efciency, exhaust gas composition and temperature. Gas turbine manufacturers give correction curves that allow the estimation of performance deviations from some reference conditions, usually ISO (15  C, 1 atmosphere and 60% relative humidity). In the case of cogeneration plants, not only is the gas turbine affected, but also the performance of the bottom system installed in the exhaust, a heat recovery boiler in this case, is also affected. Therefore an analysis is needed for the effect of any change of external conditions on the performance of the whole power plant [7,8]. Ambient conditions, which are outside the control of those responsible for the plant, vary throughout the year, in Cdiz (Spain), where the plant is located. Using the regulation methods described in this study, the performance changes can be controlled and taken advantage of in order to increase plant efciency and protability.

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Nomenclature A Adw CH4 C2H6 C3H8 C4H10 CO2 CHP Cpg cpw EEE EHP Eoil EU GT H2 O HRSG Hp HP IGV IPC K2 _ mair _ mf MP N2 surface area price of the deionised water in V/Tm methane ethane propane butane carbon dioxide combined heat and power gas specic heat water/steam specic heat electrical equivalent efciency necessary energy to produce a kg of high-pressure steam necessary energy to produce a kg of oil European Union gas turbine water heat recovery steam generator fuel lower heating value high pressure inlet guide vanes national index of consumer prices constant of evaporator formulation gas turbine inlet air mass gas turbine fuel mass medium pressure diatomic nitrogen

NTU O2 Pcomb PHP PMP Poil T t1 t2 T48 Tamb Tg tg1 tg2 ts tw1 tw2 TIT U VSV _ We Wg WQ Ww x y

3 henergy

number of transfer units diatomic oxygen price of the fuel used in the gas turbine in V/kWh high-pressure steam assessment medium-pressure steam assessment oil assessment temperature entry gas temperature to the evaporator exit gas temperature of the evaporator power turbine inlet temperature ambient temperature exhaust gas turbine gases temperature entry gas temperature to the economizer exit gas temperature of the economizer saturation temperature entry water/steam temperature to the economizer exit water/steam temperature of the economizer turbine inlet temperature overall heat transfer coefcient variable stator vanes produced electricity power mass gas ow consumed thermal power water/steam ow moles of carbon of the hydrocarbon moles of hydrogen of the hydrocarbon efciency for NTU method energetic efciency

Cogeneration plants can operate at off-design conditions during a considerable part of their lifetime, thus they usually suffer frequent load changes. Consequently, it is very important to pay attention to their performance characteristics at design and in part load conditions. This is of particular interest in the case of gas turbines where efciency is very sensitive to operation point. In the design of a new plant, the study by Bringhenti [9] proposes the inclusion of not only variable compressor geometry but also turbine variable geometry for part load operation, in order to improve the poor characteristics of gas turbines at part load. Along these lines, one of the methods analyzed by Carcasci [6] for power output reduction in the context of CHP (combined heat and power) is IGV (inlet guide vanes) and VSV (variable stator vanes). Although this control method improves both gas turbine and overall energy plant efciency at part load, the applicability range is limited, mainly because exhaust temperature increases rapidly with electrical power reduction, reaching the safety limit. In addition, the onset of compressor ow instability for low ow values limits this method. The gas turbines used in this study, two units of LM 2500, have the rst six stator variable (VSV) which allows increasing gas turbine efciency at part load. Other strategies for part load control are variable speed and fuel only control, analyzed by Kim [10] and Fabio Bozza [11] for recuperated gas turbines. This last method not only reduces gas turbine efciency but also overall CHP efciency, mainly because both exhaust temperature and electrical power are reduced when fuel is diminished, although a small mass ow increase is produced. Compressor discharge recirculation and compressor mass bleeding are methods that are also used for gas turbine power reduction that have advantages in CHP over fuel only control, mainly because of the same power reduction, the rst two methods reduce exhaust energy less than the latter.

Other CHP regulation methods are based on control of the HRSG performance separately from the gas turbines. Frequently, secondary combustion is used for the exhaust gases, just before entry to the HRSG. This method is applied by Coelho et al. [12] in a chemical plant. Seth Beaver [13] analyses six different thermal arrangements and Na Zhang [14] analyses the effects of part load on the HRSG performance. Another HRSG control method is to vary typical parameters such as the pinch point, the approach temperature, the rst and second stage pressures, mass ratios etc. The work of Bassam et al. [15] describes the changes in the HRSG performance related to those terms. In this study, exhaust gases are used to produce steam and heat thermal oil, a process also used by Seth Beaver [13]. In Beavers case, the steam is used to produce electric energy in a steam turbine, while in this case the steam is sold. The application of this project does not need to follow a demand curve (all the electricity, steam and oil produced are sold), but the model can be applied as Fabio Bozza does [11] in a way that regulation is affected by ambient and demand conditions. Another aspect considered in this study is the local legislation regarding CHP, derived from Directive 2004/8/EC [16] on the promotion of cogeneration which, in Spain, is regulated by RD 661/ 2007 [17]. This Spanish law denes a local tariff system for CHP plants which can generate extra income if they reach a minimum overall efciency. Other EU Members have adopted this EU Directive and developed local laws [18,19]. The nal objective of this study is to show the existence of a plant regulation methodology to maximize running prots, while being compatible with local cogeneration law. In this complex system, not only is it necessary to increase the electricity produced by the gas turbine; but also the HRSG is affected by the regulation and has to be considered [20,21].

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2. Spanish legislation for cogeneration The European Commission adopted Directive 2004/8/EC, on the promotion of cogeneration, based on the demand for useful heat in the internal energy market, for the purpose of increasing energy efciency, reducing green house emissions and assuring reliable energy supply. Among other conditions, this Directive requires EU Member States to develop certain support mechanisms for cogeneration in order to obtain shorter returns on investments in cogeneration plants. The remuneration of the energy generated by cogeneration is based on the services provided to the system, both by the status of distributed generation and by it greatest energy efciency. For the rst time, it introduces a remuneration that is a direct role of the primary energy savings that exceed of the one which corresponds to the fullment of the minimum requirements. In the particular case of Spain, RD 661/2007 provides legal and economic support to non-conventional systems, included CHP plants, with incentives to complement the emoluments of the installations. A cogeneration plant can access to special regulation in the a category of article 2. The plant considered in this study belongs to subgroup a.1.1., that is, a CHP plant where at least 95% of the primary energy consumed is natural gas. These facilities have priority access and connection to the electrical grid, and can sell all the net electricity produced if it is technically possible, either through the distribution network or through direct connections to consumers. The net electricity is the difference between the electricity produced and losses and selfconsumption. The distribution company has the obligation to subscribe to this contract. Also, as stated in article 17, it is possible to connect two generation groups in parallel to the electrical grid, the option chosen in this study. Not only is electricity production important. In order to be covered by this law [17], the CHP plants have to formalize one or several contracts for the sale of the thermal energy of the useful heat of the plant. The electricity produced can be sold in three main ways, to be chosen by the producer. - To sell the electricity at a regulated, at rate tariff, for all periods.

- To sell the electricity to the energy production market with a prime if minimum efciency is reached, as dened by current Spanish law. - To sell directly to the energy production market without any prime. The regulated tariff is a xed amount, established quarterly on the basis of the variations of the reference values of the fuel prices indices, as dened in annex VI [17], and the consumer price index for that period. The economic prime consists of an additional amount to the price resulting in the organised market or the price freely negotiated by the holder or the representative of the installation, which is calculated following the procedure described in annex VII. The minimum average annual EEE (electrical equivalent efciency) that this type of cogeneration plant must reach to receive a subsidy under the legislation is 0.59. EEE has to be calculated as follows:

EEE

E Q V=refH

(1)

E is the electric energy generated, Q is the primary energy consumption, V is the production of useful heat and refH is a reference value of the efciency of the separated production of heat that is in the range 0.72e0.9 [17]. 3. Power plant description The cogeneration plant analyzed in this study is composed of two general electric gas turbines, model LM2500, coupled to a heat recovery boiler (HRSG) which allows after burning. Fig. 1 shows a general overview of the cogeneration plant. This gas turbine has a two-shaft conguration, gas generator followed by power turbine with 6 stages and 885  C power turbine TIT (turbine inlet temperature) limit. The main characteristics at ISO conditions and 3000 rpm of the power turbine are as follows. Nominal power: 24,293 kW. Nominal heat rate: 10,086 kJ/kWh. Nominal exhaust gas ow: 254.6 t/h. The gas turbines are coupled to a natural circulation heat recovery steam generator (HRSG) which makes use of the residual

Fig. 1. Scheme of cogeneration plant.

F. Jimnez-Espadafor Aguilar et al. / Energy 36 (2011) 742e754 Table 1 HRSG production at ISO conditions. Production (t/h) Steam 64 bar Steam 10 bar Thermal oil 40.7 13.7 395.0 Outlet temperature ( C) 480 187 345

745

40000 30000 Electric Power (kW) 20000 Thermal Power (kW) CpMg(Tg-150) 10000 0 400 500 600 700 800 900

HRSG energy recovery. LM2500 power control is based on the simultaneous regulation of the fuel ow and the position of IGV and VSV. Exhaust gas ow and temperature also change with electrical power regulation, which is relevant for the performance of the whole cogeneration plant. Fig. 2 shows the relationship between electrical power, at 3000 rpm power turbine speed, and thermal power referred to exhaust gases cooling up to 150  C, for different power turbine inlet temperatures (T48) at ISO conditions [23]. It can be observed that any reduction in T48 diminishes both electrical and thermal power. A reduction of GT efciency is also observed (not shown). 4.2. Heat and power regulation by inlet gas turbine temperature Fig. 3 shows the relationship between electrical power, at 3000 rpm power turbine speed, and thermal power referred to exhaust gases cooling up to 150  C for different ambient temperatures [23]. Maximum mechanical power, limited by internal GT controls, is reached at an ambient temperature of 15  C and the minimum at 54  C. As can be observed, at constant shaft power any increase of ambient temperature also increases thermal power. Although an increase in ambient temperature reduces GT mass ow (mainly through air density), GT compression ratio diminishes and therefore exhaust gas temperature is increased, which more than offsets mass ow reduction increasing exhaust thermal power. This result suggests that heating inlet gas turbine ow is a candidate for cogeneration plant control. For the current cogeneration plant conguration, inlet air heating is performed by a heat exchanger situated at the front of the gas turbine. Because the maximum allowed GT inlet temperature is 54  C, medium steam pressure from HRSG is used for inlet heating. Fig. 4 shows a diagram of the cogeneration plant with regulation from medium steam pressure extraction. 4.3. Supplementary ring

Power Turbine Inlet Temperature (T48) (C)

Fig. 2. Thermal and electric power as function of power turbine inlet temperature (T48).

heat of the exhaust gases. The HRSG is composed of 10 sections made up of evaporators, economizers and super heaters with two boilers for steam and one economizer for heating oil. The thermal oil is Therminol 68 [22]. In the HRSG, superheated steam is generated at two pressures (10 and 64 bar) and thermal oil is heated from 290  C to 345  C. All these products are sold to the chemical industries near the plant. Table 1 shows generated ows for steam and oil from HRSG at ISO conditions when HRSG inlet gas ow from GT (gas turbine) is 500 t/h at 555  C. Five percent of the electric power generated by GT is consumed in the plant and the remainder is exported to the electrical grid. 4. Description of regulation methods 4.1. Gas turbine electrical power regulation Although GT power control through TIT regulation is a very fast method implemented on every GT, TIT reduction not only diminishes GT efciency but also reduces thermal power, penalizing

The third method considered for cogeneration control is supplementary ring in the side of the duct upstream of the HRSG to raise the temperature of the inlet gas stream. This type of regulation affects the performance of the HRSG and its objective is to control steam production and the ow of thermal oil heated. The minimum excess air allowed is 10%.

Thermal power as function of the engine shaft power and the ambient temperature. (1 bar, 60% relative humidity)
70000

60000
Thermal Power (kW) CpWg(Tg-150)
-6C 4C 10C 15C 21C 27C 32C 38C 43C 54C

50000

40000

30000

20000

10000 1000

6000

11000

16000

21000

26000

31000

36000

41000

46000

Engine Shaft Power (kW)

Fig. 3. Thermal power as function of engine shaft power for admissible ambient temperature (1 bar and 60% relative humidity).

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Fig. 4. Scheme of cogeneration plant with power and heat regulation by inlet temperature control.

integrated model, considering the gas turbines and the HRSG, has been developed. 5.1. Gas turbine model Twin turbines operate simultaneously. Therefore, an operational map has been developed from manufacturer curves which gives the following relationship:

_ _ _ _ Tg ; wg ; mair ; mf f Tamb ; W mec

(2)

Fig. 5. High-pressure steam production real data.

The thermal properties of exhaust gases affect thermal power production and steam ow-temperature evolution through HRSG. For this reason stoichiometry balance with a xed combustion efciency of 96% has been considered. Eq. (3) is applied to each hydrocarbon fuel composition using air as an oxidizing agent,

In order to prevent any mechanical failure, the maximum thermal power allowed has been the maximum measured in the current performance of the cogeneration plant.

  y y y $H2 O Cx Hy x $O2 3:76$ x $N2 0x$CO2 4 2 2   y 3:76$ x $N2 4 (3)

The fuel burned is natural gas from Algeria, the most frequently used in Spain, with a typical composition indicated below. 91.2% methane (CH4). 7.4% ethane (C2H6).

5. Plant model In order to evaluate the effect of the cogeneration plant regulation methods on plant performance and protability, an

Fig. 6. Medium-pressure steam production real data.

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Fig. 7. Thermal oil production real data.

0.8% propane (C3H8). 0.1% butane (C4H10). 0.5% other components. The same model is applied to model supplementary ring at HRSG. 5.2. HRSG model Operational data of HRSG is known for the whole of 2008. However, in order to develop a model for HRSG prediction at full load and part load, plant data was ltered, discarding anomalous or non-valid data. More precisely, data corresponding to operative

conditions in which the values of power delivery by the gas turbine indicated start or stop conditions or compressor washing was discarded. After ltering the data, about 85% of the 2008 registered was found to be valid. Figs. 5e7 represent steam ow production and the ow of heated oil for this data, expressed as function of heat capacity of exhaust turbine ow at the HRSG entrance, and the regression curve. Although the ltered plant data allow a complete HRSG model at full load using parameter correlation, there is not any operational data or characteristic curves that can provide HRSG performance at part load. Thus a complete model for HRSG part load performance has been developed based on the NTU (number of transfer unit) method. 5.2.1. Evaporator Global heat transfer model for the evaporator is reduced to the Eq. (4) [24].

ln

t1 ts UA t2 ts Wg Cpg

(4)

The used evaporators are represented in Fig. 8 by a sketch. Because this HRSG uses water tube evaporators, overall heat 0;6 transfer coefcient (U) is proportional to Wg , where Wg is the exhaust gas ow [24]. Including this in Eq. (4) yields:

ln

t1 ts K2 0:4 t2 ts Wg

(5)

where K2 is calculated from HRSG operational data at full load.

Table 2 Geometric data of economizers necessary to calculate the U coefcient. High-pressure economizer 1 Design pressure Design temperature Surface area Tube outer diameter Tube wall thickness Material Number of tubes wide Longitudinal tubes Transverse pitch Longitudinal pitch: Fins per inch Fin material Fin height Fin thickness Fig. 8. Sketch of water tube evaporators. 75,2 bar 371  C 1523 m2 31.8 mm 3.2 mm SA-192 46 2 76.25 mm 66.04 mm 5.5 Carbon steel 16 mm 1.27 mm High-pressure economizer 2 75,2 bar 371  C 3047 m2 31.8 mm 3.2 mm SA-192 46 4 76.25 mm 66.04 mm 5.5 Carbon steel 16 mm 1.27 mm High-pressure economizer 3 75,2 bar 371  C 4371 m2 31.8 mm 3.2 mm SA-192 44 4 79.8 mm 69.06 mm 5.5 Carbon steel 16 mm 1.27 mm

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tw2 tw1 tg2 tg1

Q Ww Cpw

(10)

Q Wg Cpg

(11)

5.2.3. Super heater The super heater has been considered at constant efciency, that of full load, and is given by Eq. (12). For a better understanding, see Fig. 9.

Tsteamout Tsteamentry Tgasentry Tsteamentry

(12)

Fig. 9. Super heater scheme.

5.2.2. Economizer The overall heat transfer coefcient (U) is calculated from the geometric data of the HRSG using the Briggs and Youngs correlation for circular or helical nned tubes [24].The geometric data is given in Table 2: Heat power transferred in the economizer is approximated by Eq. (6)

5.2.4. Part load HRSG model result The quality of the HRSG model has been tested comparing full load simulation results to full load operational data, shown in Fig. 10. It can be observed that both simulated gas turbine gases and steam ows present quite close evolution in the temperatureethermal power diagram to the HRSG data. The TeQ diagram is also created for part load situations, shown in Fig. 11 for 30% of the maximum thermal power. 6. Economical aspects of electric and thermal energy This epigraph is devoted to the economic analysis of the cogeneration plant. In order to carry this out, it is necessary to study the expenditure and revenues of electric and thermal energy generation separately. In this plant, all the electricity produced is absorbed by the power grid. Thermal production, steam at medium and high pressure and thermal oil, are entirely consumed by one factory near the cogeneration plant. 6.1. Plant expenditures Thermal energy production cost comes from the deionised water used to produce steam and from the natural gas consumed when supplementary ring is used. Electricity production cost comes from the natural gas consumed by the gas turbines. Deionised water cost is calculated from real data updated online with the consumer price index for 2008. Deionised water cost in 2008 was 1.79V/ton. In the case of natural gas, part of the price is xed, while the other part is variable. This cost is updated each quarter. The updated prices can be obtained from the Ofcial State Gazette (BOE) or the Spanish Gas Association (Sedigas) [25]. Changes in the price of natural gas in 2008 can be seen in Fig. 12, while the xed prize was 65.77V/Month.

Q 3Cmin tg1 tw1

(6)

Counter ow type economizers are used, therefore efciency e is modelled as [24]

1 expNTU$1C 1 C$expNTU$1C

(7)

Considering

NTU
and

UA Cmin

(8)

WCp min WCp max

(9)

where (WCp)min and (WCp)max corresponds to steam and gas properties, respectively. Combining the previous equations, the following can be obtained:

600
Gas turbine exhaust gases

500
Temperature (C)
Oil Economizer

Simulation Operational data

400 300 200 100

MP Super Heater HP Super Heater + HP Evaporator 1 HP Evaporator 2 HP Economizer 1 HP Economizer 2 HP Economizer 1 MP Evaporator

0 20000

30000

40000

50000

60000

70000

80000

90000

Thermal power (kW)

Fig. 10. TeQ diagram at full load at ISO conditions.

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749

500
Gas turbine exhaust gases

Temperature (C)

400 300 200 100 0 15000

HP Economizer 1 MP Super Heater

Oil Economizer

Simulation HP Evaporator 2 HP Economizer 1 HP Economizer 2 MP Evaporator HP Super Heater + HP Evaporator 1

25000

35000

45000

55000

65000

Thermal power (kW)

Fig. 11. TeQ diagram at part load, 67% of nominal thermal power to the HRSG at ISO conditions.

An additional, expenditure is related to the operation and maintenance of the cogeneration plant. These costs are estimated as 6V/MWh, which is an expected value and a restrictive one compared with reference [26], where the maintenance cost is 5$/ MWh for a cogeneration plant. Finally, it is necessary to take into account and control the electricity consumption of the plant itself. Although this is not a cost, only net energy can benet from the nancial subsidies available under current Spanish legislation. Electricity consumption of the plant itself is taken to be 5% of the total electricity generated by the gas turbines alternators. This is a typical value close to that given by Muginstein et al. [27], where the self-consumption of electricity is between 2.3% and 6.37%. 6.2. Plant incomes Incomes due to cogeneration activity come from: * selling the net electricity produced; * selling medium and high-pressure steam ow; and * selling heated thermal oil. The price of high- and medium-pressure steam produced by the cogeneration plant is a function of the cost of natural gas and the cost of deionised water. These prices are dened by the following equations. High-pressure steam assessment:

PMP =Tm

1:108$Pcomb 664 15 Adw 0:86 0:9

(14)

The economic assessment of thermal oil comes from the reduction in high-pressure steam ow due to thermal oil production:

10$Eoil Poil =Tm PHP $ EHP

(15)

Net electricity produced by gas turbines can be sold by two different procedures to be chosen by plant owner.  Free market price. In this case, electricity is sold daily on the market, with a precedence of a day. The resulting price can be complemented by a supplement given by the government if the plant meets cogeneration regulation requirements, see Section 2.  Regulated tariff. In this case the selling price is xed if cogeneration regulation requirements are fullled. The principal parameter to meet legislation requirements, once the plant has been included in a specic category, is that for gas natural fuel minimum average annual EEE be 0.59 [17]. 7. Optimization This epigraph analyses different plant control strategies based on the methods dened in Section 5 with the focus on the plants prot, where the economic analysis is compatible with Spanish law [17]. All feasible strategies with proposed plant control methods will be analyzed and then compared. This will allow dening

PHP =Tm

1:108$Pcomb 670 15 Adw 0:86 0:9

(13)

Medium-pressure steam assessment:

Natural gas variable price (cent/kWh)

4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 From 1/1/08 to 11/4/08 From 12/4/08 to 11/7/08 From 12/7/08 to 11/10/08 From12/10/08 to 31/12/08

Periods
Fig. 12. Natural gas variable price evolution.

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Profit as a function of engine shaft power and ambient temperature

18000.00 16000.00 14000.00 12000.00 10000.00 8000.00 6000.00 4000.00 2000.00 0.00 10000 Tamb=4C Tamb=10C Tamb=15C Tamb=21C Tamb=27C Tamb=32C Tamb=38C Tamb=43C Tamb=54C

Profit ()

15000

20000

25000

30000 35000

40000

45000

50000

Engine shaft power (kW)

Fig. 13. Prot evolution on the basis of ambient temperature and engine shaft power.

a cogeneration plant regulation methodology to be followed by the plant operator in order to increase protability of the plant. Data is available for the year 2008, so that year is considered for analysis. Firstly, the complete year is analyzed; secondly a regulation method is developed to control EEE online. Fig. 13 shows hourly prot variation for a large range of ambient temperatures at electricity market prices including the income from selling thermal oil and steam, without the application of the special legislation for cogeneration. Two main conclusions can be drawn from this gure.  For any shaft power, prot increases as the ambient temperature reduces. This is due to the increase in gas turbine efciency, as inlet temperature diminishes, that more than offsets the reduction in steam and oil production.  Regardless of the ambient temperature the higher the engine shaft power, the higher the prot. Considering current Spanish Law and in other to warrant the economic viability of the plant, it is highly recommended that the cogeneration plant obtains at least the minimum EEE every year. An erroneous choice of plant regulation method could result in the plant being unprotable. Fig. 14 describes the evolution of EEE on the basis of ambient temperature and engine shaft power. It can be observed that EEE increases as the ambient temperature and engine shaft power increase, in this case because of the increase in the thermal energy produced. Afterburning increases steam and oil production and therefore inuences EEE of the cogeneration plant, which is shown in Fig. 15. It can be observed that EEE increases as ambient temperature and engine shaft power increase; for the same gas turbine shaft power and ambient temperature, afterburning increases EEE (see Figs.14 and 15). From these results, it can be concluded that any control strategy should consider heating inlet air, mainly to reach a minimum EEE of 0.59. On the other hand, plant performance, prot and EEE are clearly inuenced by ambient temperature. To study this effect, two different locations are analyzed: the current one in Cdiz with an

average temperature throughout the year of between 15  C and 25  C, and in Burgos, with an average ambient temperature eight degrees below that of Cdiz. In the following, different control strategies are analyzed for fuel saving, increasing plant prot and minimizing CO2 production. 7.1. Complete year Four different control strategies are analyzed. - Gas turbine shaft power regulation alone. - Gas turbine shaft power regulation with afterburning. - Gas turbine shaft power regulation combined with control of admission temperature. - Using all of the above. For each regulation method a complete annual economic analysis has been performed along with CO2 emission evaluations and plant efciency, which is dened as:

henergy

_ _ We WQ _ f $Hp m

(16)

_ _ where W e and W Q are the produced electricity power and _ consumed thermal power, respectively, and mf $Hp is the power introduced in the cogeneration plant by the fuel consumed. 7.1.1. Gas turbine shaft power regulation alone The operation is carried out at maximum engine shaft power. Table 3 shows the results for Cdiz, and Table 4 for Burgos. Table 5 outlines the most important results. The minimum average annual EEE is not reached and the legislation possibilities could not be applied. 7.1.2. Gas turbine shaft power regulation with afterburning Fig. 16 shows the prot for the plant operating without prime at ISO conditions. Thermal power goes from 54.3 MW without post-

EEE evolution for some ambient temperatures

0.64 0.59 Tamb=4,44C Tamb=10C Tamb=15C Tamb=21,11C Tamb=26,67C Tamb=32,22C Tamb=37,78C Tamb=43,3C Tamb=54,4C

EEE

0.54 0.49 0.44 12000

22000

32000

42000

Engine shaft power (kW)

Fig. 14. EEE evolution on the basis of ambient temperature and engine shaft power.

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EEE evolution for some ambient temperatures using afterburning

0.64 Tamb=4,44C Tamb=10C Tamb=15C Tamb=21,11C Tamb=26,67C Tamb=32,22C Tamb=37,78C Tamb=43,3C Tamb=54,4C

0.59

EEE

0.54

0.49

0.44 10000 15000 20000 25000 30000 35000 40000 45000 50000

Engine shaft power (kW)

Fig. 15. EEE evolution on the basis of ambient temperature and engine shaft power using afterburning.

combustion up to the maximum attainable afterburning, 98.7 MW. It can be seen that prot falls when secondary combustion increases. From this gure, it can be concluded that afterburning should be used to enhance the average annual EEE and therefore to get the prime compatible with Spanish law. The results are shown in Table 5. As it can be observed, the best prot is achieved in Cdiz, where the EEE is reached selling electricity at the regulated tariff without hourly variation. Moreover the prot detailed in all cases in Table 5 includes the income from selling thermal oil and steam. 7.1.3. Gas turbine shaft power regulation combined with control of admission temperature Fig. 17 shows the prot for the plant operating without prime at 1 bar and 60% relative humidity for variable inlet thermal power to the HRSG. The changes in this thermal power come from heating the gas turbine inlet, see Fig. 4, where is a scheme of the method. Controlling the admission temperature can achieve an increase of average annual EEE, see Fig. 15. As can be extracted from Fig. 17, for constant electrical power, prot (without prime) reduces as thermal power increases.

The most important results are shown in Table 5 for Cdiz and Burgos. As can be seen, this method is less protable than afterburning and therefore would only be used if the afterburning is not sufcient to reach the required EEE of 0.59. 7.1.4. Regulation using a combination of all possibilities This regulation is convenient, from an economic point of view, if it is necessary to reach the minimum average annual EEE, so it does not make sense to use it in Cdiz, while it is necessary in Burgos. The process consists of a maximum increment of afterburning, and adds admission temperature regulation to reach the required EEE, because is cheaper to increase afterburning than to increase the admission temperature for the same increment of EEE. Again, the results are shown in Table 5, in this case only for the case of Burgos. 7.2. Online The previous analyses are carried out with a knowledge of the ambient temperature during plant operation throughout a whole year. From the point of view of the daily running of the plant, it would be very useful to develop a strategy for plant operation that

Table 3 Regulation in engine shaft power results for the cogeneration plant in Cdiz.

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Table 4 Regulation in engine shaft power results for the cogeneration plant in Burgos.

would allow it to reach maximum prot at the end of the year, in this case without knowledge of the ambient temperature variation. Every strategy has to reach the minimum EEE of 0.59 throughout year in order to get Spanish law prime. Two methodologies have been analyzed. One of the methods is based on obtaining the minimum EEE every operation hour. If in some hours it is not possible, the plant is operated in order to reach the maximum attainable EEE. The instruction to the operator to implement this regulation method is based on the ambient temperature as can be seen in Table 6. The representative results of this method in the location of Cdiz can be seen in Table 7. In Burgos, this regulation is not sufcient. The lower temperatures make it necessary to maximize the EEE each hour, due to the number of hours when the EEE is lower than the minimum. So the results of the regulation are the same as shown before in Table 5, where maximum regulation was used, combining all possibilities.

The second technique to ensure the minimum average annual EEE is to operate to maximum prot the rst few months and then to regulate the remaining months in order to compensate. This form of regulation makes sense in hotter areas because the lower EEE in cold months can be compensated for in hotter months with little regulation. In Burgos this regulation cannot be applied. However, in Cdiz, this operation mode means operating to maximum prot for the rst ten months, then regulating in November and December to reach the minimum average annual EEE. Results are shown in Table 7. 8. Results and discussion Focusing our attention on the prots shown in Tables 5 And 7, some conclusions are obtained. Firstly, plant operation has to be designed to reach at least the minimum average annual EEE in order to be able to receive the benets of current Spanish legislation. In the case where the market price is the chosen method of sale, the prime increases the prot in Cdiz by up to 26.5% and in Burgos by up to 12.1%. Even so, the best choice, at least for the conditions in 2008, is to sell electricity at the regulated tariff; in this case, the increase in prot is up to 80.3% in Cdiz and 62.9% in Burgos.

Table 5 Resume of regulation results for the cogeneration plant in Cdiz and Burgos. Localization Regulation in engine shaft power EEE Best prot (millions V) Energetic efciency Emissions of CO2 (kton) Cdiz 0.581 132.8 0.772 271.8 Burgos 0.579 142.0 0.761 273.8 0.580 135.1 0.744 280.7 0.579 125.8 0.756 271.2 0.590 231.4 0.782 268.1

Regulation in engine shaft power using afterburning EEE 0.590 Best prot (millions V) 239.5 Energetic efciency 0.761 276.7 Emissions of CO2 (kton) Regulation in engine shaft power and admission temperature EEE 0.590 Best prot (millions V) 236.4 Energetic efciency 0.769 272.0 Emissions of CO2 (kton) Regulation using a combination of all possibilities EEE e Best prot (millions V) e Energetic efciency e e Emissions of CO2 (kton)

Fig. 16. Prot evolution on the basis of electric and thermal power for afterburning regulation.

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As far as online regulation is concerned, the techniques studied are very close to the maximum prot possible, the regulation to reach the minimum EEE each hour obtains 98% of the maximum prot, while the second possibility obtains 99% of the maximum prot. 9. Conclusions A study of how an operating plant can improve its performance and increase its prot has been carried out. Two different locations in Spain with clearly different annual temperature variations have been analyzed. The necessary investment to apply some regulation methods in a cogeneration plant to reach the minimum average annual EEE is totally justied by the important augmentation of the prot due to the advantages of the legislation about this special regime in Spain. Moreover, the recovery period for the investment is not large because the increase of prot is up to an 80%. Although changes of fuel and other elements prices may vary the optimal solution, the methodologies followed do not change to nd new solutions, and the great range of increase of prot allows saying that the new solutions will be benecial too. The most important need of regulation in cold climates is manifested, due to the higher EEE as ambient temperature raise. Finally, the initial objective of this study is achieved because an operational regulation is obtained, so the operator of the plant can easily follow the instructions only as a function of the ambient temperature to nally obtain the required minimum average annual EEE of 0.59. References Secondly, it is more difcult to obtain the minimum EEE in colder locations such as Burgos. In this location, the use of regulation is more intense and it results in a reduction in prot when compared to Cdiz, even though the increase in prot in Burgos is very substantial. In a warm location like Cdiz where the minimum EEE can be obtained by different regulation methods, the most protable choice would be to use maximum engine shaft power and afterburning. Comparing engine shaft power and control of admission temperature, the increase in prot for the former is close to 1.3% more. Nevertheless, from the point of view of CO2 emissions maximum reduction is achieved with afterburning and inlet heating. Comparing both methods, the latter reduces CO2 emissions by 2% which is nearly 5000 tons each year. Growing support for renewable and cleaner energy systems increases the importance of the aspect of emissions. An economical value of the emissions maybe varies with the best regulation election.
[1] Ghosh S, De S. Energy analysis of a cogeneration plant using coal gasication and solid oxide fuel cell. Energy 2006;31:345e63. [2] Mujeebu MA, Jayaraj S, Ashok S, Abdullah MZ, Khalil M. Feasibility study of cogeneration in a plywood industry with power export to grid. Appl Energy 2009;86:657e62. [3] Uran V. Optimization system for combined heat and electricity production in the wood-processing industry. Energy 2006;31:2996e3016. [4] Mancarella P, Chicco G. Global and local emission impact assessment of distributed cogeneration systems with partial-load models. Appl Energy 2009;86:2096e106. [5] Kanoglu M, Dincer I. Performance assessment of cogeneration plants. Energy Convers Manage 2009;50:76e81. [6] Carcasci C, Cormacchione NA- C. Part load operating strategies for gas turbines in district heating applications. Proc Inst Mech Eng A 2001;215:529e44. [7] Lazzaretto A, Toffolo A. Prediction of performance and emissions of a twoshaft gas turbine from experimental data. Appl Therm Eng 2008;28:2405e15. [8] Bhargava R, Bianchi M, Montenegro G, Peretto A. Thermoeconomic Analysis of an intercooled, reheat, and recuperated gas turbine for cogeneration applications e part II: part-load operation. J Eng Gas Turbines Power 2002; 124:892e903. [9] Bringhenti C, Barbosa JR. Methodology for gas turbine performance improvement using variable-geometry compressors and turbines. Proc Inst Mech Eng A: J Power Energy 2004;218:541e9. [10] Kim TS, Hwang SH. Part load performance analysis of recuperated gas turbines considering engine conguration and operation strategy. Energy 2006;31: 260e77. [11] Bozza F, Cameretti MC, Tuccillo R. Adapting the micro-gas turbine operation to variable thermal and electrical requirements. J Eng Gas Turbines Power 2005;127:514e24. [12] Coelho M, Nash F, Linsell D, Barciela JP. Cogeneration-the development and implementation of a cogeneration system for a chemical plant, using a reciprocating heavy fuel oil engine with a supplementary red boiler. Proc Inst Mech Eng A: J Power Energy 2003;217:493e503. [13] Beaver S, Matamoros J, Prokopec A, Retallick W, Churchill S. An analysis of the effects of heat exchange and heat reuxing in the generation of electricity with a gas turbine. Energy 2005;30:103e10. [14] Zhang N, Cai N. Analytical solutions and typical characteristics of part-load performances of single shaft gas turbine and its cogeneration. Energy Conversd Manage 2002;43:1323e37. [15] Jabboury B, Darwish M. The effect of the operating parameters of heat recovery steam generators on combined cycle/sea-water desalination plant performance. Heat Recover Syst CHP 1990;10:255e67. [16] Directive 2004/8/EC of the european parliament and of the council of 11 February 2004 on the promotion of cogeneration based on a useful heat

Fig. 17. Prot evolution on the basis of electric and thermal power for admission temperature regulation.

Table 6 Operation instruction to regularize each hour. Ambient temperature Tamb < 16.5  C Regulation Engine Shaft Power Maximum Afterburning Maximum Admission The amount necessary to reach the minimum EEE e

16.5  C < Tamb < 18.9  C

Maximum

Tamb > 18.9  C

Maximum

The amount necessary to reach the minimum EEE e

Table 7 Resume of on line regulation results. Localization Regulation each hour EEE Best prot (millions V) Energetic efciency Emissions of CO2 (kTon) Cdiz 0.592 236.5 0.760 278.1

Regulation with some months to the maximum prot EEE 0.590 Best prot (millions V) 239.2 Energetic efciency 0.771 272.0 Emissions of CO2 (kTon)

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