Aspen Plus

Aspen Plus Cogeneration Model

Version Number: V7.0 July 2008

Copyright 2008 by Aspen Technology, Inc. All rights reserved. Aspen Plus, Aspen Properties, the aspen leaf logo and Plantelligence and Enterprise Optimization are trademarks or registered trademarks of Aspen Technology, Inc., Burlington, MA. All other brand and product names are trademarks or registered trademarks of their respective companies. This document is intended as a guide to using AspenTech's software. This documentation contains AspenTech proprietary and confidential information and may not be disclosed, used, or copied without the prior consent of AspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of the software and the application of the results obtained. Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the software may be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803-5501 USA Phone: (1) (781) 221-6400 Toll Free: (1) (888) 996-7100 URL: http://www.aspentech.com

Contents
1 Introduction .........................................................................................................1 2 Components .........................................................................................................2 3 Process Description..............................................................................................3 4 Physical Properties...............................................................................................5 5 Chemical Reactions ..............................................................................................6 6 Simulation Approaches.........................................................................................7 7 Simulation Results ...............................................................................................8 8 Conclusions ........................................................................................................12 9 References .........................................................................................................13

Contents

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1 Introduction

This model simulates an integrated cogeneration process. It includes the following features: A set of conventional chemical species for this process. Typical process areas including: burning, compression, heat exchange, power generation, and the main streams connecting these units. Property methods and unit operation models used in this process.

1 Introduction

2 Components

The table below lists the components modeled in the simulation.

Component ID H2O N2 O2 CO CO2 ARGON METHANE ETHANE PROPANE Type CONV CONV CONV CONV CONV CONV CONV CONV CONV Component name WATER NITROGEN OXYGEN CARBON-MONOXIDE CARBON-DIOXIDE ARGON METHANE ETHANE PROPANE Formula H2O N2 O2 CO CO2 AR CH4 C2H6 C3H8

2 Components

3 Process Description

An outline of the cogeneration process which includes the letdown, Gas Turbine and Steam Generation sections is shown in Figure 1.
W
POWERMIX POWER 1 POWER 2 M IX ER POWER OU T W

WATER1 WATER14 POWER 3X STEAM-A LETDOWN N ATGAS H IERA RCH Y NATGAS2 HIERA RCH Y GASTU RB HOTGAS1 H IERA RCHY STEAM-C STMGEN STEAM-B

RC
AIR HOTGAS9

RC
NOXSTEAM

WATER 24

Figure 1: Cogeneration Overall Process

The feedstock of this cogeneration process is natural gas, which contains Methane (83.62%wt), Ethane (7.33%wt), Propane (7.25%wt) and Argon (1.8%wt). Firstly, a turbine is used in the letdown area to utilize the internal energy of the natural gas to generate electrical power. After expanding, the gas pressure drops from 19.5 bar to 8 bar while generating 0.60MW of power. Secondly, mixed with steam (8 bar) and compressed air (1324000kg/hr), the gas is burned completely in the burner to produce hot gas at 979C. The hot gas is passed through a gas turbine to produce 103.4 MW of electrical power. As a result, its temperature drops to 551C and its pressure drops from 8 bar to 1.1 bar. Thirdly, the hot gas is passed to the steam generation area to recover heat. The gas runs through 5 heat exchangers and is cooled down by water or steam as follows: E100 - cooled from 551to 492C E101 - cooled from 492 to 320C

3 Process Description

E102 - cooled from 320 to 238C E103 - cooled from 238 to 234C E104 - cooled from 234 to 175C Then the outlet stream HOTGAS6 from E104 is split into HOTGAS7A and HOTGAS7B. HOTGAS7A is cooled to 108C in E106 and HOTGAS7B is cooled to 131C in E105. Afterwards these two streams are mixed again and are vented out of the process. The BFW (boiler feed water) used in this area includes two pressure grades, one at 76.5 bar and the other at 6.9 bar. Heated by the hot gas, BFW turns to steam. Then the steam is let down through a turbine to produce electrical power. Finally, three steam products, each at different pressure grades, are obtained and 37.6MW of electrical power is generated.

Process summary
Area Let Down Gas Turbine Steam Generation Purpose Uses the internal energy of the natural gas to generate electrical power Burns the natural gas to generate electrical power using a gas turbine Recovers the heat from the hot gas to generate steam and electrical power using steam turbines

3 Process Description

4 Physical Properties

The PR-BM property method (Peng-Robinson equation of state with BostonMathias modifications) is used for the properties of the natural gas and combustion products. For the steam system in the steam generation area the STEAMNBS property method is used.

4 Physical Properties

5 Chemical Reactions

The only reactor unit in this process is the burner modeled with RGibbs which uses the Gibbs free energy minimization method. This determines the equilibrium composition of the products resulting from the many reactions that can occur.

5 Chemical Reactions

6 Simulation Approaches

Unit Operations The major unit operations are represented by Aspen Plus models as shown in the following table:
Unit Operation Heat exchanger Flash Compressor/Turbine Aspen Plus Model HeatX Flash2 Compr Comments / Specifications Simplified shortcut design calculations. Rigorous simulation of gas-liquid equilibrium. Calculates electric power required or produced.

6 Simulation Approaches

7 Simulation Results

The Aspen Plus simulation flowsheet is shown in Figures 2, 3, and 4.

POWER1

POWER1(OUT)

NATGA S(IN)

NATGA S

EXP1

NATGA S2

NATGA S2(OUT)

Figure 2: Flowsheet of Letdown area

7 Simulation Results

NATGA S2(IN) NOXSTEAM

NATGA S2

MIX1

BURN1 HOTGA S EXP2

MIXGAS

A IR1

POWER2A

A IR2 HOTGA S1 A IRCOMP

WORKMIX HOTGA S1(OUT)

A CPOWER

POWER2

POWER2(OUT)

Figure 3: Flowsheet of Gas Turbine area

HOTGAS9 MIX1

HOTGAS8A

HOTGAS8B

WATER1 HOTGAS4

WATER14 E106 E105

Water & Steam

SPLIT1 HOTGAS6

HOTGAS7B

E104 STM18

WATER15 V101

Hot Gas
WATER2

Power Generated

HOTGAS5 P103

WATER16

E103

STEAM-C(OUT) STM19

SPL103 STM20

STM21

STEAM-B(OUT) MIX103

STM23

STM22 V100 WATER3 E102

STM13 STM12

V102

WATER4 WATER4A P101

HOTGAS3 SPL102 E101 STM10 STM11 K102 WATER24

STM5 HOTGAS2 STM8 K101 POWER5

STM9

STM6 E100 HOTGAS1(IN) HOTGAS1

STM7 STEAM-A(OUT) POWER4 POWER3X POWER3X(OUT) POWER3 POWMIX

K100

Figure 4: Flowsheet of Steam Generation area

No errors occur in the simulation. Key simulation results are shown in the following tables:

7 Simulation Results

Key Stream Simulation Results

Flowsheet Variable NATGAS total NATGAS-Methane NATGAS-Ethane NATGAS-Propane NATGAS-Ar Steam for Burner Boiler feed water (High Pressure) Boiler feed water (Low Pressure) Feed Air for Burner Steam-A Steam-B Steam-C Product Waste Electrical Power Water Exhaust Hot Gas (24bar) (5bar) (1bar) Value 25000 20905 1832.5 1812.5 450 45000 180800 42600 1324000 27120 6390 185659 140189.6 4231 1394000 Unit kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kg/hr kW kg/hr kg/hr

Key Process Simulation Results

Key Process Variable Temperature of Burner Pressure of Burner Discharge Pressure of the NATGAS Turbine Discharge Pressure of the HOTGAS Turbine Discharge Pressure of High Pressure Steam Turbine Discharge Pressure of Medium Pressure Steam Turbine Discharge Pressure of Low Pressure Steam Turbine Value 978 8 8 1.1 24 5 1 Unit C bar bar bar bar bar bar

Heat Balance in Steam Generation Area

Heat Balance of Steam Generation Process Inlet Enthalpy of Hotgas(hotgas1) Outlet Enthalpy of Hotgas(hotgas9) Heat Energy Supply of Hotgas Enthalpy of Inlet Water 1 Enthalpy of Inlet Water 14 Enthalpy of Outlet Water 24 Enthalpy of Outlet Steam 9 Enthalpy of Outlet Steam21 Enthalpy of Outlet Steam 23 Heat Energy Absorption of Water in total Value -309530 -495670 186146 -786876 -185583 -18290 -96704 -23231 -686151 148083 Unit kW kW kW kW kW kW kW kW kW kW

10

7 Simulation Results

Heat Balance of Steam Generation Process Electrical Power Generated in STMGEN Process

Value 36164

Unit kW

Steam and Power Generation per 1 kg of Natural Gas

Product Name Steam at 24bar pressure Steam at 5 bar pressure Steam at 1 bar pressure Electrical Power Product Quantity 1.085 kg 0.256 kg 7.426 kg 20187 kJ

7 Simulation Results

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8 Conclusions

The Cogeneration model provides a useful description of the process. The simulation takes advantage of Aspen Pluss capabilities for modeling. The model may be used as a guide for understanding the process and the economics, and also as a starting point for more sophisticated models for plant design and process equipment specification and purchase.

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8 Conclusions

9 References

V. I. Dlugoselskii, V. E. Belyaev, N. I. Mishustin and V. P. Rybakov, "Gasturbine units for cogeneration", Thermal Engineering, 54:1000-1003, 2007. Ligang Zheng and Edward Furimsky, ASPEN simulation of cogeneration plants, Energy Conversion and Management, 44: 1845-1851, 2003

9 References

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