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GT2014
June 16 20, 2014, Dsseldorf, Germany
GT2014-25222
Stephan Arnold
Institute of Thermal Turbomachinery
and Machinery Laboratory (ITSM)
University of Stuttgart
Stuttgart, Germany
s.arnold@dungs.com
Markus Schatz
Institute of Thermal Turbomachinery
and Machinery Laboratory (ITSM)
University of Stuttgart
Stuttgart, Germany
schatz@itsm.uni-stuttgart.de
ABSTRACT
Combined heat and power generation (CHP) is a way of providing both electric power and thermal heat for industrial and
domestic facilities at high fuel efficiencies. Often small and
medium sized gas powered internal combustion (IC) engines,
rated at electric power outputs of 50 600 kW, are used for such
applications. During the time when the available thermal heat is
used, the fuel efficiency of such CHP plants is very high, but it
drops to the efficiencies of simple power generation when there is
no heat demand, e.g. during summer. In these cases, the exhaust
heat is blown off, especially as CHP units are mainly heat-lead,
i.e. designed to cover the heat demand rather than the demand for
electrical power. Moreover, as the cooling water heat rejection is
also more difficult at elevated ambient temperatures, these units
are then operated at part load or even switched off, hence having
a lower degree of capacity utilization.
The approach of the work presented here is to replace the
turbocharger system commonly used for IC engines and to use
an electric driven compression device instead, while the turbine
serves to generate additional electric power from the exhaust gas.
Furthermore, for periods with low thermal heat demand,
steam is generated from the turbine exhaust heat. The steam is
injected in front of the turbine in order to increase the turbine
work output further. Thus, at least part of the exhaust heat available is used and the power output as well as the electric efficiency
is increased. In the present work, two configurations of the de-
Now:
NOMENCLATURE
c
velocity [m/s]
cp
specific heat [J/kgK]
g
gravity [m/s2 ]
h
specific enthalpy [J/kg]
j
specific dissipation [J/kg]
m
mass flow [kg/s]
P
Power, Power consumption [W]
p
pressure [Pa]
Q
Heat flow [J/s]
q
specific heat [J/kg]
R
gas constant [J/kgK]
T
temperature [K]
v
specific volume [m3 /kg]
Karl Dungs GmbH & Co. KG, Combustion Controls, Urbach, Ger-
many
wt
wv
y
z
Subscripts
C
compressor
c1
Configuration 1
c2
Configuration 2
in
input parameter
out
output parameter
s
isentropic
T
turbine
t
total state
Acronyms
BC
Boundary conditions
CHP
Combined heat and power
ECC
Engine cooling circuit
EEG
Engine exhaust gases
G
Generator
HBF
Heating backflow
HEX
Heat exchanger
HRSG
Heat recovery steam generator
IC
internal combustion
ORC
Organic Rankine Cycle
resp.
respective
STIG
Steam Injected Gas Turbine
TC
Turbocharger
TIT
Turbine inlet temperature
TOT
Turbine outlet temperature
INTRODUCTION
Combined generation of heat and power (CHP) is a very effective way to increase the fuel utilization and hence to reduce
primary energy consumption as well as CO2 -emissions. In order
to minimize heat transmission losses and to avoid high costs for
the construction and maintenance of large district heating systems, small and medium combined heat and power (CHP) plants
with electric power outputs in the range of 50 600 kW are usually set up for small districts or housing blocks. These units are
often equipped with gas powered, turbocharged internal combustion (IC) engines, although recently some studies have been dealing with the application of microturbines for cogeneration [1].
100
75
50
25
0
0
50
100
300
350
FIGURE 1. CUMULATED HEAT DEMAND CURVE FOR HOUSING AREAS IN GERMANY AND OPERATING MODES FOR A
CHP PLANT DESIGNED TO COVER 50% OF THE HEAT DEMAND.
chosen temperature limits. In configuration 2 heat output temperatures above the chosen temperature limits are partly traded
off by an increased water consumption because no recovery of
the injected water is implemented. The authors of this paper
are aware of the fact that a discharge of the injected steam together with the exhaust gases is a major disadvantage. In [12] it
is shown, that the costs of feedwater for steam injection into a gas
turbine without water recovery amount to about 5% of the total
fuel costs. However, the amount of water needed can be supplied by reverse-osmosis plants, possibly at operating costs that
are only slightly above those incurred with a condensator [13].
Both configurations, in comparison to usual CHP units, do
not use a turbocharger to compress the combustion air/fuel-airmixture. Instead, the expansion of the exhaust gas or the exhaust
gas/steam mixture, respectively, is done in a proper power turbine which is directly connected to a generator. To charge the IC
engine, an electric driven positive displacement device is used to
compress the fuel-air-mixture. Here it is assumed that the compressor compresses both air and natural gas which is mixed in
front of the compressor (station 0).
The mixing-process of engine exhaust gases and steam is not
examined in detail in this work. Because of the ratio of steam
mass flow and engine exhaust gas mass flow (m 9 /m 3 0.1942)
an injector-mixer according to the venturi principle can be used
to inject steam into the exhaust gas at the same pressure. Moreover, the engine performance is not affected by the different setups under study here, hence it will not be modelled in detail.
There is an identical set of components compressor, engine, mixer and turbine in both configurations. Therefore, it is
possible, in consideration of different inlet conditions, to use the
same calculation routines for these components independent of
the configuration modeled.
In this section, the modeling and calculation methods for all
components used are presented.
MODELING
Two different CHP configurations are examined here. The
first configuration (Fig. 2) features a condenser to recover the
water used generation of steam thus operating in a closed water
circuit. In the second configuration (Fig. 3), which is an improved design based on configuration 1, no water recovery is
considered and the steam is discharged together with the exhaust
gases. The improvement was made because of several difficulties of configuration 1 with heat output temperatures below the
chimney
engine
compressor
turbine
mixer
1
RT0
wv01s =
C 1 ,
1
HEX/condenser
reservoir
condensate
seperator
HRSG
s, C =
gas-air-mixture / exhaust gas
steam-exhaust-gas-mixture
steam
water
mixer
turbine
cooler
waste HEX
HEX 1
Q = Q in = Q out .
HEX 3
HEX 2
Q = m c p T.
(6)
1
1
1
. [15]
T3 = T5 1 s, T 1
(7)
T
can be determined.
Heat losses in the piping between HRSG and steam injection
are neglected, therefore
Z 1
p dv .
(5)
wv01 =
(4)
engine
G HRSG
(3)
PC = m C wv01 .
chimney
wv01s
,
wv01
compressor
(2)
(1)
T9 = Tsteam, HRSG .
(8)
by
Q 3 + Q 9 = Q 4 .
(9)
(10)
(11)
mech =
Turbine Similar to the compressor, an isentropic efficiency s, T is assumed for the turbine. Generally the first and
second law of thermodynamics are applied [15]:
wt45 + q45 = (h5 h4 ) +
1 2
c5 c24 + g (z5 z4 )
2
(12)
(13)
For an adiabatic process of gaseous fluid, assuming equal velocities at turbine inlet and outlet, eq. 12 and 13 reduce to
wt45 = ht5 ht4 = h5 h4 = c p (T5 T4 ) .
(14)
T5 = T4 1 s, T 1
1
T
1
(15)
(16)
System Efficiencies There are two relevant system efficiencies. On the one hand the thermal efficiency therm and on
the other hand the electric efficiency el . The thermal efficiency
in this paper is defined as
therm =
Q used
Q input (fuel)
(18)
Pel
Pshaft
el =
.
Qinput (fuel)
Qinput (fuel)
Boundary Conditions
Because both configurations are based on the same IC engine, the boundary conditions are basically identical. All temperatures, pressures and mass flows shown here are normalized
based on the corresponding values given at the engine outlet and
based on the engine power and heat output at 100% load ( ). The
resulting values for the boundary conditions are presented in table 1.
(17)
steam
massflow
BC
compressor
(iterative)
compressor
power
consumption
HRSG +
turbine
(iterative)
waste heat
waste HEX /
condenser
turbine
performance
engine
cooling circuit
heat buffer
heating circuit
/ condenser
cooling circuit
heat output
Configuration 1
Configuration 1 is a very simple set-up with only one HEX
which will also be used as a condenser here and a reservoir where
the heat from the engine cooling system and the exhaust gas is
delivered to the heating system. Figure 6 shows the course of
turbine output with increasing steam injection. The steam mass
flow is limited by the appearance of condensation in the turbine
exhaust flow. The maximum steam mass flows calculated at the
different performance levels under consideration are given in table 2. For the calculation of the turbine power output the mass
flow of injected steam was increased incrementally from m 9 = 0
to the maximum values stated in table 2.
Figure 6 shows the increase of net turbine power output
PT, net = PT, gross PC as a function of steam injection rate.
Note that the use of a power turbine already increases the
overall power output of the CHP plant by 2.41% to 7.05%, depending on the engine load. However, using a power turbine
without steam injection would not solve the problem of the unused heat and cooling system heat rejection in periods with low
thermal heat demand.
FIGURE 4. SCHEMATIC PROGRAM FLOW OF CONFIGURATION 1 STARTING FROM THE GIVEN BOUNDARY CONDITIONS
compressor
power
consumption
BC
compressor
(iterative)
turbine
performance
HRSG
(iterative)
steam
preheating
steam
massflow
preheating
circuit with
enginge
waste heat
waste heat
heating circuit
cooler power
consumption
TABLE 1.
heat output
FIGURE 5. SCHEMATIC PROGRAM FLOW OF CONFIGURATION 2 STARTING FROM THE GIVEN BOUNDARY CONDITIONS
A compressor pressure ratio C = 2 and an isentropic efficiency of s, C = 0.81 was chosen [6]. For the turbine the pressure ratio was set to T = 2.5 and the isentropic efficiency to
s, T = 0.8. The remaining temperature difference between the
different fluids in the heat exchangers usually was set to 10 K except for the cooling fan system in configuration 2, for which 5 K
was assumed.
Variable
Value
Description
T0 /T3
0.4015
TECC /T3
0.5219
TFW /T3
0.4254
THBF /T3
0.4442
p0 /p3
0.3579
TABLE 2. MAXIMUM STEAM MASS FLOW OF CONFIGURATION 1 BEFORE CONDENSATION IN THE MIXER OCCURS
Engine load
100%
75%
50%
25%
m 9 /m 3
0.1852
0.1545
0.1143
0.0677
el [%]
55.0
100%
75%
50%
25%
0.08
0.06
50.0
45.0
0.04
40.0
0.02
35.0
0.00
0.00
0.05
0.10
0.15
m 9 /m 3
0.20
30.0
0.00
0.25
FIGURE 6. NET TURBINE POWER OUTPUT OF CONFIGURATION 1 AS A FUNCTION OF STEAM MASS FLOW AT DIFFERENT ENGINE LOADS
100%
75%
50%
25%
0.05
0.10
0.15
m 9 /m 3
0.20
0.25
Q out /Pengine
0.50
100%
75%
50%
25%
0.40
0.30
0.20
0.10
0.00
0.00
0.05
0.10
0.15
m 9 /m 3
0.20
0.25
Thermal Heat Output and Thermal Efficiency without Water Recovery The calculated thermal heat output
without condensation in the waste HEX for water recovery is
therm [%]
50.0
Q out /Pengine
0.50
100%
75%
50%
25%
40.0
30.0
0.40
0.30
20.0
0.20
10.0
0.10
0.0
0.00
0.05
0.10
0.15
m 9 /m 3
0.20
0.00
0.00
0.25
100%
75%
50%
25%
0.05
0.10
0.15
m 9 /m 3
0.20
0.25
full load and from about 47% to 20% at low load, which corresponds to the heat flow of the engine cooling system. This heat
flow, however, still has to be rejected at low heat demand.
Configuration 2
Based on the results obtained for configuration 1, the system has been adjusted in order to provide a possibility to reject
the heat from the engine cooling system or use it to preheat the
feedwater for the HRSG, see figure 2. Because of the low temperature level and the increased complexity of the system, water
recovery has not been considered further. While in configuration 1, only the power consumption of the compressor and the
feedwater pump had to be considered, configuration 2 features
an additional cooling device for which a fan is necessary. Thus,
the net turbine power output of configuration 2 reduces to
(19)
As in configuration 1, the maximum steam mass flow is limited to the point where condensation occurs in the mixer. The
maximum steam injection rates calculated for configuration 2 are
shown in table 3. Compared to the results for configuration 1
given in table 2, higher steam injection is possible because of
the feedwater preheating from the engine cooling system for all
operation points except for the low load case.
The level of the gross turbine performance is up to 1.6%
higher compared to configuration 1, which can be attributed to
the higher steam mass flow rate obtained in this configuration.
The steam injection rate is up to 1.4% higher compared to that
of configuration 1. However, the net performance, shown in figure 11, is about 15% lower because of the power consumption of
the additional cooling fan. The overall plant output increases by
TABLE 3. MAXIMUM STEAM MASS FLOW OF CONFIGURATION 2 BEFORE CONDENSATION IN THE MIXER OCCURS
Engine load
100%
75%
50%
25%
m 9 /m 3
0.1942
0.1592
0.1177
0.0714
el/mech [%]
55.0
100%
75%
50%
25%
0.08
0.06
50.0
45.0
0.04
40.0
0.02
35.0
0.00
0.00
0.05
0.10
0.15
m 9 /m 3
0.20
30.0
0.00
0.25
FIGURE 11. NET TURBINE POWER OUTPUT OF CONFIGURATION 2 AS A FUNCTION OF STEAM MASS FLOW AT DIFFERENT ENGINE LOADS
100%
75%
50%
25%
0.05
0.10
0.15
m 9 /m 3
0.20
0.25
FIGURE 12. ELECTRIC / MECHANIC EFFICIENCY OF CONFIGURATION 2 AS A FUNCTION OF STEAM MASS FLOW AT
DIFFERENT ENGINE LOADS
100%
75%
50%
25%
0.40
0.30
0.20
0.10
0.00
0.00
0.05
0.10
0.15
m 9 /m 3
0.20
0.25
therm [%]
50.0
heat, the CHP plant only generates electric power, thereby using engine cooling and engine exhaust heat to generate steam to
maximize power output.
CONCLUSIONS
In the present paper, the idea of using the exhaust heat of
CHP plants to generate steam at times of low heat demands has
been studied. The basic goal was to increase the plant power
output while decreasing the thermal heat to be consumed in order
to reduce the amount of heat discharged and hence to keep the
plant efficiency at higher levels.
It has been shown that already by using a power turbine instead of a turbocharger, the power output of the CHP plant can
be increased at configuration 1 by 2.41% to 7.05% and at configuration 2 by 1.98% to 6.17%, depending on the load point.
In configuration 1 a simple set-up for steam injection, yet
with water recovery was modeled. The electric efficiency is increased further by 1.76 2.3 percentage points compared to the
case without steam injection depending on the operating point
of the engine. However, an actual demand of thermal heat is
still necessary, especially because the heat of the engine cooling system cannot be rejected. Water recovery using a condenser
actually aggravates the problem, because it results in an even increased heat delivery at temperatures below the minimum heating water temperature, so that it is not even suitable to cover a
low thermal heat demand. As a consequence, configuration 1 is
not practicable.
Configuration 2 has been set up according to the conclusions
drawn from the study of configuration 1. A separate cooling device has been provided, moreover the steam is discharged together with the exhaust gas. The electric efficiency is increased
further by 1.5 1.7 percentage points compared to the case without steam injection depending on the operating point of the engine. The temperature in the heat exchanger circuit used to cover
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