An Approach To Reduce Cooling Water Consumption in Thermal Power Plant by Vapor Absorption Refrigeration Plant Using Taguchi L9 Orthogonal Analysis

IDL - International Digital Library Of
Technology & Research

Volume 1, Issue 5, May 2017 Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
An approach to reduce cooling water

consumption in thermal power plant by vapor
absorption refrigeration plant using Taguchi L9
orthogonal analysis
AsimMahapatra1,Bishal Dey2
1
Asst. Professor, Department of Mechanical Engineering, Jalpaiguri Govt. Engineering College
2
Post Graduate Scholar, Department of Mechanical Engineering, Jalpaiguri Govt. Engineering College
Jalpaiguri, India
1
bishaldey92@gmail.com
Abstract: Low water levels in feeder canals of Keywords: Cooling Water, Thermal Power plant,
Solar refrigeration, Vapor absorption
thermal power plants causes shut down of power
refrigeration, power generation, Taguchi L9
generations for a few days in the last few years. Apart
analysis.
from that the Central Electricity Authority produced
a report on minimizing the overall water requirement
of coal based thermal power stations, and as the report
tells that a major proportion of the total water
1. INTRODUCTION
requirement of the power stations is the cooling water
A thermal power station is a power plant in which heat
used.In this paper we made an attempt to perform a energy is converted to electric power. In most of the
thermodynamic study and analysis of a 250 MW places in the world, as well as in India
thermal power plant, to reduce the mass flow of the turbine is steam-driven. Water is heated, turns into
cooling water by decreasing its temperature with the steam and spins a steam turbine which drives
help of solar powered refrigeration system. So, here an electrical generator. After it passes through the
we are going to study an analytical mathematical turbine, the steam is condensed in a condenser and
recycled to where it was heated; this is known as
model of a vapor absorption refrigeration system, and
a Rankine cycle. Now this is a big deal to condense the
we will try to optimize its control parameters using steam (working fluid), because this needs a large
Taguchi L9 orthogonal array. where the cooling water amount of cooling water to take away that large
coming from the cooling tower enters into a solar amount of heat from steam. But the cooling water is
refrigeration system before entering to the condenser recycled through Cooling Tower. Cooling towers are a
of the power plant. , and we will try to optimize its very important part of many chemical plants. The
control parameters using Taguchi L9 orthogonal array. primary task of a cooling tower is to reject heat into
the atmosphere. They represent a relatively
As the temperature of the cooling water drops down
inexpensive and dependable means of removing low-
because of the refrigeration system, the overall grade heat from cooling water. The make-up water
requirement of cooling water reduces. A mathematical source is used to replenish water lost to evaporation.
model of amount of cooling water flow per second is Hot water from condenser is sent to the cooling tower.
made in this paper using Taguchi analysis. The water exits the cooling tower and is sent back to
the condenser for further cooling. Now, the amount of
IDL - International Digital Library 1|P a g e Copyright@IDL-2017


make-up water is also very large, though its 2-5% of internet. Now if we consider that there is no heat loss,
the total cooling water, it is not available now-a-days then we can assume that the Cooling water
through-out the year. So this is time to think about temperature at cooling tower inlet is equals to the
reducing the consumption of cooling water.
cooling water temp. at high temperature leaving the
So, in this context we are proposing to set a
refrigeration system in order to cool down the cooling condenser. As well as the cooling water temperature at
water further before entering the condenser. But to cooling tower outlet is equals to the temperature of
avoid environmental hazards and energy crisis we low temperature cooling water going to power plant
would like to run the refrigeration system with the condenser.
help of solar energy.
Now as our prime focus is to design and set up a solar So, here we take some of these values, like-
powered refrigeration system, which can cool a large
amount of water, we have to be specific on large scale Mass flow rate of cooling water (m) = 3632 3 /hr.
solar refrigeration system. Before that we limit our = 1.01 /
research into the two main kind of refrigeration system
(a) Vapour compression refrigeration system and (b) Temperature of cooling water going to condenser =
Vapour absorption refrigeration system.
29.4
And in this paper we will focus on the second one or
the vapour absorption refrigeration system and the
Temperature of cooling water coming out from
effect of some guiding parameters to optimise the
system. condenser = 46.1
So, heat extracted from the condenser,
2. OBJECTIVES Q = m.cp.dT , where, m = mass flow rate of

In this context we are proposing to set a refrigeration cooling water
system in order to cool down the cooling water further
Cp = Specific heat of water at constant pressure, for
before entering the condenser. But to avoid
water = 4.184 KJ/Kg-K
environmental hazards and energy crisis we would like
to run the refrigeration system with the help of solar dT = Temperature difference in Kelvin (K)
energy.
So, Q = 1.01 103 4.184 (319.1 302.4) KJ/s
Now as our prime focus is to design and set up a solar =70571.528 KJ/s or KW (= 60.3 Million Kcal/hr )
powered refrigeration system, which can cool a large
amount of water, we have to be specific on large scale So, we have got the amount of heat the cooling water
solar refrigeration system. Before that we limit our extracts from the condenser.
research into the two main kind of refrigeration system
Evaporation Loss (m3/hr) = 0.00085 x 1.8 x
(a) Vapour compression refrigeration system and (b)
circulation rate (m3/hr) x (T1-T2)
Vapour absorption refrigeration system.
And in this paper we will focus on the second one or the

vapour absorption refrigeration system and the effect of T1-T2 = Temp. difference between inlet and outlet
some guiding parameters to optimise the system. water
3. METHODOLOGY For circulation rate= 1010 Kg/s and Temperature

For a general cooling tower of a 250 MW thermal difference between inlet and outlet temperature =
power plant, we have collected some data from the (319.1 302.4)K


Evaporation Loss = 25.82 Kg/s ;which is 2.56% of Refriger 3985. 7547. 10746 13636. 1626
the circulating water. ating 176 68 .89 995 0.7
Effect or
Now, as we are going to set up a refrigeration plant load
which will cool down the cooling water temperature (RE) in
further after coming from cooling tower, so, if the (KW)
temperature can further decreased by 1K, the cooling
water mass flow rate becomes- Now, we are going to focus on the refrigeration plant
to be used.
m = 952.48 Kg/s
For this operation we have chosen LiBr-H2O
So, the mass flow rate decreases by = 57.52 Kg/s or VaporAbsorption Refrigeration System where H2O
5.7% () as refrigerant and LiBr as absorbent.
Now, for reducing the temperature of 952.5Kg/s The parameters which are kept constants are,
cooling water by 1K, the Refrigerating Effect or Load
is 3985.176KJ/s or KW Mass flow rate of cooling water (Mw) =
1.01103Kg/s
Like the same way, for decreasing the cooling water
temperature further by 2K, 3K, 4K and 5K, where the Cp of water= . /
mass flow rate without refrigeration is 1010 Kg/s, we
get Condenser Temperature (Tc) = 313K
Table: Reduction of mass flow of cooling water with REGRESSION ANALYSIS

decreasing temperature-
Regression analysis is a statistical tool toprovides
1K 2K 3K 4K 5K relationship between response and predictor variables.
By regression analysis we can determine how response
Mass 952.4 901.9 856.1 814.83 777.2 variable changes with change of the predictor
flow 8 7 9 8 variables. Now, Simple regression equation is Y=
rate(m) a+bX. But we have to consider more than one
in(Kg/s) predictor variables, so we are not going to use simple
regression analysis. In this problem we apply
Reductio 57.52 108.0 153.8 195.17 232.7 polynomial multiple regression analysis to obtain the
n of 3 1 2 mathematical model.
mass
flow Polynomial multiple regression
rate(Kg/s analysis(Second order or more )i.e.-
)
Y= 0 + 1 X1 + 2 X2+3 X3 +
% reduct 5.7 10.7 15.23 19.32 23.1 4X1X1+5X2X2+6X3
ion of X3+7X1X2+8X2X3+
mass 9(X3X1)
flow rate This equation is second order polynomial equation
with three variables i.e. X1, X2, X3; Y is the response
variable and is the coefficients. In our project we


have used this equation to form the mathematical Generator 358K 363K 368K
model. Temperature drop from the inlet to outlet of the temperature
refrigerator (dT),Generator temperature (Tg)
(Tg)&Evaporator Temperature (Te) are control
factors, final equation looks like Evaporator 278K 279K 280K
Temperature
Qg= + dT + Tg + Te + (dT*dT) (Te)
+ (Tg*Tg) + (Te*Te) + (dT*Tg) + (Tg*Te)
+ (Te*dT)
This equation is solved by following matrix method

[] = [Y]*INV[X], Where, [] = Coefficients matrix;
In this study, values of control parameters or factors
[Y] = Response variable matrix; INV[X]= inverse of
(dT, Tg, Te) were put and correspondingon heat given
control variables matrix;
to the refrigerant in generator(Qg) was calculated from

In this problem three variables are there with three the equation, = where, = Specific heat
[ ]
different range or level, so Taguchi L9DOA matrix
at constant pressure of Water= 4.184 KJ/Kg-K. Nine
table is used to do the theoretical experiment. But L9
experiment were done according to the L9 Orthogonal
Orthogonal table gives us nine equations and number
array and one according to L18 Orthogonal array.
of unknown coefficients are ten (i.e. - [X] = [10*9]).
Then these ten sets of equation are solved in
To solve this we did one extra experiment taken from
MATLAB by matrix method and got the required
L18 Orthogonal array. Now number of equations is
values of co-efficient.
equal to know of unknown co-efficient (i.e. [X] =
[10*10]).
The proposed mathematical model from theoretical
experiment:
Qg= . + . dT . Tg
+ . Te + . (dT*dT) + . (Tg*Tg)
Control Factors & their ranges- 0.0001(Te*Te) 0.0001(dT*Tg) + 0.00(Tg*Te)
+0.0001 (Te*dT)
Three control factors and their range or level are
shown in below-
CONTROL LEVEL
4. OUTCOMES
FACTORS LOW(1) MEDIUM(2) HIGH(3) Above regression equation was simulated in computer to
find out the effect of control factors (dT, Tg, Te) on change
inHeat given to the refrigerant in generator (Qg) within
the considered range or levels. A computer C-Programming
Temperature 1 2 3 gives the responses for each input and this is done by
drop from the varying one parameter within the considered range while
inlet to outlet keeping other two parameters constant.
of the
refrigerator(dT) Effect of Control Factors on mass flow rate of cooling
water (m):


1. Variation of Heat given to the refrigerant in
generator (Qg) on temperature drop(dT) while
other two parameters, Generator temperature
(Tg)&Evaporator temperature (Te) were kept
constant at 363K &279K respectively Qg
Qg
Te
dT
We, also used Taguchi method to analyze the guiding

parameters for smaller the better criteria. The S/N
2. Variation of Heat given to the refrigerant in ratio forheat given to the refrigerant in generator (Qg) is
generator (Qg) on Generator temperature (Tg) calculated by using MINITAB 17 software:
while other two parameters, temperature drop (dT)
& Evaporator temperature (Te) were kept constant
at 2& 279K respectively
Qg
Tg
CONCLUSION
3. Variation of Heat given to the refrigerant in
generator (Qg) on Evaporator temperature (Te)
In this study Taguchi methods of Design of
while other two parameters, temperature drop (dT)
Experiment (DOE) was used to examine how heat
&Generator temperature (Tg) were kept constant
at 2&363K respectively given to the refrigerant in generator (Qg) in an steady
flow refrigeration process of a VARS vary with


temperature drop, Generator temperature&Evaporator [8]. Design of Solar Powered Vapour Absorption
temperature. Conclusion can be made from the SystemByV.K.Bajpai
analysis of results obtained from the mathematical
model is that we came to know What are the optimum
values of the control factors to decrease the heat given
to the refrigerant in generator and by lowering this we
can make the refrigeration less costly and affordable
and that is how we will be able to decrease mass flow
rate of cooling water. And this can be a one-time
investment process, even the maintenance cost is very
low. But the Main thing is that power generation will
not get hampered due to scarcity of cooling water,
besides when there water much available we can use
this system to produce additional electricity.
REFERENCES
[1].http://www.thehindubusinessline.com/companies/fi
veunitsinntpcfarakkaplantshutdownduetolackofwater/a
rticle8346477.ece
[2]. Bureau of Energy Efficiency

(https://www.beeindia.gov.in/sites/default/files/3Ch7.p
df)
[3]. Saving Water With Cooling Towers, By Frank

Morrison, Member ASHRAE
[4]. A textbook of Refrigeration and Air Conditioning,

By R. S. Khurmi and J. K. Gupta
[5]. A solar refrigeration system to reduce cooling

water consumption in a thermal power plant. By
AsimMahapatra and BishalDey
[6]. Report on Minimization of Water Requirement in

Coal Based Thermal Power Stations, From Central
Electricity Authority, New Delhi- 110066
[7].Performance of a Single Effect Solar Absorption

Cooling System (Libr-H2O) By Omar Ketfia,b*,
Mustapha Merzouka, NachidaKasbadjiMerzoukb, Said
El Metenanb

An Approach To Reduce Cooling Water Consumption in Thermal Power Plant by Vapor Absorption Refrigeration Plant Using Taguchi L9 Orthogonal Analysis

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International e-Journal For Technology And Research-2017