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Published by : International Journal of Engineering Research & Technology (IJERT)

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Vol. 7 Issue 06, June-2018

Exergy Analysis of a Thermal Power Plant


Hemanta kumar Pandaa, Dr. Alok Chaubeb
a b
Research scholar, Fourth Semester , Head of Department
M.Tech.(Thermal Engg.) Department of Mechanical Engineering,
Department of Mechanical Engineering, JEC Jabalpur (MP), Gokalpur ,
Uttrakhand Technical University, Jabalpur(MP)-482011,India
Dehradun, India

Abstract - The research is based on the exergy analysis of a INTRODUCTION


thermal power plant, for which M/s. Bhushan Power & Steel, 1.1 Introduction of power sector
Thelkoli, Odisha has been taken into consideration. The pri- Now-a-days, electricity is a basic need to human life. From
mary objective of the work is to analyse the system components personal to professional life, from home accessories to in-
separately to identify the parts responsible for having loss of dustrial machineries nothing can be imagined making aside
exergy at large. The conclusion of the research can enable to the electricity. As such, power generation industry reflects a
configure suitable modifications to improve efficiency of the major role in the economic upliftment of the country. Pres-
system components and to minimize the exergy loss of the pow-
ently, 80% approx. of total electricity consumed in the world
er plant.
is being produced from fossil fuels i.e. coal & petroleum
Based on a study of exergy destruction, the boiler products and only 20% approx. is produced from other
system is having a max. 64.04% of exergy loss. The exergy effi- sources like wind, water, hydraulic, solar, biogas, geother-
ciency of the power plant is found 50.41%, which is low as mal etc.
compared to modern power plants. According to analysis it is Now a day exergy analysis of power plant is of sci-
found that boiler is the major source of irreversibility in the entific interest for making efficient utilization of energy
power plant, butexergy destruction rate in boiler can be re- resources as they are constant in nature. The analysis of an
duced by introducing reheating system. It is a suitable tech- energy conversion process is normally carried out by the
nique to decrease boiler’s irreversibility. The effect of reheat-
first law of thermodynamics. But now a day, there is an in-
ing for improvement of overall performance is compared to the
real condition of power plant in this research work. Without creasing interest in the combined utilization of the first and
any change of fuel consumption, the effect of reheating to min- second laws of thermodynamics, using both the law exergy
imize exergy destruction has been also investigated. By intro- and irreversibility can be calculated. By which one can eval-
ducing reheating system it is found that not only boiler’s exer- uate the efficiency with which the maximum available ener-
gy destruction minimized but also overall plant efficiency and gy is consumed. Exergy analysis method is a tool for clear
power generation has been increased. distinction between the energy losses to the environment and
Keywords: Exergy analysis; exergy efficiency; Exergy destruc- internal irreversibility of the process.
tion; dead state; steam power plant.
1.2 Thermal power plant
Nomenclature Thermal power plants are the back bone of In-
dian power sector. In India 68.14 % of electricity is generat-
h Enthalpy (kj/kg) ed by the thermal power plant. A thermal power plant con-
X Exergy (KW) tinuously convert the energy stored in fossil fuels (coal, oil,
M Mass flow rate natural gas) into shaft work and ultimately into electricity.
P Pressure (bar) Thermal power plant converts heat energy of the working
Q Heat transfer (kj) fluid into electrical energy. The working fluid is sometime
S Entropy (kJ/kg) in the liquid phase and sometime in the vapour phase during
T Temperature (k) its cyclic operations.
I X destruction
X Exergy
ST Steam turbine QOUT
In Inlet
G Gas
I Irreversibility
Greek symbols
η Exergy efficiency wOUT
Ψ Specific exergy (kj/kg) WIN
S Steam

Fig: 1 Common power cycle of thermal power plant

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1.2.1 Working Principle of thermal power plant: In the first step, steam expands in the high pressure
The thermal power station is a power plant in turbine from the initial state and the steam is then reheated
which the prime mover is driven by steam. Water is heated in the boiler and the remaining expansion is carried out in
in a boiler converts into steam and the steam passes through low pressure turbine. With the use of reheat cycle the net-
a nozzle which impact force on the turbine blade. This im- work output of the plant and performance will increase of as
pact force produces turning moment to rotate the turbine the fuel consumption is same.
shaft which drives an electrical generator to produce elec-
tricity. After expansion of stem in the steam turbine, it pass- 1.3 Plant description
es to the condenser where heat is taken away by the cooling Bhusan power and steel plant is located 300 m
water coming from the cooling tower or river bed. Makeup above the sea level at village thelkoli, 10 km away from
water is supplied to make the water level constant in the Jharsuguda district head quarter, Odisha (India).The power
boiler. The condensed steam along with the makeup water is plant has total installed power capacity of 300 MW in full
recycled to the boiler by a feed pump where it is again heat- load condition. It has been started to produce power in the
ed. The cycle is repeated continuously. This is known as a last of nineties.The plant produces 300 MW (at full load)
“Rankine cycle”. from three number turbine generators each 100 MW capaci-
ty. For running of these turbine generators there are five
1.2.2 Reheating cycle number of boiler. For turbine no I, two number boiler having
If higher steam pressures are used, in order to limit capacity 210 ton per hour is used. For turbine no II, two
the quality of steam to 0.85 at the turbine exhaust reheating number boiler having capacity 210 ton per hour is used. For
system is adopted. In that case all the steam after partial turbine no III only one boiler having capacity 390 ton per
expansion in the high pressure turbine is brought return back hour is used. Till to date there is no reheating system used in
to the boiler reheater, reheated by combustion gases and this thermal power plant. The power plant used coal and
then feed back to the low pressure turbine for further expan- sometimes charcoal as fuel.
sion.
The schematic flow diagram of actual power plant
is shown in Fig. 1.3.1. Feed water heating is carried out in
three stages i.e. low pressure heater, high pressure heater I
and high pressure heater II. Steam is superheated to 793 K
(T) and 96.108 (P) bar in the boiler and fed to the turbine.
There are four number of turbine bleed. One number for lp
heater, two number for hp heater and one number for
dearator. The turbine exhaust streams are sent to condenser
at 0.09 Bar and 42.9°C, the steam is condensed in the con-
denser and go to hot well. The makeup water enters to the
hot well at temperature 54°C. The condensate sent to the
dearator through lp heater by the condensate extraction
pump. Then the water is recycled to boiler through hp heat-
er-I and hp heater-II by the feed pump, where water is heat-
ed; this known as a ‘Rankine cycle’. This power cycle starts
over and over again. In Bhusan thermal power plant coal
Fig: 2 Simple reheat cycle of thermal power plant (sometimes charcoal) is used as the working fluid, which
calorific value is 4011.625 Kcal/Kg, which are very low
grade coal in quality.

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Operating Parameters Of The Thermal Power Plant: Exergy defines the maximum capacity of a system to pro-
Operating condition value
duce useful work as it proceeds from a specified state to a
final state which is in equilibrium with its surroundings.
Mass flow rate of coal 8.226 kg/sec Exergy cannot be conserved like energy as it is destructed in
the system. Exergy destruction is the measure of irreversibil-
Mass flow rate f.w 65.28 kg/sec
ity that is the source of performance loss. Therefore, exergy
Sup.steam temp. 793 K analysis enables us to identify the location, the magnitude
and the source of thermodynamic inefficiencies in the over-
Gross calorific value 4011.625 Kcal/kg all system
Boiler pressure 164.754 Bar
The minimum exergy that has to be rejected to the
Steam pressure 96.108Bar sink by the second law is called unavailable energy (U.E.).
Therefore,
Mass flow rate of air 97 kg/sec

Ambient Temperature 300 K Q1 = U.E. + Exergy


Ambient Pressure 1.01325 Bar W𝑚𝑎𝑥 = Exergy = Q1 - U.E.

Exergy analysis is a method for the evaluation of


2: EXERGY the performance of system devices or processes. It examines
2.1 Introduction
the exergy at different locations of a system through a series
It is evident that the content of energy in the universe is con-
of energy conversion steps. Exergy analysis helps to evalu-
stant. But very often, we come through different dialogues
ate exergetic efficiencies and to identify the system compo-
and articles on the topic that “How to conserve energy”.
nents having max. exergy loss. Broadly speaking, the exer-
Since time immemorial it is known that energy is constant in
gy analysis provides a more authenticated and realistic view
nature, what need to conserve the energy which is already
of the process or system analysis to improve the efficiencies
conserved. The content required to be conserved is exergy
of the power plant.
which is the vital parameter and work potential of the ener-
gy. Exergy is irrecoverable i.e. once it is wasted can never 4: MATHEMATICAL FORMULATION
be recovered. Simply, it means that when energy is used, the Exergy analysis is a method that uses both the prin-
conversion of energy in a less powerful form i.e. exergy is ciple of conservation of energy and mass along with the
used not the energy. Hence, energy is never exhausted. second law of thermodynamics. This analysis is carried in
most of the power plant for enhancement of system or sys-
tem component efficiency. The exergy analysis method is a

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useful tool for consuming energy-resource in a more effi- The above exergy balance is written in a general
cient way. It helps the engineers/designers to identify loca- way. For the boiler operation, the heat input will be included
tions and magnitudes of wastage, losses and to determine the when calculating the chemical exergy of coal. Exergy can
meaningful efficiency of the system. increases because of heat (associated with a temperature
factor) and work transferred across the system boundary.
The exergy (Ψ) of heat transfer (Q) from the con- Exergy associated with the streams of matter entering or
trol surface at temperature (T) is determined from maximum living the control volume. In real processes, exergy are de-
rate of conversion of thermal energy to work( Wmax ) . This stroyed due to irreversibility.
can be written by following equations:
The second law of efficiency or exergetic efficiency is de-
Q = Unavailable Energy + Exergy (1) Exergy output
fined as-η = ⁄Exergy input
W𝑚𝑎𝑥 = Exergy = Q - Unavailable Energy (2)
T
𝑊max = 𝑋 = ∑ Q (1– o) (3) For a steady state operation, and choosing each component
T
And the specific exergy is given by in control volume, the exergy destruction rate (I) and the
Ψ = ( h– ℎ𝑜 ) – To (s– 𝑠𝑜 ) (4) exergy efficiency (η) is shown by:I= Wmax - W
The total exergy rate associated with a fluid stream be- (12)
comesX =m . Ψ (5)
Taking the value Ψ of from equation (4) For boiler:IB = Xfuel + Xin – Xout (13)
(X − Xin )
ηB = out ⁄X (14)
X = m [( h– ho )– To (s– so )] (6) fuel
(6) For turbine: IT = Xin – Xout – WT (15)
IT
ηT = 1 – ⁄X – X (16)
Change in enthalpyΔh = h - ho (7) in out
Enthalpy gradient for a constant pressure process is given by For condenser or Hot well:
the equation Δh = mcp ΔT (8) IC = Xin – Xout + XMW (17)
Change in entropy is given by the equation Where XMW is the exergy of Makeup water
Δs = s– so (9)
Xout
ηC = ⁄X + X (18)
in MW
Change in entropy for a constant pressure process is given
T For pump:IP = Xin – Xout + WP (19)
by the equation Δs = mcp ln (10) Where WP is the work input to the pump.
To
Where ho , To and so are the value of reference condition i.e. I
ηP = 1 – P⁄W (20)
atmospheric condition. P

Exergy of fuel is given by:XFuel = mass of fuel × Calorific For overall cycle:
value of fuel (11) ICycle = ∑ Iall component (21)
Calorific value of coal = [80.8 × C + (287 × H – O/8) + 22.5 ηCycle = NET OUT PUT⁄INPUT ηCycle
× S – 6 × M] Kcal/kg W
= net out⁄X (22)
fuel
Where; C = carbon compositions in coal 𝑊Net = 𝑊T – 𝑊P (23)
H = Hydrogen compositions in coal Steam rate = Capacity of power plant
S = Sulphur compositions in coal = 1⁄W (kg/h) (24)
O = Oxygen compositions in coal Net
Q
M = Moisture composition in coal Heat Rate = 1⁄η= ⁄W (kg/h) (25)
Net

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All above formulation play the key impact for the exergy analysis of bhusan thermal power plant.

5: EXERGY ANALYSIS OF BHUSAN THERMAL POWER PLANT:

6: RESULTS AND DISCUSSION:


Thepower plant has been analyzed using the above relation- exergy loss was found in the boiler, where 64.04% of the
sand formulation by considering that the environmentaltem- total exergy loss was destroyed. Next to it was the turbine
perature and pressure are 300 K and 1.013 bar,respectively. which represents 9.0% of total exergy destruction. The per-
Coal is the supply fuel of the powerplant, with the following cent exergy destruction in the condenser was 3.33% while
components: Ash = 40%,Moisture = 8%, Hydrogen = 2.3%, all heaters and pumps destroyed less than 2% except APH.
Nitrogen = 0.7%,Sulphur = 0.30%, Oxygen = 6.60%, Car- Theexergy efficiency of the power plant was 50.41%.
bon = 42%, GCV = 16795.87KJ.In this power plant major

Table 6.1 Exergy destruction and exergy efficiency of power plant componentswhen
To = 300 K, Po = 1.013 bar.
Component Exergy destruction (KW) Percentage of destruction Efficiency (%)
Boiler 45989.74 64.04 69.76

Turbine 6535.43 9.10 93.03

Condenser 2390.77 3.33 55.17

CEP 260.69 0.36 46.19

LPH 502.70 0.70 65.13

Dearator 377.71 0.53 87.96

BFP 633.39 0.88 86.11

HPH-I 1293.76 1.80 85.81

HPH-II 310.87 0.43 97.25

APH 4185.49 5.83 66.25

To atmosphere 9334.86 13.0

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50000
45000
Irreversibility (KW)
40000
Irreversibility (KW)
35000
30000
25000
20000
15000
10000
5000
0

Fig: 6.1 Component wise exergy destruction

PERCENTAGE OF EXERGY DESTRUCTION


3.33
0.36 Boiler
9.1 0.7 0.53 Turbine
0.88 13 condenser
CEP
21.06 LPH
Dearator
64.04 5.83 1.8 BFP
HPH-I
0.43
HPH-II

Fig: 6.2 Percentage of exergy destruction

From the exergy analysis, the overall plant energy losses are Thus the analysis of the plant based only on the First law
calculated. Fig. 6.1.2 shows the comparison of exergy losses principles may mislead to the point that the chances of im-
between different components. It isprominent that the max- proving the electric power output of the plant is greater in
imum exergy loss (64.04%) occurred in the boiler. Exergy the boiler by means of reducing its huge energy losses,
destruction in the boiler was not based on the specificheat which is almost impracticable. This indicates that tremen-
input to the steam; rather, it was based on the lowerheating dous opportunities are available for enhancement of effi-
value of the fuel to incorporate the losses occurring inthe ciency. However, part of this irreversibility cannot be avoid-
furnace-boiler system due to energy lost with hot gas- ed due to technical, physical, and economic constraints.
es,incomplete combustion, etc.More than half of the total Hence reheating cycle is suggested & analysis has been
plant exergy losses occur in the boiler only and these losses done. Details of analysis are as given below.
are practically useless for the generation of electric power.

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Table 6.2 Exergy analysis of thermal power plant with reheating;

Component Exergy destruction Percentage of destruc- Efficiency (%)


(KW) tion

Boiler 33056.47 49.44 85.12

Turbine 12802.85 19.15 92.76

Condenser 2771.63 4.15 57.47

CEP 257.61 0.39 47.05

LPH 507.39 0.76 65.24

Dearator 397.88 0.60 87.40

BFP 633.39 0.95 86.11

HPH-I 1540.56 2.30 83.34

HPH-II 345.66 0.52 96.92

APH 4185.49 6.26 66.25

To atmosphere 10356.14 15.49

Destruction percentage after reheating


0.39
4.15 Boiler
0.76
19.15 0.6 Turbine
0.95
Condenser
15.49
CEP
24.57 LPH
Dearator
6.26
49.44 2.3 BFP
HPH-I
0.52
HPH-II

Fig: 6.3 Percentage of exergy destruction after Reheating.

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After reheating it is observed that the exergy destruc- fer for thesteam in the boiler to be included, but also the
tion ultimately minimized without any other effect of fuel exergy destructionassociated with fuel combustion and ex-
property or without any extra fuel consumption. It is the ergy lost with exhaust gasesfrom the furnace.
great opportunity to Bhusan thermal power plant for improv-
ing the overall performances of this thermal power plant. In Bhusan thermal power plant overall exergy de-
According to exergy analysis, in boiler system struction is 71815.4 (KW) while after reheating it can be
before reheating the exergy destruction is found 45989.74 minimized upto 66855.06 (KW) this is the great opportunity
KW, which is reduced to 33056.47 KW after reheating in for improvement of overall performance of Bhusan thermal
same plant without any extra fuel consumption. And in tur- power plant.
bine before reheating the power generation is 69.65 MW,
while after reheating the power production has been in- 7: CONCLUSION
creased to 75.202 MW. An exergy analysis as well as the effect of intro-
ducing reheating system on the Bhusan thermal power plant,
thelkoli, Odisha has been presented in this research work. In
50000 45989.74 REAL CONDITION terms of exergy destruction, the major loss is found in the
Irreversibility

40000 boiler system i.e64.04% of total exergy destruction has been


33056.47 occurred in the boiler system. Next to it was the turbine
(KW)

30000 which represents 9.10% of exergy destruction. The exergy


destruction in the condenser is 3.33% while all heaters and
20000 pumps destroyed less than 2% except air preheater, where
exergy destruction is 5.83% .The calculated exergy efficien-
10000
cy of the power cycle is 50.41%, which is low as compared
0 to modern power plants. In this power plant, boiler is the
major source of exergy destruction. Chemicalreaction in the
Boiler boiler combustion chamber is the most significant source of
Fig: 6.4 Boiler comparisons exergy destruction.

For reducing exergy destruction byintroducing re-


heating systemit is found that not only boiler’s exergy de-
120 struction minimized but also overall plant efficiency and
power generation has been increased.
In boiler actual exergy destruction is
100 found45989.74KW but after introducing reheating system it
exergy efficiency %

is reduced to 33056.47KW i.e. the exergy loss of boiler is


reduced from 64.04% to 49.44%. The overall exergy effi-
80
ciency of the power plant has alsobeen increased from
50.41% to 54.43 %. The power generation has been in-
60 creased from 69.65 MW to 75.202 MW.

40 In addition to the above other conclusions coming out from


the research work are given below;
Real condition ➢ Increasing of the boiler efficiency leads to a mean-
20 ingful improvement of the overall performance of
the plant,which is calculated by the exergy analy-
sis.
0 ➢ Exergy analysis is an effective methodfor the de-
sign and analysis of thermal power plants. It uses
the conservation of mass and conservation of ener-
gy principles together with the second law of ther-
Fig: 6.5 Component wise comparison of exergy efficiency
modynamics.
➢ Exergyanalysis shows that boiler in thermal power
Figure 6.5 showing that the component wise exergy plants isthe significant source of Irreversibility.
efficiency charts.This chart determined that after reheating ➢ Exergy analysis method gives a logical solution for
many components efficiency has been increased. For boiler improving power generation opportunities in ther-
efficiency increased 67.96 % to 85.12 % and overall plant mal power plants.
efficiency increased from 50.41 % to 54.43 %. The overall ➢ The maximum exergy destruction is found in the
efficiency of the turbine slightly decreased from 93.03 % to boiler system, hence efforts should be concentrated
92.76 % after reheating.The exergy efficiency of thepower for improving the boiler performance, which will
system may be defined in several ways, however, the used lead to the largest improvement of the plant’s effi-
definitionwill not only allow to irreversibility of heat trans- ciency and overall performance.

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