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Energy and Exergy Analysis of Extraction cum Back Pressure Steam Turbine

Article · April 2013

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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

Energy and Exergy Analysis of Extraction cum Back Pressure

Steam Turbine

A.H.Rana1, J.R.Mehta2
1
M.E.Mech (Scholar), Mechanical Engineering Department, Faculty of Technology and Engineering,
The M.S.Unirsity of Baroda, Vadodara, Gujarat (India).
2
Asst.Professor, Mechanical Engineering Department, Faculty of Technology and Engineering,
The M.S.Unirsity of Baroda, Vadodara, Gujarat (India).

Abstract: Power is very vital factor for development of any society. Coal shares major chunk of fuels used to produce
power in thermal power plants in India. Coal reserves are limited and present coal consumption rate is in increasing trend
to fulfill the power demand. Therefore energy efficiency and energy conservation are of prime importance. Moreover, fossil
fuel based power plant has significant negative environmental impacts. Energy and exergy analysis are used to analyze the
performance of thermal systems. Energy analysis deals with quantity aspect whereas exergy analysis deals with quality
aspect in addition to quantity. Exergy analysis focuses on magnitude and true location of energy loss. In this analysis,
energy efficiency, exergy destruction, exergy efficiency and turbine heat rate are evaluated at 70 % and 85 % maximum
continuous rating (MCR) of steam turbine. Analysis shows that operating turbine at 85 % MCR attract heat rate
improvement by 17.01 kJ / kWh, which reduces CO2 emission by 26.89 kg/h, SO2 emission by 26.89 kg/h and ash generation
by 41.47 kg/ day.

Keywords: Energy, Efficiency, Exergy, Exergy destruction, Power plant, Emission

I. INTRODUCTION
Steam power plants supply 57 % of total power demand in India. Coal is the major source of energy in these power
plants. The conversion efficiency from coal to electricity in steam power plants is low and combustion of coal has heavy
negative impact on environment [1]. Efficiency enhancement of coal to electric power generation is major challenge against
steam power plants. Thus, inefficient use of coal not only wastes resources but creates environmental pollution issues such
as CO2, SO2 and NOx emissions.
Energy conservation study is many times focused on energy efficiency. The first law of thermodynamics is used to
analyze the energy utilization. First law analysis doesn’t use the quality aspect of energy. Exergy is the consequent of
second law of thermodynamics. It is a property that enables us to determine the useful work potential in a given amount of
energy at reference environmental state. A thorough understanding of exergy can provide insights into the efficiency,
environmental impact and sustainability of energy systems. Exergy analysis is now widely used in design, simulation and
performance evaluation of thermal and thermo-chemical systems [2, 3].
Cogeneration turbine systems, which produce heat at useful temperatures at the expense of reduced electrical
power, have higher efficiencies than conventional steam turbine systems. The correct merit of cogeneration systems should
be determined with the help of exergy analysis because energy analysis tends to overstate performance.

Fig.1 Interdisciplinary triangle covered by exergy analysis [4]

In the steam turbine under study, steam is first expanded from inlet pressure to extraction pressure in seven stages.
The extracted high pressure and exhausted low pressure steam is being used in process heating of soda ash manufacturing.
Remaining steam expands up to exhaust pressure. Steam turbine system is usually analyzed by energy analysis which uses
first law analysis but better understanding is attained when a more complete thermodynamic view is taken, which utilises the
second law of thermodynamics in conjunction with energy analysis, via exergy methods [5].

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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

This study is focused on energy and exergy analysis of 20.6 MW Extraction cum Back Pressure Steam Turbine.
Energy efficiency, exergy destruction and exergy efficiency are worked out at two different load conditions such as 70 %
and 85 % of MCR. The turbine heat rate is also evaluated for both load conditions. The effect of turbine heat rate
improvement on coal consumption and environment pollution such as CO2 and SO2 emissions are also discussed.

II. Methodology
This section presents equations for energy and exergy analysis. It also presents schematic diagram (Fig.2) and
experimental data (Tab. I).

1. ENERGY AND SECOND LAW EFFICIENCY (EXERGY EFFICIENCY) RELATIONS

The expressions of energy and exergy efficiencies for the extraction cum back pressure steam turbine
(cogeneration) are based on the following definitions [6].

ɳ I = (Actual Power Develop by Turbine Shaft) / (Ėin - Ėout ) (1)

ɳ II = ΨPower / (Ψin- Ψout) = Ψ power / [ ṁi (hi - Tosi) - (ṁo (ho - Toso) ] (2)

2. THE REFERENCE ENVIRONMENT

Exergy is always evaluated with respect to a reference environment. The reference environment is in stable
equilibrium, acts as an infinite system and is a sink or source for heat and materials. It experiences only internal reversible
processes, in which its intensive properties (i.e. temperature T 0, pressure P0) remains constant. In this analysis surrounding
temperature and pressure are taken as T0=340C (307 K) and P0=101.325 kPa as based on weather and climate condition at
Bhavnagar, Gujarat (India).

3. DATA OF STEAM TURBINE

Data for study is taken at 70 and 85 % MCR of Extraction cum Back Pressure Steam Turbine working at
Nirma Ltd., Bhavnagar, Gujarat. The boiler of this power plant is fired by coal blend having lignite (70%) + Indonesian coal
(30%) and coal firing rate is 10.5 kg/s. The ultimate analysis of coal blend is as follows: C - 44.65 %, N - 1.21 %,
H - 3.06 %, O - 10.8 %, S - 1.87 %, Ash - 10.5 %, Moisture - 27.78 % and GCV of coal is 4226 kcal/kg (17664.68 kJ/kg).

TABLE I

EXPERIMENTAL DATA OF STEAM TURBINE

Sr. Value at Value at

Particular Unit
No. 70 % MCR 85 % MCR

1 Main Steam Flow kg/s 40.75 43.05

2 Main Steam Pressure kg/cm2 104.9 107
o
3 Main Steam Temperature C 492 497
4 Enthalpy of Inlet Steam kJ/kg 3347.3 3357.7
5 Entropy of Inlet Steam kJ/kg K 6.54 6.54
6 HP Extraction Flow kg/s 22.47 18.33
o
7 HP Extraction Temperature C 360.5 360
8 HP Extraction Pressure kg/cm2 34.48 34
9 Enthalpy of HP Ext. Steam kJ/kg 3129.3 3129.1
10 Entropy of Inlet HP Ext.Steam kJ / kg K 6.68 6.69
11 LP Extraction Flow kg/s 18.28 24.72
o
12 LP Extraction Temperature C 126 125
13 LP Extraction Pressure kg/cm2 1.6 1.72
14 Enthalpy of LP Exh. Steam kJ / kg 2716.8 2712
15 Entropy of Inlet LP Exh. Steam kJ / kg K 7.03 7.07
16 Generator Power kW 13875 17100

Assumptions:
1. There is no steam loss across steam turbine.
2. Gear box efficiency as per the manufacturer is 98.40 %
3. Generator efficiency as per the manufacturer is 98.03 %
4. High pressure extracted steam and low pressure exhaust steam from turbine is utilised in process heating of soda ash
manufacturing.

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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

4. STEAM TURBINE M AIN SPECIFICATIONS

Manufacturer: Hang Zhou Steam Turbine Co. Limited, China
Model & Type: EHNG 50/40/50
Nominal Rating: 20600 kW
Nominal Speed: 5022 rpm
Normal first bled steam pressure: 35 bar
Normal first bled steam temperature: 3660C
Normal exhaust steam pressure: 2.5 bar
Normal exhaust steam temperature: 1330C
Number of stages: (1+23) / (Impulse + Reaction)
Governor manufacturer: Wood Ward
Governor type: Electric & Hydraulic

5. SCHEMATIC DIAGRAM OF STEAM TURBINE

Fig.2 Process Flow Diagram of Steam Turbine

III. Analysis

A. ENERGY ANALYSIS FOR 70 % MCR

1. Energy input is equal to product of mass of steam into turbine and its enthalpy at entry.

Ėi = ṁi x hi (3)
= 40.75 kg/s x 3347.3 kJ/kg
= 136402.475 kJ/s.

2. Energy output is sum of heat extracted and heat exhausted.

Ėo = (ṁext x hext )+( ṁexh x hexh ) (4)

= (22.47 kg/s x 3129.3 kJ/kg ) + ( 18.28 kg/s x 2716.8 kJ/kg)
= 119978.480 kJ/s.

3. Work done is equal to the energy in steam at entry to turbine minus that at exit.
W.D = Ėi - Ėo (5)
= 136402.475 kJ/s - 119978.480 kJ/s
= 16424.00 kW.

4. Actual Power Develop by Turbine Shaft :

P = Generator Power x ɳ -1gearbox x ɳ -1generator

(6)
= 13875 kW x (0.984)-1 x (0.9803)-1
= 14380 kW.
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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

5. Energy Efficiency (1st Law efficiency) of Turbine :

ɳ I = (Actual Power Develop by Turbine Shaft) / (Ėin - Ėout) (7)
= 14380 kW / (136402.475 kJ/s-119978.480 kJ/s)
= 87.56 %.
6. Heat Rate of Turbine [7] :
HR = Net Heat Input / Turbine Power (8)
= (Ėi - Ėo) x 3600 s / 14380 kWh
= (136402.475 kJ/s - 119978.480 kJ/s) x 3600 / 14380 kWh
= 4111.71 kJ/kWh.

B. EXERGY ANALYSIS FOR 70 % MCR

1. Exergy Input :
Ψin = ṁs (hs -T0ss) (9)
= 40.75 kg/s x [3374.3 kJ/s - (307 K x 6.54 kJ/kg K)]
= 55685.690 kJ/s.

2. Exergy Out :

Ψout = ṁext (hext-T0Sext) + ṁexh (hexh-T0Sexh) (10)

= 22.47 kg/s x [3129.3 kJ/s - (307 K x 6.68 kJ/kg K)] +18.28 kg/s x [2716.8 kJ/s - (307 K x 7.03 kJ/kg K)]
= 34445.819 kJ/s.

3. Exergy Destruction in Turbine :

Ψdes= Ψin - Ψout - Ψpower (11)

= 55685.690 kJ/s – 34445.819 kJ/s – 14380 kW
= 6859.87 kJ/s.

4. Exergy Efficiency (2nd Law efficiency) of Cogeneration Turbine :

ɳ II = Ψpower / (Ψin - Ψout )

(12)
= 14380 kW / (55685.690 kJ/s -34445.819 kJ/s)
= 67.70 %

C. ENERGY ANALYSIS FOR 85 % MCR

1. Energy input is equal to product of mass of steam into turbine and its enthalpy at entry.

Ėi = ṁi x hi (13)
= 43.05 kg/s x 3357.7 kJ/kg
= 144548.985 kJ/s.

2. Energy output is sum of heat extracted and heat exhausted.

Ėo = ( ṁext x hext ) + (ṁexh x hexh ) (14)

= (18.33 kg/s x 3129.1 kJ/kg) + (24.72 kg/s x 2712 kJ/kg)
= 124397.043 kJ/s.

3. Work done is equal to the energy in steam at entry to turbine minus that at exit.
W.D = Ė i - Ė o (15)
= 144548.985 kJ/s -124397.043 kJ/s
= 20151.942 kW.
4. Actual Power Develop by Turbine Shaft :
P = Generator power x ɳ -1gearbox x ɳ -1generator
(16)
= 17100 kW x (0.984)-1 x (0.9803)-1
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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

= 17720 kW.

5. Energy Efficiency (1st Law efficiency) of Turbine :

ɳ I = (Actual Power Develop by Turbine Shaft) / (Ėin - Ėout) (17)

= 17720 kW / (144548.985 kJ/s- 124397.043 kJ/s)
= 87.94 %.

6. Heat Rate of Turbine :

HR = Net Heat Input / Turbine Power (18)

= (Ėi - Ėo) x 3600 / 17720 kWh
= (144548.985 kJ/s - 124397.043 kJ/s) x 3600 / 17720 kWh
= 4094.07 kJ/kWh.

D. EXERGY ANALYSIS FOR 85 % MCR

1. Exergy Input :

Ψin = ṁs (hs-T0ss) (19)

= 43.05 kg/s x [3357.7 kJ/s - (307 K x 6.54 kJ/kg K)]
= 58114.05 kJ/s.

2. Exergy Out :

Ψout = ṁext (hext -T0sext) + ṁexh (hexh-T0sexh) (20)

= 18.33 kg/s x [3129.1 kJ/s-(307 K x 6.69 kJ/kg K)] + 24.72 kg/s x [2712 kJ/s -(307 K x 7.07 kJ/kg K)]
= 33095.82 kJ/s.

3. Exergy Destruction in Turbine :

Ψdes = Ψin - Ψout – Ψpower (21)

= 58114.05 kJ/s - 33095.81 kJ/s - 17720 kW
= 7298.24 kJ/s.

4. Exergy Efficiency (2nd Law efficiency) of Cogeneration Turbine :

ɳ II = Ψpower / (Ψin - Ψout )

(22)
= 17720 kW / (58114.05 kJ/s -33095.82 kJ/s)
= 70.83 %.

E. CO2 AND SO2 EMISSION REDUCTION BY TURBINE HEAT RATE IMPROVEMENT

1. Coal Saving = HR Improvement x Generator Power / GCV (23)

= 17.01 kJ/ kWh x 17100 kW / 17664.68 kJ/kg
= 16.46 kg/h.
2. Combustion Equation : C + O2 = CO2 (24)
3. 1 kg Carbon Generates 3.66 kg of CO2 [8]
4. CO2 Emission Reduction =3.66 x Carbon percentage in coal x Coal saving (25)
= 3.66 x 0.4465 x 16.46 kg/h
= 26.89 kg/h
5. 1 kg Sulphur Generates 2 kg of SO2 [9]
6. SO2 Emission Reduction = 2 x Sulphur percentage in coal x Coal saving (26)
= 2 x 0.0187 x 16.46 kg/h
= 0.62 kg/h.

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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

F. ASH GENERATION REDUCTION BY TURBINE HEAT RATE IMPROVEMENT

1. Ash Generation Reduction = Coal saving x Ash percentage in coal (27)
= 16.46 kg/h x 0.105 = 1.72 kg/h x 24 h/day = 41.47 kg/day

IV. Result And Discussion

TABLE II
EXPERIMENTAL RESULTS

Sr. 20.6 MW Extraction Cum Back Pressure Steam Turbine

No Particulars Value at 70 % MCR Value at 85 % MCR
1 Energy Efficiency (%) 87.56 87.94
2 Exergy Destruction (kJ/s) 6859.87 7298.24
3 Heat input (kJ/s) 136402.475 144548.985
4 Useful heat output (kJ/s) 119978.480 124397.043
5 Turbine Work output (Kw) 14380 17720
3 Exergy Efficiency (%) 67.70 70.83
4 Heat Rate (kJ/kWh ) 4111.71 4094.07
5 CO2 emission reduction 26.89 kg/h
6 SO2 emission reduction 0.62 kg/h
7 Ash generation reduction 41.47 kg/day

EXERGY LOSS
12.32 %

EXERGY OF POWER 25.82 %

EXERGY OF INPUT STEAM

TO TURBINE 100 %

EXERGY OF HP AND LP
STEAM 61.86 %

Fig.3 Grassman diagram for exergy flow through Steam Turbine at 70 % MCR

EXERGY LOSS
12.56 %

EXERGY OF POWER 30.49 %

EXERGY OF INPUT STEAM

TO TURBINE 100 %
EXERGY OF HP AND LP
STEAM 56.95 %

Fig.4 Grassman diagram for exergy flow through Steam Turbine at 85 % MCR

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 International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.3, Issue.2, March-April. 2013 pp-626-632 ISSN: 2249-6645

 Experimental results show that as power load on steam turbine increases from 70 % to 85 % MCR,
1. Turbine’s energy and exergy efficiency increases by 0.38 % and 3.13 %.
2. The exergy destruction is increased by 438.34 kJ/s due to steam turbine irreversibilities and lower exergy output of HP
and L.P.Steam.
3. The exergy efficiency is remarkably lower than energy efficiency in both the cases. This is mainly due to thermal
product, which is higher than electrical power, is delivered at a lower temperature.
4. There is an improvement observed in turbine heat rate by 17.01 kJ/kWh.
5. Coal saving achieved due to heat rate improvement is 395 kg/day.
6. Ash handling plant load is reduced by 41.47 kg/day. This improves life of plant because ash is highly erosive in nature.
It creates mechanical wear during handling.
7. Heat rate improvement lead to CO2 emission reduction by 26.89 kg/h and SO2 emission reduction by 0.62 kg/h.

V. Conclusion
Turbine exergy efficiency is lower than its energy efficiency as utilization of heat is at lower temperature than inlet. Turbine
exergy loss is 12.32 % and 12.56 % at 70 % and 85 % MCR. When Turbine MCR is increased from 70 to 85%, coal
consumption is reduced by 16.46 kg/h and ash handling plant load is reduced by 41.47 kg/day. CO2 emission is reduced by
26.89 kg/h, while SO2 emission is reduced by 0.62 kg/h. Thus, it is more advantageous to run turbine at higher MCR.

VI. Acknowledgment
The support for this work provided by Shri G.J Adroja, Shri D.G.Jakhade, Shri L.M.Mavani, Shri D.R.Fondekar,
Shri K.N.Pandya and Shri H V Mendpara of The Nirma Ltd, Kalatalav, Bhavnagar, Gujarat (India) is gratefully
acknowledged.

Nomenclature
Ėi - Energy in [kJ/s], Ėout - Energy out [kJ/s], Ψin - Exergy in [kJ/s], Ψout - Exergy out [kJ/s], Ψdes - Exergy destruction [kJ/s]
Ψpower - Exergy of power [kJ/s], ṁ - Mass flow rate [kg/s], h - Specific enthalpy [kJ/kg], s - Specific entropy [kJ/kg K],
P -Turbine actual power [kW], T0 -Atmospheric temperature [K], P0 -Atmospheric pressure [kPa] , i - Inlet, o – Outlet,
ɳ I - Energy efficiency [%], ɳ II - Exergy efficiency [%], HR- Heat rate [kJ/kWh], ext - steam extraction, exh - steam
exhaust,
MCR - Maximum continuous rating, GCV - Gross calorific value [kJ/kg], C – Carbon, H – Hydrogen , O – Oxygen,
N – Nitrogen, S – Sulphur, SO2 - Sulphur dioxide, CO2 - Carbon dioxide, NOx - Nitrogen oxide, HP – High pressure,
LP – Low pressure.

References
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[1] Ministry of Power, Govt. of India, Web site,www.powermin.nic.in/Indian_electricity_scenario. (Accessed on 7 December 2012)
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[3] Kanoglu, M, Dincer, I, Rosen, M A., 2007, “Understanding energy and exergy efficiencies for improved energy management in
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[4] Rosen, M.A., Dincer I.2001.Exergy as the confluence of energy, environment and sustainable development .Exergy, an International
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[5] I.Dincer and M.Rosen,”Energy, Exergy and Sustainable Development”, Elsevier, 2007, Chap- 12,257-265
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[9] N.C.Pandya and NC.S.Shah, “Heat Engines”, 9th edition, Charotar Publishing House, Anand, 1990, Chap-13,594.

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