steam power plant cycle design

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Welcome!Best Practices for Cycle Improvement

in Fossil-Fuel Steam Power Plants

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Best Practices for Cycle Improvement in Fossil-Fuel Steam Power Plants

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About SoftInWayFounded in 1999, we are an international engineering company headquartered in Burlington, Massachusetts.

SoftInWay Inc. specializes in developing efficient turbomachinery. We provide extensive expertise through our services, software, and training. We offer our flagship AxSTREAM® software platform for turbomachinery design, redesign, analysis, and optimization, as well as AxCYCLETM - for the design and simulation of full thermodynamic cycles.

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We provide more than 285 companies with our software, have 60+ engineers, and more than 600 years of combined experience.

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ExperienceDr. Leonid MorozFounder & CEO

30+ years industrial & research experience Lead designer for AxSTREAM®

Formerly with NPO TURBOATOM Expertise in flow path design of gas turbines and steam turbines,

analysis of transient operating conditions and in thermal field testing (220MW – 1000 MW)

Dr. Boris FrolovDirector of Engineering

35+ years of industrial & research experience Expert in long blade aeromechanics with numerous publications &

patents Formerly with GE Energy, Russia PhD thesis on Optimization with Controlled Reaction

Dr. GovorushenkoChief Scientist

30+ years of academic, research and industrial experience Co-authored 2 books on turbine design and optimization Has more than 80 publications on turbomachinery PhD in Axial Turbine Optimal Design Methods

Dr. RomanenkoStructural Expert

24+ years of academic and research experience PhD in Machine Dynamic and Strength 15+ years experience in programming & numerical methods

Mr. Petr PagurDirector of Strategic Development

25+ years experience in IT & CAD Formerly Chief of Turbomachinery CAD at TURBOATOM Key developer of AxSTREAM® and AxCYCLE™ Head of Technical Support for AxCYCLE™


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• AxCYCLE™• AxSTRESS (2nd gen)

2012 • AxSLICE • AxSTREAM® Hydro2010

2008

AxSTREAM® for radial machines2006

AxSTREAM® for axial compressor

2005 AxSTREAM® for axial turbine

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AxSTREAM® development starts1999

SoftInWay founded as a consulting company

2013


Product Milestones

2014

• AxSTREAM® Net (Cooling systems)

• Rotor Design (2nd gen)

2015

NOW

AxCFD & AxSTRESS (1st gen)

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AxSTREAM® V.3 released

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gen) & Rotor Dynamics Modules

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AxSTREAM® is a multidisciplinary design, analysis and optimization software platform that provides a fully integrated and streamlined solutions, encompassing the complete turbomachinery design process, all in a seamless interactive user interface.

Design & analyze turbines, compressors, pumps with axial, radial, mixed flow, & diagonal configurations, for applications in turbochargers, gas turbines, combined cycles, waste heat recovery systems, vapor compression systems, turbo-pumps, etc.



AxSTREAM®

Software Platform

Simulate many types of cycles with any desired combination of turbomachinery components:

Steam Cycles Supercritical CO2 Cycles Refrigeration Cycles Organic Rankine Cycles Combined Steam & Gas

Cycles Turbocharger Cycles Gas Cycles

Design and analyze the cycle for a variety power systems.

Simulate the performance of existing systems at "off-design" operating conditions.

Perform cycle optimization based on DoE.

Evaluate cycle parameters based on the random search approach.

NEW Economic Module: Perform power plant equipment cost estimation & investment analysis of plant construction.

Connect directly with AxSTREAM®

AxCYCLE™Thermodynamic Cycle Design &

Analysis

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1. Project Definition and Technical Specifications2. Research & Development to Support New Designs3. Preliminary Design & Feasibility Studies4. Analysis of Existing Machine5. Turbomachinery Retrofitting & Upgrades6. FEA/CFD Analysis7. Heat Transfer Simulations8. Rotor Dynamics9. Complete Design Process10. Mechanical Design of Components

Executed more than 120 consulting projects since inception to Industry and Research Organizations

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1. Online & classroom training Steam and Gas Turbine Design Centrifugal Compressor Axial Compressor Axial and Centrifugal Pumps Turbocharger Design and

Performance Matching Design of Waste Heat Recovery

Systems Heat Balance Calculation of Steam

Cycles and Combined Cycles and Supercritical CO2 with AxCYCLE™

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offered at any location necessary

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Contact

Europe Contact:[email protected]: +41 44 586-1998SoftInWay Switzerland GmbHBaarerstrasse 2 – 6300 Zug, Switzerland

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Designed for the thermodynamic simulation and heat balance calculation of heat production and electric energy cycles.

Thermodynamic Cycle Design & Analysis Tool


The latest product from SoftInWay


Scope of AxCYCLE:

Steam Power Plants Gas Turbine Units Combined Power Plants Waste Heat Recovery Systems

based on ORC Heat Pumps Refrigeration Units Geothermal Power Plants Solar Power Plants Desalination Units Supercritical CO2 Units and many others

Main Features of AxCYCLE:

Universality Flexibility Embedded Libraries of fluids, GT engines,

diesel engines Useful Internal Tools: Map, Plan, Fluid

Calculator, Process Constructor Steady State and Off-design Simulation Outstanding & Intuitive Interface Integrated with SoftInWay’s AxSTREAM®

software

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Current state of electricity production by fossil-fired power plants Steam power units improvement by high pressure turbine superstructure Reconstruction of steam power units into combined Replacement of the motor driven feed pumps with steam turbine driven Improvement of the regeneration system of a steam power plant AxCYCLE™ as tool for steam power plant cycle improvement implementation Demonstration of cycle redesign using AxCYCLE™

Webinar Program


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Fuel Electricity Generation (1990-2040)


Source: U.S. Energy Information Administration – Annual Energy Outlook 2014 Early Release Overview. http://www.eia.gov/forecasts/aeo/er/pdf/0383er(2014).pdf

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Power Plant Improvement


The important tasks in response to fuel resource depletion and the growth of electricity consumption are efficiency improvement and capacity increase of fossil-fuel steam power plants.

The implementation of reconstruction projects and upgrading of available capacities is a more optimal option of electricity generation development than the construction of new energy generating capacities of thermal power plants.

Improvement in the performance of existing power plants can be obtained by modifying their thermodynamic cycles.

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HR Improvement Projects


Source: National Energy Technology Laboratory (2008).

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Power Plant Capacity & HR Improvement


1. Exclusion of additional losses and bringing the plant operation to design conditions

2. Improvement of characteristics of separate cycle components and systems

3. Cycle modification


The regional growth of energy demands requires greater electric generation. The increase in the power of an individual power plant is the most expedient solution to the issue.

Steam Power Units Improvement by Superstructure


Superstructure consists of the addition of a new high pressure turbine to an existing power unit. Live steam at first expands in the new turbine to a backpressure level that is slightly higher than the initial pressure of the old turbine.

Assumed application effects: Increase in power generation without additional losses in the condenser Increase in cycle efficiency

High Pressure Superstructure

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High Pressure Superstructure


Superstructure

PartialTotal

All steam MFR passes through the new high pressure turbine.

Only part of steam MFR passes through the new high pressure turbine.

Existing Equipment

Additional Equipment

Existing Equipment

Additional Equipment


Enlargement Based on Turbine K 100-90-7

Main parameters of K 100-90-7Electrical power – 118 MWMass flow rate – 420 t/hLive steam pressure – 8.8 MPaLive steam temperature – 535 CCondenser pressure – 3.5 kPaFeed water temperature – 210 C

Process of Steam Power Plant Cycle in t-s coordinates


Examined Cycles

Embodiment 1: Steam Power Plant with Total SuperstructureEmbodiment 2: Steam Power Plant with Total Superstructure and ReheatEmbodiment 3: Steam Power Plant with Total Superstructure, Reheat and HP FWHEmbodiment 4: Steam Power Plant with Partial Superstructure


Embodiment 1

Processes of Initial Cycle (1-6) and Modified Cycle (1a-7a) in t-s coordinates

Existing Equipment

New HP Turbine with Generator

New SG

HP FWH operate under higher FW

pressure

Parameters of Superstructure:Live steam pressure 19 MPaLive steam temperature 535 CBackpressure 8.8 MPaOutlet steam temperature 411.8 CSteam MFR 420 t/hElectrical power 23.6 MW Feed water temperature 210 C

Assumed parameters of new components:HP turbine efficiency 0.9SG efficiency 0.88FW pump efficiency 0.8Generator efficiency 0.98

Steam Power Plant with Total Superstructure


Processes of Initial Cycle (1-6) and Modified Cycle (1a-8a) in t-s

coordinates

Existing Equipment

New HP Turbine with Generator

New SG and Reheat

Parameters of Superstructure:Live steam pressure 19 MPaLive steam temperature 535 CBackpressure 9.4 MPaSteam MFR 420 t/hElectrical power 21.7 MW Steam temperature after reheat 535CSteam pressure after reheat 8.8 MPaFeed water temperature 210 C

Steam Power Plant with Total Superstructure and ReheatEmbodiment 2

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Embodiment 3


Additional Extraction

Additional HP FWH

Parameters of Superstructure:Live steam pressure 19 MPaLive steam temperature 535 CBackpressure 9.4 MPaSteam MFR 448.8 t/hElectrical power 23.2 MW Steam temperature after reheat 535CSteam pressure after reheat 8.8 MPaFeed water temperature 245 C

Processes of Initial Cycle (1-6) and Modified Cycle (1a-9a) in t-s

coordinates

Steam Power Plant with Total Superstructure, Reheat and Additional FWH

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Splitter

Existing SG


Parameters of Superstructure:Live steam pressure 1 9 MPa;Live steam temperature 535 C;Backpressure 9.4 MPa;Steam MFR 210 t/h;Electrical power 10.9 MW; Steam temperature after reheat 535 C;Steam pressure after reheat 8.8 MPa;Feed water temperature 213 C.

Processes in t-s coordinates for modified cycle:

0.5 steam MFR operates according to initial process 1-7; the other steam MFR operates by

process 1a-2a-3a-4a/5-…-3

Steam Power Plant with Partial SuperstructureEmbodiment 4


Type of scheme Electrical Power, MW Net power, MW Outlet steam

qualityHeat

consumption, kJ/s

Heat Rate, kJ/kWh

Thermal Eff

Original SPP K-100 118.791 117.736 0.88 353310 10836.25 0.332

Embodiment 1(Total superstructure) 125.066 122.05 0.82 332475 9806.72 0.367

Embodiment 2 (Total superstructure

with Reheat) 140.507 137.483 0.88 359785 9421 0.3821

Embodiment 3 (Total superstructure

with Reheat and FWH) 141.997 138.767 0.88 361279 9372 0.3841

Embodiment 4 (Partial Superstructure) 129.649 127.367 0.88 356476 10075.72 0.3573

Calculated Performances


Reconstruction of Existing Steam Power Plants Into Combined Power

PlantsPower generation via combined-cycle plants is one of the most effective

techniques of rational energy conversion, as it involves a more complete energy use.


Addition of Upper GTUTransformation of the existing steam turbine plant into a combined power plant

with the addition of upper GTU allows the increase of their power production and thermodynamic efficiency.

Main tasks: Selection of a means of flue gas heat recovery Selection of a suitable upper gas turbine (power, flue gas parameters)

FG Heat Utilization

HRSG FW Heating

+ High efficiency;+ Thermal scheme of steam cycle is unchanged;- SG replacement is required.

+ SG left unchanged;+ Increased power of steam turbine;- FWH replacement by FG/water heaters is required;- Increased condenser load;- Decreased efficiency of bottoming steam cycle.


Examined Combined CyclesEmbodiment 1: Upper GTU and Steam Power Plant with discharge of the gas turbine exhaust to HRSG

Embodiment 2: Upper GTU and Steam Power Plant with use of the gas turbine exhaust for heating of feedwater


Initial Steam Turbine

Parameters of Steam Power Plant: Electrical power 39.3 MWMass flow rate 40 kg/sLive steam pressure 80 barLive steam temperature 500 CCondenser pressure 0.085 barPumps efficiency 0.8FW temperature 165 CBoiler efficiency 0.85

Process of the steam cycle in t-s coordinates


Embodiment 1

Performances of the upper GTU (Alstom GT11N2):Electrical output 113.7 MWElectrical efficiency 33.3 %Exhaust gas flow 400 kg/sExhaust gas temperature 524 C

GT Exhaust Discharged to HRSG


Performances of the upper GTU (GE 10):

Electrical output 11. 7MWElectrical efficiency 32%Exhaust gas flow 47.216 kg/sExhaust gas temperature 483 C

GT Exhaust is Used for Heating of the Feedwater

Embodiment 2

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Addition of Upper GTU


Type of scheme Electrical Power, MW

Net Power, MW

Heat Consumptio

n, kJ/sHeat Rate,

J/WhThermal

Eff

Initial Steam Power Plant 39.35 38.909 107374 9934.65 0.36

Embodiment 1: GT Exhaust Discharged to

HRSG153.048 152.607 330059 7786.86 0.462

Embodiment 2: GT Exhaust is Used for FW

Heating53.331 52.890 137375 9350.43 0.385


Replacement of the Motor Driven Feed Pumps by Steam Turbine Driven

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The history of turbine construction around the world shows that the replacement of the motor driven feed pumps with the steam turbine driven pump allows an increase of up to 0.7 % in fuel economy.

Main task: Definition of the location of steam extraction from the main turbine to supply turbine drive and the point where steam flow returns to the main cycle after an expansion in the driven turbine.

Requirements: Maximized fuel economy Minimal changes in existing flow diagram.


Replacement of the Motor Driven Feed Pumps with Steam Turbine DrivenFeed Pump Replacement


Advantages: Reduction of the auxiliary power

consumption Fuel economy due to exception of few

intermediate members in the process of energy transfer from steam to feedwater pump.

Field of Application: Powerful steam plants (when power

production exceeds 200-250 MW) Power plants with high live steam pressure.

Feed Pump Replacement


Improvement of the Regeneration System of a Steam Power Plant


Regeneration System Improvement

Addition of drain coolers and superheated steam coolers to

feedwater heaters

Modification of drain system with cascade condensate drain

Advantages: Increase in the feedwater temperature Reduction of the amount of heat discharged into the condenser Full utilization of the extracted steam heat


240 MW Power Plant (Initial Scheme)

Main parameters of Steam Power Plant:Mass flow rate 740 t/hLive steam pressure 150 barLive temperature 537CBack pressure 0,1033 atFW temperature 242 C


Efficiencies new components:

Driving steam turbine efficiency 0.85Feedwater pump efficiency 0.8Drain pump efficiency 0.8

Parameters of steam coolers and drain coolers:

FW underheating to hot steam saturationtemperature in SC1 and SC2 -0.36 CTemperature difference between inlet FWand outlet drain in DC1 and DC2 5 C; 9 C

DC1DC2

SC1SC2

240 MW Power Plant (Modified Scheme)


Initial vs. Modified Schemes

Parameter Initial Design Modified Cycle

1 Electrical Power Production (EPP), MW 246.365 240.852 Total Power Consumption, kW 6475.19 403.8433 Net Power Production (NPP), MW 239.890 240.4464 Heat Consumption, kJ/s 623640 6186925 Thermal Efficiency, % 38.47 38.866 Heat Rate by EPP, kJ/kWh 9112.92 9247.637 Heat Rate by NPP, kJ/kWh 9358.89 9263.1668 Gain in Thermal Efficiency, % - 0.399 Gain in Net Power Production, MW - 0.55610 Heat economy, kJ/s - 494811 Heat Rate decrease (NPP), kJ/kWh - 95.724


AxCYCLE™ as Tool for Steam Power Plant Cycle Improvement Implementation Analysis and redesign of the thermodynamic cycle of a steam power unit are the first and most important phases of the unit performance improvement process. Solving these tasks with minimal time and financial costs is impossible without the use of reliable and effective tools. Today, a wide range of software products for the thermodynamic simulation of cycles is available for engineers and researchers, but not all of the software is universal. Additionally, not all of them contain the necessary tools and features for the cycle redesign. AxCYCLE is best suited for solving the tasks of analysis and redesign of steam power plant cycles. All mentioned embodiments of improvement of steam turbine cycles were realized with the AxCYCLE program without any essential efforts.

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AxCYCLE™ as Tool for Steam Power Plant Cycle Improvement Implementation


AxCYCLE advantages for cycle redesign problems: Easy to use All necessary components are included AxCYCLE allows to solve simulation tasks in different statements with

minimal set of initial data AxCYCLE includes a lot of useful tools, that facilitate and accelerate the

solution of the cycle redesign problem.

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Technical Demonstration


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Contact

Europe Contact:[email protected]: +41 44 586-1998SoftInWay Switzerland GmbHBaarerstrasse 2 – 6300 Zug, Switzerland

United States (HQ) Contact:[email protected]: +1‐781‐685‐494215 New England Executive ParkBurlington, MA 01803

Just Released: SoftInWay Turbomachinery University

Visit our online learning center to take self-paced course and exams to learn turbomachinery design certifications. The center is up and running and is updated every day

learn.softinway.com

Visit www.SoftInWay.com for detailed information

Global Sales [email protected]: +1-347-580-1459149 Madison Ave.New York, NY 10016



