THERMODYNAMIC ANALYSIS OF COMBINED POWER HOUSE AND BOILER ROOM

RAJBY INDUSTRIES WASHING UNIT – 2A

OVERALL OPERATING PLANT

MAIN BOILER

GAS GENERATOR

GENERATOR COOLING SYSTEM

HEAT RECOVERY BOILER

ANALYSIS BASIS

THERMODYNAMIC ANALYSIS BASED ON

• ENTROPY GENERATION• LOST WORK

MAIN BOILER EFFICIENCY

Table 1.• Flowrate of air ---------- 12387 kg/hr• Theoretical gas flowrate ---------- 650.3 kg/hr• Actual gas flowrate ---------- 691 kg/hr• Actual gas flow to theoretical flow ratio --------- 96/90 m3/ton steam • Boiler efficiency ---------- 90%

FOR MAIN BOILER & HEAT RECOVERY BOILER

THE ENTROPY GENERATION DEPENDS UPON• THE FUEL BURNING REACTION• TEMPERATURE DECREASES OF BURN GASES• STEAM PRODUCTION

POWER SYSTEM

• GAS GENERATOR - FEED BURNER - TURBINE - EXHAUST• WATER COOLING CYCLE - PUMP - HEATER / HX - CONDENSER

GAS GENERATOR CYCLE

FOR GAS GENERATOR CYCLE

ENTROPY GENERATION DEPENDS UPON- REACTION INSIDE FEED BURNER- TRANSFER OF ENERGY FROM BURN GASES TO

TURBINE- EXHAUST OF BURN GASES AT LOWER

PRESSURE

GENERATOR COOLING CYCLE

FOR GENERATOR COOLING CYCLE

ENTROPY GENERATION DEPENDS UPON• COOLING WATER PRESSURE INCREASED BY

PUMP• HEAT ABSORBED BY WATER FROM HEATER/HX• TEMPERATURE & PRESSURE DROP OF WATER

IN CONDENSER

TOTAL ENTROPY GENERATION• Table 10.

SYSTEM Total entropy Percent entropy generation generated

• Main boiler 2.9144 kW/k 16.2%• Gas generator 0.5567 kW/k 3.1%• Heat recovery boiler 1.82 kW/k 10.1%• Cooling cycle 2.609 kW/k 70.4%

• TOTAL 17.9001 kW/k 100 %

TOTAL LOST WORK

Table 11. SYSTEM Lost work Lost work ratio Percent (Kw) lost work• Main boiler 873 0.16 16%• Gas generator 165 0.038 3.8%• Heat recovery boiler 552 0.103 10.3%• Cooling cycle 3759 0.702 70.2%

TOTAL 5.349x103 1.00 100%

CONCLUSION:

• The total lost work from the power and boiler room is 5349 kW or 5.3 MW.

• The most inefficient system being the power generation unit (gas generator and water cooling system).

• Lost work or inefficiencies in present facility is not very high.

• Drawback of the working facility is that no enhancement can be made on account of removing the inefficiencies.

• If the capacity of present facility needs to be expanded, very little changes can be made possible.