Institut Teknologi Bandung, Indonesia Fakultas Teknologi Industri - Departemen Teknik Kimia 30 March 2010 in Bandung

ADVANCED COGENERATION SYSTEMS A DESALINATION-POWER PLANT-CONCEPT Dr.-Ing. Claudia Werner

Technische Universitt Berlin, Germany
Fachgebiet

Anlagen- und Sicherheitstechnik

CONTENT
1. Introduction 2. State of the Art of Desalination/Electricity Production 3. Combination - Desalination Plant /CCGT Plant 4. Recent Research - Thermoeconomics and Optimisation Approaches 5. Simulation Process 6. Results of the Simulation Process 7. Conclusion and Outlook 8. Acknowledgement
Dr.-Ing. Claudia Werner

1. INTRODUCTION - Cogeneration Systems

Cogeneration is the simultaneous production of heat and power in a single thermodynamic process Cogeneration systems such as CCGT power plants or block heat and power plants are available on the market Application is motivated by different issues of climate protection Advanced cogeneration systems:
- Combined production of Electricity/District Cooling - Combined production of Electricity/Chemicals - Combined production of Electricity/Fresh Water

Source: http://www.vattenfall.de, 2010.

Dr.-Ing. Claudia Werner

1. INTRODUCTION - Water Supply/Water Withdrawal

Increasing world water withdrawals since 1900

Source: http://www.worldwatercouncil.org, 2010.
Dr.-Ing. Claudia Werner

1. INTRODUCTION - Withdrawal to Availability Ratio

Source: Konishi,T. Global Water Issues and Nuclear Seawater Desalination, 2010.
Dr.-Ing. Claudia Werner

1. INTRODUCTION - Situation in Indonesia

18,000 island, 6,000 inhabited by 215 million people endowed with 5,590 rivers flowing over 5,500 km/year of water

Source: www.weltkarte.com, 2010 .

annual amount of precipitation in the range of 1,000 mm to 5,000 mm fresh water supply by shallow water wells and deep water ground surface annual water resources in Indonesia: 1,690 x 10 m/km or 16.8 x 10 m/capita intrusions of seawater detected in Jakarta, Medan, Semarang, Surabaya
and Ujung Pandang
Dr.-Ing. Claudia Werner

1. INTRODUCTION - Water Resource and Water Demand

Island(s) Water Resource (mill. m/year) Java Lesser Sunda Celebes Sumatra Borneo Mollucas+Papua Indonesia 187,000 60,000 247,000 738,000 1,008,000 981,000 3,221,000 Water Demand (mill. m/year) 2000 83,378 13,827 25,555 25,298 8,204 589 156,850 2015 164,672 42,274 77,305 49,583 23,093 1,886 358,813

Source: Sunaryo, G. R. Prospect on Desalination and other non-electric Applications of Nuclear Energy in Indonesia, 2010.
Dr.-Ing. Claudia Werner

1. INTRODUCTION - Desalination Processes and Projects

Thermal Processes
- Multi Effect Distillation (MED) - Multi Stage Flash (MSF) - Thermal Vapor Compression (TVC)

Non-Thermal Processes
- Reverse Osmosis (RO) - Mechanical Vapor Compression (MVC)

Desalination Projects in Indonesia

- Fossil Desalination Projects (Pulau Seribu, Sulawesi) - Nuclear Desalination Projects (Madura Island) - Renewable Desalination Projects (Cituis)
Source: Konishi,T. Global Water Issues and Nuclear Seawater Desalination, 2010.
Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Desalination Plants

Multi Effect Distillation (MED)

Typical capacity:

500 - 18,000 m/d

Electric consumption: 1 - 2.5 kWh/m Heat consumption: 150 - 260 MJ/m Product salinity: < 10 ppm TDS

Facility:

Telde & Las Palmas Gran Canaria Multi Effect Distillation Process

Source: http://www.ide-tech.com, 2009.

Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Desalination Plants

p1 > p2 > p3 T1 > T2 > T3
stage 1 stage 2 stage 3 steam

final condenser feed

steam from CCGT steam to CCGT

condensate sole

product sole
H. Mller-Holst: Mehrfacheffekt-Feuchtluftdestillation bei Umgebungsdruck, 2002.
Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Desalination Plants

Reverse Osmosis (RO)
Typical capacity: Product salinity: 1 - 10,900 m/d < 500 ppm TDS

Electric consumption: 4 - 9 kWh/m

HP PUMP feed pretreatment posttreatment product concentrate

H. Mller-Holst: Mehrfacheffekt-Feuchtluftdestillation bei Umgebungsdruck, 2002.
Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Hybrid Desalination Plants

Increased flexibility in desalination plant management Economic aspects of hybrid desalination plants Modulation of the Power-to-Water-Ratio (PWR) as required

MED-RO

MED-VC

MED-MSF-VC

MED-MSF

Thermal ratio of hybrid MED plants Figure: Hybrid desalination plants based on MED according to the thermal ratio
Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Hybrid Desalination Plants

MED/RO in parallel connection - independent operation of the desalination units (MED/RO) - complete sharing of the energy supply, the water pre- and posttreatment as well as the product and sole removal facilities - examples (parallel connection): Jubail (Saudi Arabia) Madina-Yanbu (Saudi Arabia)
MED plant

product

common intake RO plant

outfall

Source: M. A. Helal, et al.: Optimal design of hybrid RO/MSF desalination plant, 2003.
Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Hybrid Desalination Plants

Hybrid desalination plant feed (seawater) MED Plant RO Plant sole product water

A2

A1

A3

(1) (2) (3)

66 t/h / 1.1 bar / 157 C 66 t/h / 1.1 bar / 102 C 1.3 kWh/m / 6.5 kWh/m

steam requirement (MED) steam recirculation (MED) electric power requirement (MED/RO)

Total desalination capacity = 2 x 17,500 m/d MED capacity / RO capacity = 1 : 1

Dr.-Ing. Claudia Werner

2. STATE OF THE ART - Electricity Production (750 MW)

Source: Kraftwerksschule Essen e.V.

CCGT Seabank Power Station Electric base and mid-load supply

Dr.-Ing. Claudia Werner

Electricity Production: CCGT Seabank Power Station

CCGT Power Station on natural gas basis Electricity yield: 57.8 % Triple-pressure process and single reheat

253.3 t/h / 110 bar / 550 C 52.1 t/h / 30 bar / 320 C 36.2 t/h / 4.8 bar / 235 C 247.6 t/h / 28.5 bar / 550 C

high pressure parameter medium pressure parameter low pressure parameter reheat parameter

Dr.-Ing. Claudia Werner

3. COMBINATION - Desalination plant /CCGT plant

Hybrid desalination plant feed (seawater) MED Plant RO Plant sole product water

A2
air natural gas CCGT power plant gas turbines HRSG

A1

A3
electric power

steam turbines

flue gas

(1) (2) (3)

66 t/h / 1.1 bar / 157 C 66 t/h / 1.1 bar / 102 C 1.3 kWh/m / 6.5 kWh/m

steam requirement (MED) steam recirculation (MED) electric power requirement (MED/RO)
Dr.-Ing. Claudia Werner

Interfaces Desalination Plant - CCGT Power Station

Interface Desalination Plant Interfaces Interfaces Desalination Desalination Plant Plant

Dr.-Ing. Claudia Werner

4. RECENT RESEARCH Aspects of Thermoeconomics

& =c E & = c m e C j j j j j j
& Z
& C 1 , k , in
1 2
2 , k , in n , k , in k

& = Z

CI k

& + Z
1 2

OM k

& C 1 , k , out

& C & C

component k
n m

& C & C

2 , k , out m , k , out

(c
j =1

& E j

)k ,in +

& CI Z k

& OM Z k

(c
j =1

& E j

)k ,out
Dr.-Ing. Claudia Werner

Source: A. Bejan, et al.: Thermal design and optimization, 1996

4. RECENT RESEARCH Optimisation Approach according to Ogriseck/Meyer

low medium high

(Z/ED)/(Z/ED)max in %

An increase of the capital cost of these components is recommended

ED/ED,max in %
Dr.-Ing. Claudia Werner

low

medium

A decrease of the capital cost of these components is recommended

high

4. RECENT RESEARCH Optimisation Approach according to Scheffler

Direction and extent specifications for the input parameter variations within the optimisation process Example of an isoline illustration to describe the . nonlinear correlation of the input parameters (x1, x2 - cp. figure)
.

Source: E. Scheffler: Statistische Versuchsplanung und -auswertung, 1997.

Dr.-Ing. Claudia Werner

5. SIMULATION /OPTIMISATION PROCESS

Combination of the parameters of both subsystems Stationary nominal operation of the cogeneration system

SOFTWARE APPLICATIONS: Simulation of the energy supply of the hybrid desalination plant on the basis of GE Energy - GateCycle Thermoeconomic analyses on the basis GATEX, MATLAB and Microsoft Excel

Dr.-Ing. Claudia Werner

5. SIMULATION PROCESS
low medium high

100
high CMB1/CMB2 HPSHT3/HPSH23

(Zk /ED)/(Zk /ED)max in %

67

PUMP2 PUMP3 MPECO/MPECO2 ST2 ST1 PUMP1 MPZHT2/MPZH22

33
low

0 0 33 ED/ED,max in % 67 100

Electricity cost: 4.32 ct/kWh

Water cost: 2.08 EUR/m

Dr.-Ing. Claudia Werner

medium

6. RESULTS OF THE SIMULATION PROCESS

Exergy efficiency CMB1/CMB2
Fuel preheating Outlet Temperature

Electricity cost - 0.03 % 0.00 %

Water cost - 0.07 % 0.00 %

100 C 1220 C

140 C - 0.22 % 1220 C 0.00 %

Dr.-Ing. Claudia Werner

6. RESULTS OF THE SIMULATION PROCESS

Exergy efficiency CMB1/CMB2
Fuel preheating Outlet Temperature

Electricity cost - 0.03 % 0.00 % 0.00 % 0.00 % 0.00 % - 0.03 % - 0.03 % - 0.58 % - 0.43 % - 1.01 %

Water cost - 0.07 % 0.00 % - 0.01 % 0.00 % 0.00 % - 0.04 % - 0.01 % - 0.34 % - 0.37 % - 0.41 %

100 C 1220 C 85.0 % 85.0 % 85.0 % 85.0 % 89.0 %

140 C - 0.22 % 1220 C 0.00 % 80.5 % - 0.02 % 85.0 % 0.00 % 83.0 % - 0.02 % 82.0 % 87.5 % 54.3 K 67.8 K 81.9 K - 0.20 % - 0.12 % - 0.10 % 0.00 % - 1.31 %

PUMP1 PUMP2 PUMP3

Isentropic efficiency

ST1 ST2
Isentropic efficiency

HPSHT3/HPSH23 25.3 K MPECO/MPECO2 9.8 K MPZHT2/MPZHT22 33.9 K

Temperature difference

Dr.-Ing. Claudia Werner

6. RESULTS OF THE SIMULATION PROCESS

low 100 prior to optimisation after optimistion (Zk/ED)/(Zk/ED)max in % high 100
Dr.-Ing. Claudia Werner

medium

high

67 medium 33 low 0 0 33 ED/ED,max in % 67

Electricity cost: 4.23 ct/kWh

Water cost: 2.05 EUR/m

7. CONCLUSION AND OUTLOOK

Each component is characterised by specific dimensioning parameters, which qualify the relative exergy destruction and the specific cost ratios According to the optimisation approach by Ogriseck/Meyer different components are determined to affect the exergy or cost efficiency Modifications investigated result in decreased product cost (electricity/water) and decreased exergy efficiency

Application of combined methods including thermoeconomic and statistical approaches Investigation of further cogeneration concepts, e. g. combined production of hydrogen and electricity
Dr.-Ing. Claudia Werner

The author gratefully acknowledge the support of the Kraftwerksschule Essen e.V. and Siemens AG.

Contact Data:

Dr.-Ing. Claudia Werner Technische Universitt Berlin Institut fr Prozess- und Verfahrenstechnik Fachgebiet: Anlagen- und Sicherheitstechnik (TK-01) Strae des 17. Juni 135 D-10623 Berlin http://www.ast.tu-berlin.de/ claudia.werner@tu-berlin.de
Fachgebiet

Anlagen- und Sicherheitstechnik

Sensitivity Analyses - Product Cost (Electricity/Water)

1.5 1.5

Electricity
cost variation in % cost variation in % 1.0 1.0

Water (MED/RO)

0.5

0.5

0.0 -5 -0.5 parameter variation in % -2.5 0 2.5 5

0.0 -5 -0.5 parameter variation in % -2.5 0 2.5 5

CMB1/CMB2 - Fuel preheating PUMP1 - Isentropic efficiency PUMP3 - Isentropic efficiency ST2 - Isentropic efficiency MPECO/MPECO2 - Temperature difference

CMB1/CMB2 - Outlet temperature PUMP2 - Isentropic efficiency ST1 - Isentropic efficiency HPSHT3/HPSH23 - Temperature difference MPZHT2/MPZH22 - Temperature difference

Variation of the component parameters 5 % (prior to optimisation)

Dr.-Ing. Claudia Werner

Economic Aspects of Hybrid Desalination Plants (MED : RO)

67500
desalination capacity in m/d Totaltotal desalination capacity in m/d

60750 54000 47250 40500 33750 27000 20250 13500 4.0 9.0

1.00-1.25

1.25-1.50

1.50-1.75

1.75-2.00

2.00-2.25

2.25-2.50

2.50-2.75

2.75-3.00

0.0 0.1

0.3

0.4

0.7

1.0

1.5

2.3

MED:RO-Verhltnis MED : RO

Water cost in EUR/m related to the ratio of MED : RO and the total desalination capacity
Dr.-Ing. Claudia Werner

Economic Data of the Desalination Plant /CCGT Plant (Selection)

Desalination data according to the publications of Wangnick Consulting GmbH, IDE Technologies Ltd. and A. M. Helal et al.
reference date life cycle annual utilisation period interest rate inflation general escalation fuel escalation fuel cost emission certificate (CO2 ) 01/2007 30 a 7446 h 12 % 2.3 % 0.7 % 1.0 % 2.63 EUR/GJ 10.32 EUR/t
Dr.-Ing. Claudia Werner