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Chapter 12

Exergy Analysis of Steam Power Plants


Chapter Outline
12.1 Introduction 261 12.6.5.3 Losses in Steam Condensers 279
12.2 Analysis 262 12.6.5.4 Miscellaneous Losses 280
12.2.1 Balances 262 12.6.5.5 Environmental Impact
12.2.2 Overall Efficiencies 262 and Sustainability 280
12.2.3 Material Energy and Exergy Values 263 12.6.6 Comparison and Summary 280
12.3 Spreadsheet Calculation Approaches 264 12.7 Improving Steam Power Plant Efficiency 280
12.4 Example: Analysis of a Coal Steam Power Plant 266 12.7.1 Exergy-Related Techniques 281
12.5 Example: Impact on Power Plant Efficiencies of 12.7.2 Computer-Aided Design, Analysis,
Varying Boiler Temperature and Pressure 268 and Optimization 281
12.6 Case Study: Energy and Exergy Analyses of Coal-Fired 12.7.3 Maintenance and Control 281
and Nuclear Steam Power Plants 270 12.7.4 Steam Generator Improvements 282
12.6.1 Process Descriptions 270 12.7.4.1 Combustion-Related Improvements 282
12.6.1.1 Steam Generation 270 12.7.4.2 Heat Transfer-Related Improvements 282
12.6.1.2 Power Production 271 12.7.4.3 Other Steam Generator
12.6.1.3 Condensation 274 Improvements 282
12.6.1.4 Preheating 274 12.7.5 Condenser Improvements 282
12.6.2 Approach 275 12.7.6 Reheating Improvements 283
12.6.3 Analysis 275 12.7.7 Regenerative Feedwater Heating Improvements 283
12.6.4 Results 275 12.7.8 Improving Other Plant Components 283
12.6.5 Discussion 276 12.8 Closing Remarks 284
12.6.5.1 Overall Process Efficiencies 276 Problems 284
12.6.5.2 Efficiencies and Losses in Steam
Generators 277

12.1 INTRODUCTION
ABSTRACT
In this chapter, energy and exergy analyses are utilized to examine Steam power plants are widely utilized throughout the
and better understand the performance of steam power plants and world for electricity generation, and coal is often used to
to identify and evaluate possible process modifications to improve fuel these plants. Although the worlds existing coal
the plant efficiencies. Numerous steam power plants driven by reserves are sufficient for about two centuries, the tech-
fossil fuels like oil, coal and natural gas or by other energy nology largely used today to produce electricity from coal
resources like uranium are in service today. Steam power plants causes a significant negative environmental impact. To
are widely utilized throughout the world for electricity generation. utilize coal more effectively, efficiently, and cleanly in
Exergy is useful for improving the efficiency (or heat rate) of electricity generation processes, efforts are often expended
steam power plants, and for providing a detailed breakdown of the to improve the efficiency and performance of existing
losses, in terms of waste exergy emissions and irreversibilities, for
plants through modifications and retrofits, and to develop
the overall plants and their components. Some illustrative exam-
advanced coal utilization technologies.
ples are presented to demonstrate the importance of exergy in
performance improvement of the steam power plants. Today, many electrical generating utilities are striving
to improve the efficiency (or heat rate) at their existing
KEYWORDS thermal electric generating stations, many of which are
Exergy; Steam power plant; Fossil fuel power, Coal power over 25 years old. Often, a heat rate improvement of only
plant; Nuclear power; Steam generator; Boiler; Condenser;
a few percent appears desirable as it is thought that the costs
Reheating; Feedwater heating; Regenerative feedwater heat-
and complexity of such measures may be more manageable
ing; Rankine cycle.
than more expensive options.

Exergy. http://dx.doi.org/10.1016/B978-0-08-097089-9.00012-7
2013 Ibrahim Dincer and Marc A. Rosen. Published by Elsevier Ltd. All rights reserved 261
262 Exergy

To assist in improving the efficiencies of coal-to-electricity components: (1) steam generator, (2) turbine, (3) condenser,
technologies, their thermodynamic performances are usually and (4) pump. Additional components are usually added to
investigated. In general, energy technologies are normally enhance cycle performance and to improve efficiency.
examined using energy analysis. A better understanding is The Rankine cycle used in actual steam power plants is
attained when a more complete thermodynamic view is generally more complex, and is considered later in this
taken, which uses the Second Law of Thermodynamics in chapter.
conjunction with energy analysis, via exergy methods.
Of the analysis techniques available, exergy analysis is
12.2.1 Balances
perhaps the most important because it is a useful, convenient,
and straightforward method for assessing and improving For each component, balances for mass, energy, and exergy
thermal generating stations. The insights gained with exergy can be applied to find energy terms such as work output and
analysis into plant performance are informative (e.g., effi- heat addition, exergy flows and irreversibilities, and energy
ciencies are determined that measure the approach to ideality, and exergy efficiencies. Several balances, based on energy
and the causes and locations of losses in efficiency and and exergy, for the system components are given below,
electricity generation potential are accurately pinpointed). along with energy and exergy efficiency expressions for the
Exergy analysis results can aid efforts to improve the effi- overall plant.
ciency, and possibly the economic and environmental For a steady-state process, respective balances for mass,
performance, of thermal generating stations. Improvement, energy, and exergy can be written as follows:
X : X :
design, and optimization efforts are likely to be more rational mi me (12.1)
and comprehensive if exergy factors are considered. One i e
reason is that exergy methods can prioritize the parts of a plant
in terms of greatest margin for improvement by focusing on X : : X : :
Ei Q Ee W (12.2)
plant components responsible for the largest exergy losses. i e
For example, the authors previously showed that efficiency-
improvement efforts for coal-fired electrical generation X X 
To : X : :
should focus on the steam generator (where large losses occur _ i
Ex 1 Qj _ eW I
Ex (12.3)
Tj e
from combustion and heat transfer across large temperature i j
differences), the turbines, the electrical generator, and the
transformer. In addition, however, other components should Neglecting potential and kinetic energy, Equation 12.2 can
be considered where economically beneficial improvements be written as:
X : : X : :
can be identified, even if they are small. mi hi Q m e he W (12.4)
In most countries, numerous steam power plants driven by i e
fossil fuels like oil, coal, and natural gas or by other energy
resources like uranium are in service today. During the past and the exergy flow rate of a flowing stream of matter as:
decade, many power-generation companies have paid atten-
tion to process improvement in steam power plants by taking _ m: ex m: exph exch
Ex (12.5)
measures to improve the plant efficiencies and to minimize
the environmental impact (e.g., by reducing the emissions of where the specific physical exergy exph is expressed as:
major air pollutants such as CO2, SO2, and NOx). Exergy
analysis is a useful tool in such efforts. exph h  ho  To s  so (12.6)
In this chapter, energy and exergy analyses are utilized to The irreversibility rates for the plant components are
examine and better understand the performance of steam assessed using a rearranged form of the exergy balance in
power plants and to identify and evaluate possible process Equation 12.3:
modifications to improve the plant efficiencies. Some alter-
: X X : X 
To :
native process configurations are then proposed. Exergy is I _ i
Ex _ eW
Ex 1 Q (12.7)
useful for providing a detailed breakdown of the losses, in i e j
Tj j
terms of waste exergy emissions and irreversibilities, for the
overall plants and their components. Some illustrative exam- Note that: for all components except the turbines and
ples are presented to demonstrate the importance of exergy in pumps, W is equal to zero.
performance improvement of the steam power plants.
12.2.2 Overall Efficiencies
12.2 ANALYSIS The overall plant efficiency can be expressed as:
:
W net
The Rankine cycle (Figure 12.1) is used in a variety of power hplant : (12.8)
plants. A simple Rankine cycle consists of four main Ef
Chapter | 12 Exergy Analysis of Steam Power Plants 263

Turbine Wnet
Boiler

Ef 4
6

Condenser Qc
2
Pump
1

Wp
T

3 5

4
4s

2
2s

1 6s 6
s
FIGURE 12.1 A Rankine cycle steam power plant and its T-s diagram.

:
where the net power output W net can be written as: Using Equations 12.5 and 12.6 and noting that the
: : : : physical exergy of coal is zero at its assumed input
W net W tur hmech htrans hgen  W pump  W ser (12.9)
conditions of To and Po, the fuel exergy can be written
:
Here, W tur: denotes the gross power generated by the as:
turbines,
: W pump is the power used by the hot well pump, _ f n: f exch
Ex (12.12)
and W ser is the power for station services. Also hmech, htrans,
and hgen denote the mechanical, transformer, and generator
efficiencies, respectively. 2. Liquid and vapor flows. All liquid flows in the plant
The plant exergy efficiency is expressible as: contain H2O. The energy flow rate of an H2O flow can
: be written as:
W net : :
jplant (12.10) E mh  ho (12.13)
_ f
Ex
Using Equations 12.5 and 12.6 and noting that the
chemical exergy of H2O is zero, the exergy flow rate of
12.2.3 Material Energy and Exergy Values an H2O flow can be written as:
_ m: h  ho  To s  so 
Ex (12.14)
The energy and exergy flow rates for materials, such as
solids, liquids, and gases, within the plant can be evaluated
as follows: 3. Gas flows. The energy flow rate of a gas flow can be
1. Solid flows. The chemical energy for the fuel can be written as the sum of the energy flow rates for its
constituents:
written as:
: : X: h i
: E ni h  h o (12.15)
Ef nf HHV (12.11) i
i
264 Exergy

The exergy flow rate of a gas flow can be written with The adiabatic combustion temperature is determined
: : using
Equations 12.5 and 12.6 as: the energy balance in Equation 12.2 with Q 0 and W 0:
X: h   i E_ f E_ a E_ p (12.23)
_ e
Ex ni h  ho  To s  so exch (12.16)
i Substituting Equations 12.11, 12.19, and 12.21 into 12.23
i
and simplifying yields:
For example, modeling the coal used in a coal-fired power h
plant as carbon (C) and assuming complete combustion    i
HHV 1 l h  ho O2 3:76 h  ho N2
with excess air, the combustion reaction can be expressed h
Ta
as follows:   
h  ho CO2 l h  ho O2
C 1 lO2 3:76N2   i
3:761 l h  ho N2 (12.24)
/CO2 l O2 3:761 lN2 (12.17) Tp

where l denotes the fraction of excess combustion air. The Here Tp can be evaluated using an iterative : solution tech-
air-fuel (AF) ratio can be written as: nique. Note that the flow rates of energy Eg and exergy Ex _ g
for the stack gas can then be evaluated using Equations
: : 12.21 and 12.22 because the composition of stack gas is the
ma na M a 1 l 4:76 Ma
AF : : (12.18) same as that of the product gas.
mf nf M f Mf
An energy balance for the steam generator can be written as:
:   :  
E_ f  E_ g ms hs  hfeed mre hre;e  hre;i (12.25)
The energy and exergy flow rate of combustion air can be
:
written in terms of the mole flow rate of fuel nf , using In an analysis, the flow rate of fuel (mole or mass) can
Equations 12.15 through 12.17 and noting that the chemical be determined for a fixed steam generator output by
exergy of air is zero, as: substituting Equations 12.11 and 12.21 into Equation
: :
h i 12.25. Then the energy and exergy flow rates of the fuel can
Ea nf 1 l h  ho O2 3:76h  ho N2 (12.19) be evaluated with Equations 12.11 and 12.12, of the
gaseous streams (i.e., preheated combustion air, combus-
and tion gas, and stack gas) with Equations 12.19e12.22, and
n  
_ a n: f 1 l h  ho  To s  so
Ex
of the H2O streams with Equations 12.11 and 12.14. The
O2 irreversibilities for plant components can be assessed using
   o Equation 12.7, and the plant energy and exergy efficiencies
3:76 h  ho  To s  so N2 (12.20)
evaluated using Equations 12.8 and 12.10, respectively.
It is useful to determine the hypothetical temperature
of combustion gas in the steam generator without any
heat transfer (i.e., the adiabatic combustion temperature) 12.3 SPREADSHEET CALCULATION
to facilitate the evaluation of its energy and exergy flows APPROACHES
and the breakdown of the steam-generator irreversibility
The complexity of power generating units makes it difficult
into portions related to combustion and heat transfer (see
to determine properties and quantities simply and accu-
Table 12.1). The energy and exergy flow rates of the
rately. The effort required for thermodynamic calculation
products of combustion can be written using Equations
during design and optimization has grown tremendously.
12.15e12.17 as:
h To be competitive and to reduce planning and design time,
: :     as well as errors, companies apply computer-aided
Ep nf h  ho CO2 l h  ho O2
  i methods. Such methods also facilitate optimization, which
3:761 l h  ho N2 (12.21) also can be time-consuming (Perz, 1991).
The ability to quickly evaluate the impact of changes in
and system parameters is crucial to safe and efficient operation.
n   Spreadsheet calculation schemes provide inexpensive
_ p n: f
Ex h  ho  To s  so exch CO2 methods for energy and exergy calculations in steam power
   plants and allow for visualization of operation (Hughes, 1991).
l h  ho  To s  so exch O2 Using thermodynamic water tables in Sonntag et al.
   o (2006), the enthalpy and entropy values for each state point
3:76 1 l h  ho  To s  so exch N2
in a plant are calculated, and these data are entered in an
(12.22) Excel worksheet, which can be used to calculate the energy
Chapter | 12 Exergy Analysis of Steam Power Plants 265

TABLE 12.1 Main Flow Data for the Sample Coal-Fired Steam Power Plant in Section 12.4

Section Mass flow rate (kg/s) Temperature (oC) Pressure (MPa) Vapor fraction*
Steam generator
Feedwater in 423.19 253.28 18.62 0

Main steam out 423.19 537.78 16.31 1


Reheat steam in 376.75 343.39 4.29 1
Reheat steam out 376.75 537.78 3.99 1
Steam turbine
Inlet flows, by turbine section:
High-pressure turbine 421.18 537.78 15.42 1

Intermediate-pressure turbine 376.65 537.78 3.99 1


Low-pressure turbines 314.30 251.56 0.46 1
Extraction steam flows, by destination:
Feedwater heater no. 1 (closed) 17.08 69.89 0.03 1
Feedwater heater no. 2 (closed) 11.25 89.67 0.07 1
Feedwater heater no. 3 (closed) 17.40 166.00 0.19 1

Feedwater heater no. 4 (closed) 17.18 251.56 0.44 1


Feedwater heater no. 5 (open) 17.28 329.56 0.87 1
Feedwater heater no. 6 (closed) 18.13 419.56 1.72 1
Feedwater heater no. 7 (closed) 43.07 343.39 4.22 1
Condenser
Condensate out 281.62 31.96 0.01 0

Cooling water in 5899.55 8.00 0.10 0


Cooling water out 5899.55 33.78 0.10 0

*A vapor fraction of 0 denotes a saturated or subcooled liquid; a vapor fraction of 1 denotes a dry saturated or superheated vapor.

and exergy efficiencies of the cycle. A sample calculation T0 25 C 298.15 K


procedure is summarized below: Initial state of the flue gas is the reference state.
State properties are:
l Given:
h1 3348 kJ/kg s1 6.487 kJ/kg.K
P1 12 MPa, T1 500 C
h2 2957 kJ/kg s2 6.569 kJ/kg.K
P2 P3 2.4 MPa, T3 500 C
h3 3463 kJ/kg s3 7.343 kJ/kg.K
P5 P6 Psat 7 kPa, T5 Tsat 39 C
h4 2813 kJ/kg s4 7.513 kJ/kg.K
P4 P7 P8 0.15 MPa
h5 2399 kJ/kg s5 7.720 kJ/kg.K
h6 163.4 kJ/kg s6 0.5591 kJ/kg.K
Flue gas inlet conditions: P 102 kPa, T 1500 C
h7 163.5 kJ/kg s7 0.5592 kJ/kg.K
Flue gas outlet conditions: P 101 kPa, T 400 C
l Find: h8 462.8 kJ/kg s8 1.4225 kJ/kg.K
w, q, h, J, X h9 474.3 kJ/kg s9 1.4254 kJ/kg.K
l Assumptions and data determination:
m_ w 1 kg/s
266 Exergy

l Calculation: l Fuel and 40% excess combustion air are supplied at


 
environmental temperature To and pressure Po.
X hg  h7 h4  h7 462:8  163:5= l The combustion air is preheated to 267 C using
regenerative air heating.
2813  163:5 0:1130 l The stack-gas exit temperature is 149 C.
l All components have adiabatic boundaries.
w wHPT wLPT l The turbines have isentropic and mechanical efficien-
cies of 91% and 99.63%, respectively.
h1  h2 h3  Xh4  1  Xh5 
l The generator and transformer efficiencies are both
3348  2957 3463  0:113  2813 98.32%.
l The reference-environment model used has the following
 1  0:113  2399 property values: temperature To 8 C, pressure Po
1408 kJ=kg 101.315 kPa (1 atm), and a chemical composition as
specified elsewhere (Rosen and Dincer, 2003aed).
q h1  h9 h3  h2
Steam properties are obtained using software based on
3348  474:3 3463  2957 3380 kJ=kg the National Bureau of Standards/National Regulatory
Committee Steam Tables. Air properties are obtained
h w=q 1408=3380 0:4166 from tables based on data from the thermodynamic tables.
   A schematic of the coal-fired steam power plant is
m_ gas q= CP Tg;o  Tg;i shown in Figure 12.1, and the component irreversibility
3380=1:10581500  400 2:779 kg=s rates are given in Table 12.2. Two key points are observed.
1. With the data in Table 12.1 and Equations 12.8e12.10,
exg;i hg;i  T0  sg;i 0:0  298:15  0:0
the plant energy efficiency hplant and exergy efficiency
0 kJ=kg jplant can be evaluated as:
 
exg;o hg;o  T0 sg;o CP Tg;o  Tg;i  T0
516:79 0:996 0:98 0:98  0:67  15:06
     hplant
 ln Tg;o =Tg;i  k  1=k  ln Pg;o =Pg;i 1238:68
38:9%
1:1058400  1500  298:15
516:79 0:996 0:98 0:98  0:67  15:06
jplant
 ln637:15=1773:15  0:35=1:35 1292:24
37:3%
 ln101=102

897:9 kJ=kg The small difference in efficiencies is due to the specific


 
_ d m_ gas ag;i  ag;o 2:7790  897:9
Ex chemical exergy of coal being slightly greater than its
specific energy as measured by its higher heating values
2495 kw (HHV). Energy analysis indicates that the largest waste
j m_ w w=RED 1408=2495 0:5643 losses for the coal-fired steam power plant are attribut-
able to the condenser, with condenser waste-heat
rejection accounting for more than 50% of energy input
with coal. However, exergy analysis indicates that the
12.4 EXAMPLE: ANALYSIS OF A COAL
waste-heat emissions from the condenser, although
STEAM POWER PLANT great in quantity, are low in quality (i.e., have little
The mainstream data for a typical modern coal-fired steam exergy) because their temperatures are near to that of the
power plant are summarized in Table 12.1. The plant is environment. Therefore, condenser improvements can
examined using energy and exergy analyses in order to: (1) typically yield only slight increases in plant exergy
improve understanding of its behavior and performance and efficiency.
(2) provide a base-case reference for efficiency improve- 2. It can be seen from Table 12.2 that most (approxi-
ment investigations. mately 84%) of the total exergy destruction occurs in
Several assumptions and simplifications are used in the the steam generator, while the remainder occurs in
energy and exergy analyses: other devices (approximately 10% in the turbine
Chapter | 12 Exergy Analysis of Steam Power Plants 267

TABLE 12.2 Breakdown of Exergy Consumption Rates for Devices for the Sample Power Plant in Section 12.4

Irreversibility rate

Device (MW) (% of total)


Steam generator
Combustion 305.77 43.61
Heat transfer 282.81 40.34
Total 588.58 83.95
Power production devices
High-pressure turbine 6.05 0.86

Intermediate-pressure turbine 10.04 1.43


Low-pressure turbines 36.06 5.14
Mechanical shafts 2.07 0.30
Generator 8.75 1.25
Transformer 8.75 1.25
Total 71.72 10.23

Condenser 27.85 3.97


Total 27.85 3.97
Heaters
Closed feedwater heaters
Low-pressure heaters
Heater no. 0 0.1 0.01

Heater no. 1 2.01 0.29


Heater no. 2 0.75 0.11
Heater no. 3 1.55 0.22
Heater no. 4 1.40 0.20
High-pressure heaters
Heater no. 6 2.36 0.34
Heater no. 7 2.64 0.38

Open feedwater heater


Heater no. 5 1.51 0.22
Total 12.32 1.76
Pumps
Hot well pump 0.32 0.05
Boiler feed pump 0.35 0.05

Total 0.67 0.10


Plant total 701.14 100.00
268 Exergy

generators, 4% in the condenser, and 2% in the feed- The pressure at the regenerator is set to 0.15 MPa. The
water heaters and pumps). The steam generator is thus water coming from the regenerator is saturated. The isen-
the most inefficient plant device, with combustion in tropic efficiencies of the turbines and pumps are both
that device accounting for nearly 44% of the plant assumed to be 0.9.
exergy consumption and heat transfer nearly 40%. As In Figure 12.2a, the energy efficiency is plotted against
a result, significant potential exists for improving plant boiler temperature for values between 400 C and 600 C.
efficiency by reducing steam-generator irreversibilities The six energy-efficiency profiles shown represent six
by modifying the combustion and/or heat-transfer different boiler pressures (10, 11, 12, 13, 14, and 15 MPa).
processes occurring within it. All energy-efficiency profiles increase almost linearly with
the boiler temperature and the energy efficiencies vary from
0.38 to 0.45. Figure 12.2b shows the corresponding exergy-
12.5 EXAMPLE: IMPACT ON POWER PLANT efficiency distributions for several boiler pressures against
EFFICIENCIES OF VARYING BOILER the boiler temperature. The trend of the exergy-efficiency
profiles appears similar to that for the energy-efficiency
TEMPERATURE AND PRESSURE profiles. However, the exergy-efficiency values vary
Thermodynamic parameters are taken from the Ghazlan between 0.525 and 0.6. The exergy efficiencies are higher
Power Plant in Saudi Arabia (Al-Bagawi, 1994). The boiler than the energy efficiencies at different pressures, due to the
pressure is 12.5 MPa and temperature is 510 C. The fact that high-quality (or high-temperature) energy sources
condenser pressure is 50.8 mmHg and temperature is such as fossil fuels are used for high-temperature applica-
38.4 C. The regenerator pressure is 132 kPa. Habib et al. tions (e.g., 400 Ce590 C). Therefore, in practical
(1995) indicated that for maximum efficiency of a single processes, both quantity and quality are well accounted for
reheat cycle, the reheat pressure should be approximately by exergy, but not by energy. The results obtained here
19% of the boiler pressure. Balances for the plant compo- agree well with other reports (Habib et al., 1995, 1999).
nents are given in Table 12.3. Energy and exergy efficiency are plotted against boiler
In the simulation, we change the inlet temperature of the pressure in Figure 12.3a and b for three different temper-
high-pressure turbine (or the outlet temperature of the atures (400 C, 500 C, and 590 C). Although both energy
boiler) between 400 C and 600 C in steps of 10 C. For and exergy efficiencies increase slightly with increasing
each temperature, the pressure is changed from 10 to 15 pressure, this increase is not appreciable. The increase
MPa in steps of 1 MPa. The pressure at the inlet of the low- must be weighed against the added cost of equipment
pressure turbine is 20% of that of the high-pressure turbine. to increase the pressure. The maximum energy efficiency
The temperature is assumed to be equal to that of the high- for the three curves occurs at a boiler pressure of 14
pressure turbine. These two conditions have been cited as MPa. Therefore, this pressure can be considered a ther-
important for maximizing the efficiency of the reheat cycle. modynamic optimum for such a cycle under the design
The practical value of the temperature of the condenser conditions. Exergy-efficiency profiles in Figure 12.2b
ranges between 35 C and 40 C. For a temperature of 39 C, follow the same trend as energy-efficiency curves in
the water is saturated so the saturation pressure is 7 kPa. Figure 12.2a. Moreover, the pressure of 14 MPa appears to

TABLE 12.3 Balances and Other Equations for System Components in the Ghazlan Power Plant

Component Energy analysis Exergy analysis


High-pressure turbine wHPT h1  h2 ex h1  h2  T0 s1  s2

Low-pressure turbine wLPT h3  X  h4  1  X h5 ex h3  X  h4  1  X  h5


T0 s3  X  s4  1  X  s5 

Regenerator X h8  h7 =h4  h7 ex T0 X  s4 1  X  s7  s8 

Condenser mcw 1  Xh5  h6 = ex T0 1  Xs5  s6


hco  hci mcw sci  sco 

Boiler mg h1  h9 h3  h2 = ex T0 s9  s1 s2  s3
CpTg2  Tg1 mg sg1  sg2 

Pump 1 wp1 1  Xh6  h7 ex 1  Xh6  h7  T0 s6  s7 


Pump 2 wp2 h8  h9 ex h8  h9  T0 s8  s9
Chapter | 12 Exergy Analysis of Steam Power Plants 269

(a) FIGURE 12.2 Variation of (a) energy efficiency and (b)


0.5 exergy efficiency with boiler temperature for various boiler
pressures (A, 10 MPa; n, 11 MPa; :, 12 MPa; ,13 MPa; *,
Energy e fficiency

0.475
0.45 14 MPa; l,15 MPa) for the Ghazlan Power Plant.

0.425
0.4
0.375
0.35
400 420 440 460 480 500 520 540 560 580 600
Boiler temperature (C)
(b) 0.65
0.625
Exergy e fficiency

0.6
0.575
0.55
0.525
0.5
400 420 440 460 480 500 520 540 560 580 600
Boiler temperature (C)

be the optimum pressure from an exergy perspective. 400 C, they approach each other as temperature increases
Because of the quality aspect, the exergy efficiencies are and tend to match near 600 C. This means that if the
higher than energy efficiencies. system works at high temperatures (>600 C), the pressure
A linear relationship is observed between the heat input effect becomes less dominant (Dincer and Al-Muslim,
to the boiler and the boiler temperature at pressures ranging 2001).
from 10 to 15 MPa. It is evident that increasing heat input In Figure 12.4a and b, we compare the present
increases boiler temperature. Although the difference energy- and exergy-efficiency distributions versus the
between the profiles is larger at lower temperatures like boiler temperature and pressure values with the actual

FIGURE 12.3 Variation of (a) energy efficiency and (b)


(a) 0.5 exergy efficiency with boiler pressure for various boiler
0.475 temperatures (A, 400 C; n, 500 C; :, 590 C) for the
Energy efficiency

Ghazlan Power Plant.


0.45
0.425
0.4
0.375
0.35
10 11 12 13 14 15
Boiler pressure (MPa)

(b) 0.65
0.625
Exergy efficiency

0.6
0.575
0.55
0.525
0.5
10 11 12 13 14 15
Boiler pressure (MPa)
270 Exergy

FIGURE 12.4 Comparison of the energy and exergy effi-


ciencies for the Ghazlan Power Plant with (a) boiler temperature
(a) 0.75
0.7 exergy, actual
and (b) boiler pressure for the actual data presented by Al-
0.65

Efficiency
Bagawi (1994) and the values calculated with the present model 0.6 exergy, present model
discussed in the text. 0.55
0.5 energy, actual
0.45
0.4
energy, present model
0.35
400 420 440 460 480 500 520 540 560 580 600
Boiler temperature (C)

(b) 0.75
0.7
0.65 exergy, actual

Efficiency
0.6
0.55 exergy, present model
0.5 energy, actual
0.45
0.4 energy, present model
0.35
10 11 12 13 14 15
Boiler pressure (MPa)

data presented in Al-Bagawi (1994). The energy effi- l The individual units in each station have similar net
ciencies are in good agreement with differences less than electrical outputs (approximately 500 MW).
10%. For exergy efficiency, however, much greater l A substantial base of operating data has been obtained
differences appear due to fact that the system studied by for them over several years (NGS has been operating
Al-Bagawi (1994) is for a three-stage Rankine cycle since 1981 and PNGS since 1971).
steam power plant with feedwater heating to increase l They are relatively representative of present technology.
efficiency. This modification increases the exergy l They operate in similar physical environments.
efficiency significantly while the change in energy effi-
ciency is small.
12.6.1 Process Descriptions
Detailed flow diagrams for single units of NGS and PNGS
12.6 CASE STUDY: ENERGY AND EXERGY are shown in Figure 12.5. The symbols identifying the
ANALYSES OF COAL-FIRED AND NUCLEAR streams are described in Table 12.4a and b and the main
STEAM POWER PLANTS process data is described in Table 12.5. Process descrip-
tions reported previously (Ontario Hydro, 1996) for each
In this section, thermodynamic analyses and comparisons are summarized below in terms of the four main sections
of coal-fired and nuclear electrical generating stations are identified in the caption of Figure 12.5. Process data are
performed using energy and exergy analyses. This section also obtained by computer simulation.
strives to improve understanding of the thermodynamic
performance of steam power plants, and to identify areas
12.6.1.1 Steam Generation
where the potential for performance improvement is high
and identify trends that may aid in the design of future Heat is produced and used to generate and reheat steam. In
stations. NGS, eight pulverized coal-fired natural circulation steam
The coal-fired Nanticoke Generating Station (NGS) and generators each produce 453.6 kg/s steam at 16.89 MPa and
the Pickering Nuclear Generating Station (PNGS) are 538 C and 411.3 kg/s of reheat steam at 4.00 MPa and
selected as the representative stations upon which the 538 C. Air is supplied to the furnace by two 1080 kW 600
comparisons are based (Ontario Hydro, 1996). Both rpm motor-driven forced draft fans. Regenerative air
stations are located in Ontario, Canada, and are operated by preheaters are used. The flue gas passes through an elec-
the provincial electrical utility, Ontario Power Generation trostatic precipitator rated at 99.5% collection efficiency
(formerly Ontario Hydro). The reasons these stations were and exits the plant through two multiflued, 198 m high
selected include the following: chimneys.
Chapter | 12 Exergy Analysis of Steam Power Plants 271

FIGURE 12.5 Process diagrams for single units


(a) S20 Q5 & Q6 of (a) NGS and (b) PNGS. The flow of uranium into
and out of the nuclear reactor, and the net heat
P8 delivered, are indicated. Lines exiting turbines
B C D D E
S5A represent flows of extraction steam. Stream S16 in
Figure 12.4b represents the mixed contents of the
S4 S15 four indicated flows of extraction steam. The
S2 S33
A S21 diagrams are each divided into four main sections:
S1 (1) steam generation (device A for NGS, and
S14 devices AeD for PNGS); (2) power production
S36 S37
F
S42 S8 S22 S25 S34 S35 S13 (devices BeE for NGS, and EeI for PNGS); (3)
S10 condensation (device F for NGS and J for PNGS);
P1
I and (4) preheating (devices GeK for NGS and
K S41 S39 H S11 G
KeP for PNGS).
S40
S12 J S38
P15
A: Steam generator and reheater G: Hot well pump
B: High-pressure turbine H: Low-pressure heat exchangers
C: Intermediate-pressure turbine I: Open de-aerating heat exchanger
D: Low-pressure turbines J: Boiler feed pump
E: Generator and transformer K: High-pressure heat exchangers
F: Condenser

Q9 & Q10
(b) S11
G S15
S40 F
S9 S10

P8
E H H H I
S1

(NET) A D S12A S17

Q1 & Q2 S3A S18


S14 S39 S29
B
S4 S24 S16 J
S2 S28
S6 S20
C S26
M P3
S7 S27 P S22 L S21 K
O S25
S5A N
S23 S19
P1 P4 P2
A: Nuclear reactor I: Generator and transformer
B: Heavy water pump J: Condenser
C: Moderator cooler K: Hot well pump
D: Steam generator L: Low-pressure heat exchangers
E: High-pressure turbine M: Open de-aerating heat exchanger
F: Moisture separator N: Boiler feed pump
G: Closed reheater O: Pump
H: Low-pressure turbines P: High-pressure heat exchangers

In each unit of PNGS, natural uranium is fissioned in the 12.6.1.2 Power Production
presence of a moderator to produce heat, which is trans-
ferred from the reactor to the boiler in the primary heat The steam produced in the Steam Generation section is
transport loop (PHTL). The flow rate of pressurized heavy passed through a series of turbine generators that are
water (D2O) in the PHTL is 7724 kg/s. The D2O is heated attached to a transformer. Extraction steam from several
from 249 C and 9.54 MPa to 293 C and 8.82 MPa in the points on the turbines preheats feedwater in several low-
nuclear reactor. Light-water steam (815 kg/s at 4.2 MPa and and high-pressure heat exchangers and one spray-type open
251 C) is produced in the boiler and transported through de-aerating heat exchanger. The low-pressure turbines
the secondary heat transport loop. Spent fuel is removed exhaust to the condenser at 5 kPa.
from the reactor, and heat generated in the moderator is Each unit of NGS has a 3600 rpm tandem-
rejected. compound impulse-reaction turbine generator containing
272 Exergy

TABLE 12.4A Flow Data for a Unit in the Coal-Fired NGSa

Mass flow Temperature Pressure Vapor Energy flow Exergy flow


Flowb ratec (kg/s) ( C) (MPa) fractiond ratee (MW) ratee (MW)
S1 41.74 15.00 0.101 solid 1367.58 1426.73
S2 668.41 15.00 0.101 1.0 0.00 0.00
S3 710.15 1673.59 0.101 1.0 1368.00 982.85

S4 710.15 119.44 0.101 1.0 74.39 62.27


S5A 453.59 538.00 16.2 1.0 1585.28 718.74
S8 42.84 323.36 3.65 1.0 135.44 51.81
S10 367.85 35.63 0.0045 0.0 36.52 1.20
S11 367.85 35.73 1.00 0.0 37.09 1.70
S12 58.82 188.33 1.21 0.0 50.28 11.11

S13 18636.00 15.00 0.101 0.0 0.00 0.00


S14 18636.00 23.30 0.101 0.0 745.95 10.54
515 410.75 323.36 3.65 1.0 1298.59 496.81
S20 367.85 360.50 1.03 1.0 1211.05 411.16
S21 410.75 538.00 4.00 1.0 1494.16 616.42
S22 15.98 423.23 1.72 1.0 54.54 20.02

S25 26.92 360.50 1.03 1.0 88.64 30.09


S33 309.62 35.63 0.0045 0.93 774.70 54.07
S34 10.47 253.22 0.379 1.0 32.31 9.24
S35 23.88 209.93 0.241 1.0 71.73 18.82
S36 12.72 108.32 0.0689 1.0 35.77 7.12
S37 11.16 60.47 0.0345 1.0 30.40 5.03

S38 58.23 55.56 0.0133 0.0 11.37 0.73


S39 367.85 124.86 1.00 0.0 195.94 30.41
S40 453.59 165.86 1.00 0.0 334.86 66.52
S41 453.59 169.28 16.2 0.0 347.05 77.57
S42 453.59 228.24 16.2 0.0 486.75 131.93
Q5 5.34 0.00

Q6 5.29 0.00
P1 0.57 0.57
P8 523.68 523.68
P15 12.19 12.19
a
Based on data obtained for Nanticoke Generating Station by computer simulation (Rosen, 2001) using given data (Ontario Hydro, 1973, 1983; Scarrow and
Wright, 1975; Bailey, 1981; Merrick, 1984).
b
Flow numbers correspond to those in Figure 12.4a, except for S3, which represents the hot product gases for adiabatic combustion. Letter prefixes indicate
material flows (S), heat flows (Q), and electricity flows (P).
c
Material flow compositions, by volume, are 100% C for S1; 79% N2, 21% O2 for S2; 79% N2, 6% O2, 15% CO2 for S3 and S4; 100% H2O for other material
flows.
d
Vapor fraction indicates fraction of a vapor-liquid flow that is vapor (not applicable to S1 since it is solid). Vapor fraction is listed as 0.0 for liquids and 1.0 for
superheated vapors.
e
Energy and exergy values are evaluated using a reference-environment model, similar to the model used by Gaggioli and Petit (1977), having a temperature of
15 C, a pressure of 1 atm; and a composition of atmospheric air saturated with H2O at 15 C and 1 atm; and the following condensed phases: water, limestone,
and gypsum.
Chapter | 12 Exergy Analysis of Steam Power Plants 273

TABLE 12.4B Flow Data for a Unit in PNGS


Mass flow Temperature Pressure Vapor Energy flow Exergy flow
Stream ratea (kg.s1) ( C) (N.m2) Fractionb rate (MW) rate (MW)
S1 7724.00 291.93 8.82  106 0.0 9548.21 2984.23

S2 7724.00 249.38 9.60  10 6


0.0 7875.44 2201.64

S3A 7724.00 249.00 8.32  10 6


0.0 7861.16 2188.64

S4 1000.00 64.52 1.01  10 5


0.0 207.02 15.99

S5A 1000.00 43.00 1.01  105 0.0 117.02 5.34

S6 1956.83 15.00 1.01  10 5


0.0 0.00 0.00

S7 1956.83 26.00 1.01  10 5


0.0 90.00 1.67

S9 698.00 151.83 5.00  10 5


0.88 1705.50 500.40

S10 603.00 160.00 5.00  105 1.0 1629.83 476.54

S11 61.00 254.00 4.25  10 6


1.0 166.88 64.62

S12A 61.00 254.00 4.25  10 6


0.0 63.57 17.78

S14 55.00 176.66 9.28  10 6


0.90 138.70 44.60

S15 603.00 237.97 4.50  105 1.0 1733.17 508.35

S16 83.00 60.81 2.07  104 0.95 204.00 28.10

S17 498.00 23.32 2.86  10 3


0.90 1125.10 44.40

S18 22.00 186.05 2.55  10 5


1.0 61.06 16.03

S19 83.00 60.81 2.07  104 0.0 15.89 1.13

S20 581.00 23.32 2.86  10 3


0.0 20.15 0.17

S21 581.00 23.40 1.48  10 6


0.0 211.55 1.13

S22 581.00 100.20 1.40  106 0.0 207.88 26.50

S23 150.00 134.00 3.04  105 0.0 75.04 12.29

S24 150.00 134.17 1.48  10 6


0.0 75.27 12.50

S25 753.00 123.69 1.40  10 6


0.0 344.21 53.16

S26 753.00 124.20 5.40  106 0.0 347.93 56.53

S27 753.00 163.94 5.35  10 6


0.0 476.02 96.07

S28 24073.00 15.00 1.01  10 5


0.0 0.00 0.00

S29 24073.00 26.00 1.01  10 5


0.0 1107.20 20.61

S39 95.00 160.00 6.18  105 0.03 75.70 23.70

S40 753.00 254.00 4.25  10 6


1.0 2060.02 797.70

Q1 1673.00 1673.00

Q2 90.00 90.00

Q9 5.56 0.00

Q10 5.50 0.00

P1 14.28 14.28

P2 3.73 3.73

P3 1.00 1.00

P4 0.23 0.23

P8 544.78 544.78
a
All streams are modeled as 100% H2O. Streams S1, S2, S3A, S4, and S5A are actually reactor-grade D2O.
b
Vapor fraction is listed as 0.0 for liquids and 1.0 for superheated vapors.
274 Exergy

TABLE 12.5 Main Process Data for Single Units in NGS and PNGS

Section NGS PNGS


Steam generation section
Furnace

Coal consumption rate at full load (kg/s) 47.9 d



Flue gas temperature ( C) 120 d
Nuclear reactor
Heavy water mass flow rate (kg/s) d 724

Heavy water temperature at reactor inlet ( C) d 249

Heavy water temperature at reactor outlet ( C) d 293

System pressure at reactor outlet header (MPa) d 8.8


Boiler (heat-exchanger component)
Feed water temperature ( C) 253 171
Total evaporation rate (kg/s) 454 815

Steam temperature ( C) 538 251
Steam pressure (MPa) 16.9 4.2

Reheat evaporation rate (kg/s) 411 d



Reheat steam temperature ( C) 538 d
Reheat steam pressure (MPa) 4.0 d
Power production section
Turbine
Condenser pressure (kPa) 5 5

Generator
Gross power output (MW) d 542
Net power output (MW) 505 515
Condensation section
Cooling water flow rate (m3/s) 18.9 23.7

Cooling water temperature rise ( C) 8.3 11

one single-flow high-pressure cylinder, one double-flow 12.6.1.3 Condensation


intermediate-pressure cylinder, and two double-flow
low-pressure cylinders. Steam exhausted from the high- Cooling water from Lake Ontario for PNGS and Lake Erie
pressure cylinder is reheated in the combustor. for NGS condenses the steam exhausted from the turbines.
Each unit of PNGS has an 1800 rpm, tandem-compound The flow rate of cooling water is adjusted so that a specified
impulse-reaction turbine generator containing one double- temperature rise in the cooling water is achieved across the
flow high-pressure cylinder and three double-flow low- condenser.
pressure cylinders. Steam exhausted from the high-pressure
12.6.1.4 Preheating
cylinder passes through a moisture separator and a closed
reheater (which uses steam from the boiler as the heat The temperature and pressure of the feedwater are increased
source). in a series of pumps and heat exchangers (feedwater heaters).
Chapter | 12 Exergy Analysis of Steam Power Plants 275

The overall efficiency of the station is increased by raising the be considered equal. This assumption has a major effect on
temperature of the feedwater to an appropriate level before the exergy efficiencies discussed subsequently. If, as an
heat is added to the cycle in the steam generation section. alternative, fission heat is available at the temperature at
which it is actually produced (i.e., at the thermal neutron
flux-weighted average temperature of about 880 C), the
12.6.2 Approach exergy of the heat is about 75% of the energy.
The analyses and comparisons of NGS and PNGS are per-
formed using a computer code developed by enhancing
a state-of-the-art process simulator, such as Aspen Plus, for 12.6.3 Analysis
exergy analysis. The reference-environment model used by
Gaggioli and Petit (1977) and Rodriguez (1980) is used in the Energy and exergy efficiencies are evaluated as ratios of
evaluation of energy and exergy quantities, but with a refer- products to inputs. For the overall stations, the energy
ence-environment temperature T0 of 15 C (the approximate efficiency h is evaluated as follows:
mean temperature of the lake cooling water). The reference-
Net energy output with electricity
environment pressure P0 is 1 atm, and the chemical compo- h (12.26)
sition consists of air saturated with water vapor and the Energy input
following condensed phases at 15 C and 1 atm: water (H2O), and the exergy efficiency j as
gypsum (CaSO4$2H2O), and limestone (CaCO3). In addition
Net exergy output with electricity
to properties in Aspen Plus databanks, which include steam j (12.27)
properties based on the ASME steam tables, base enthalpy Exergy input
and chemical exergy values reported elsewhere (Rosen and For most of the other plant components and sections,
Dincer, 2003aed) are used. The base enthalpy of a compo- similar expressions are applied to evaluate efficiencies.
nent (at T0 and P0) is evaluated from the enthalpies of the Efficiencies are not readily defined for the condensers,
stable components of the environment (at T0 and P0). The as the purpose of such devices is to reject waste heat rather
base enthalpy of a fuel is equal to the enthalpy change in than generate a product. However, the merit of the
forming the fuel from the components of the environment (the condensers with respect to the overall plant can be assessed
same environment used in exergy calculations). A compound for comparative purposes by evaluating the net station
that exists as a stable component of the reference environment condenser heat (energy) rejection rate Renergy, where:
is defined to have an enthalpy of zero at T0 and P0.
For simplicity, the net heat produced by the uranium Heat rejected by condenser
Renergy (12.28)
fuel is considered the main energy input to PNGS, and D2O Net electrical energy produced
is modeled as H2O, coal as pure graphite (C), and air as and comparing it to an analogous quantity, the net station
79% nitrogen and 21% oxygen by volume. Also, it is condenser exergy rejection rate Rexergy, where:
assumed that:
Exergy rejected by condenser
l The turbines have isentropic and mechanical efficien- Rexergy (12.29)
Net exergy produced
cies of 80% and 95%, respectively.
l The generators and transformers are each 99% efficient,
and heat losses from their external surfaces occur at
12.6.4 Results
15 C (i.e., T0).
l The input to and output from the nuclear reactor of Simulation and analysis data (including energy and exergy
uranium is a steady-state process. values) are summarized, along with specified data, in Table
l All heat rejected by the moderator cooler is produced in 12.4 for the streams identified in Figure 12.5. Exergy-
the moderator. Ontario Hydro (1985) actually observes for consumption values for the devices are listed, according to
each PNGS unit that, of the 90 MW rejected by the process-diagram sections, in Table 12.6. Figures 12.6 and
moderator cooler, 82 MW is produced in the moderator, 12.7 illustrate the net energy and exergy flows and exergy
2.6 MW is transferred from the fuel channel to the consumptions for the four main process-diagram sections
moderator, and 6.1 MW is produced in other reactor described in the caption of Figure 12.5. The data are
components (1.1 MW in the shield, 0.1 MW in the dump summarized in overall energy and exergy balances in
tank, 2.4 MW in the calandria, and 2.5 MW in the calan- Figure 12.8.
dria tubes) and then transferred to the moderator. Regarding result validity, it is observed that:
It is further assumed that the temperature at which heat can l Simulated stream property values are within 10% of the
be produced by fissioning uranium can theoretically be so values measured at the stations (for properties for which
high that the quantities of energy and exergy of the heat can data are recorded).
276 Exergy

TABLE 12.6 Breakdown by Section and Device of Exergy Consumption Rates (in MW) in Single Units of NGS and PNGS

Section/device NGS PNGS


Steam generation section
Reactor 659.0 969.7

D2O-H2O heat exchanger d 47.4


D2O pump d 1.1
Moderator cooler d 9.0
Total 659.0 Total 1027.2
Power production section
High-pressure turbine(s) 26.4 36.9

Intermediate-pressure turbine(s) 22.3 d


Low-pressure turbine(s) 59.2 79.7
Generator 5.3 5.5
Transformer 5.3 5.5
Moisture separator d 0.2
Closed steam reheater d 15.0

Total 118.5 Total 142.8


Condensation section
Condenser 43.1 24.7
Total 43.1 Total 24.7
Preheat section
Low-pressure heat exchangers 10.7 1.6

De-aerating heat exchanger 5.1 1.8


High-pressure heat exchangers 6.4 16.4
Hot well pumps 0.1 0.04
Heater condensate pumps 0.03
Boiler feed pumps 1.1 0.43
Total 23.4 Total 20.8

General Total 844.0 General Total 1215.5

l Energy and exergy values and efficiencies for the analyses are not significantly affected by reasonable and
overall processes and for process subsections are in realistic variations in the choice of reference-environment
broad agreement with the literature for similar properties.
processes.
l Exergy-analysis results for PNGS and NGS are rela-
tively insensitive to the composition of the reference
12.6.5 Discussion
environment.
12.6.5.1 Overall Process Efficiencies
On the last point, it is noted that the exergies of only the
coal and stack gas depend on the choice of the chemical Overall energy (h) and exergy efficiency (j) values are
composition of the environment, and that, for most elec- evaluated for the overall processes using Equations 12.8
trical generating stations, the results of energy and exergy and 12.10, respectively.
Chapter | 12 Exergy Analysis of Steam Power Plants 277

(a) Flue gas Qr (b) Qr


10 Qr
74 10
90
P.P. 524 P.P. 545
P P
2163
1780
449 775
480 1125
S.G.
C. S.G. C.

0 14
Air P
487 476
26
P. P. 4
1368 1763
Coal Qr Q
13 746 5 Qr 1107
P P
FIGURE 12.6 Simplified process diagrams for single units of (a) NGS and (b) PNGS, indicating net energy flow rates (MW) for streams. Stream widths
are proportional to energy flow rates. Sections of stations shown are steam generation (S.G.), power production (P.P.), condensation (C.), and preheating
(P.). Streams shown are electrical power (P), heat input (Q), and heat rejected (Qr).

For NGS, where coal is the only input source of energy and
or exergy,
545  19 MW
524  13 MW j 100% 30%
h 100% 37% 1763 MW
1368 MW
and Ontario Power Generation (1985) reports h 29.5% for
PNGS. Although for each station the energy and exergy
524  13 MW
j 100% 36% efficiencies are similar, these efficiencies differ markedly
1427 MW
for many station sections.
The small difference in the efficiencies is due to the fact
that the specific chemical exergy of coal is slightly greater
than its specific base enthalpy. 12.6.5.2 Efficiencies and Losses in Steam
For PNGS, where fission heat is treated as the only input Generators
source of energy and exergy,
Exergy consumptions in the steam generation sections of
545  19 MW the stations are substantial, accounting for 659 MW (or
h 100% 30%
1763 MW 72%) of the 916 MW total exergy losses for NGS and

(a) Flue gas Qr (b) Qr Qr


62 0 2 0
P.P. P.P.
P P
838 118 844 142 545
524

142 54 113 44

C. C.
43 23
S.G.
S. S.G.
S
0 659 14 1027

Air P
132 0 96 P. 0
P.
1763 22
1427 23
Coal Q
21
13 11 5
Qr
P Qr P

FIGURE 12.7 Simplified process diagrams for single units of (a) NGS and (b) PNGS, indicating net exergy flow rates for streams and consumption rates
(negative values) for devices. Stream widths are proportional to exergy flow rates and shaded regions to exergy consumption rates. All values are in MW.
Other details are as in Figure 12.6.
278 Exergy

FIGURE 12.8 Overall energy and


exergy balances for single units of (a)
(a) Exergy in Exergy out
Energy in Energy out
NGS and (b) PNGS. The left and right & consumed
halves of the energy balances represent, Stack gas + Qr
respectively, energy inputs and energy (5%)
outputs. The left and right halves of the
exergy balances represent, respectively, Power Power
exergy inputs and exergy outputs and (37%) (36%)
consumptions (exploded section of
balance). Cooling water and air inputs Coal Coal
are not shown because they contain zero (100%) (100%)
energy and exergy. The PNGS reactor Rejected heat
represents only the fission reactor, not (Qr) Reactor
(56%) (46%)
all devices in the steam generation
section.

Stack gas (6%)


Losses (1%) Other (13%)

(b) Energy in Energy out Exergy in Exergy out


& consumed
Qr
(1%)

Power Power
(30%) (30%)

Fission heat
Fission heat (100%)
(100%)
Rejected heat
(Qr) Reactor
(69%) (55%)

Losses (1%) Other (14%)

1027 MW (or 83%) of the 1237 MW total exergy losses for pellets to the cladding surface (at 304 C), and trans-
PNGS. ferring the heat from the cladding surface to the primary
Of the 659 MW of exergy consumed in this section for coolant and then to the preheated boiler feedwater to
NGS, 444 MW is due to combustion and 215 MW to heat produce steam.
transfer. The energy and exergy efficiencies for the generation
Of the 1027 MW of exergy consumed in this section section, considering the increase in energy or exergy of the
for PNGS, 47 MW is consumed in the boiler, 9 MW in water as the product, for NGS are:
the moderator cooler, 1 MW in the heavy-water pump,
and 970 MW in the reactor. The exergy consumptions in 1585  847 1494  1299MW
h 100%
the reactor can be broken down further by hypothetically 1368 MW
breaking down into steps the processes occurring within 95%
it (Figure 12.9): heating of the moderator, heating of the
and
fuel pellets (to their maximum temperature of approxi-
mately 2000 C), transferring the heat within the fuel
719  132 616  497MW
pellets to the surface of the pellets (at approximately j 100% 49%
1427 MW
400 C), transferring the heat from the surface of the fuel
Chapter | 12 Exergy Analysis of Steam Power Plants 279

9548
Transfer of (2984)
Heating of Transfer of
fuel pellets Q (T ~ 2000 C) Q (T ~ 400 C) heat to Q (T ~ 300 C) Heating of
heat to
to Tmax cladding D2O
Spent 1673 1673 pellet surface 1673 1673
( 218) sufrace ( 99)
(1673) (1455) ( 499) (956) (881)
fuel ( 75) PHT fluid
(D2O)
7875
Heat (2202)
generation Q (T ~ )
via 1763
fission (1763)

207
Nuclear (16)
fuel 90
(90) Heating of
moderator
( 79)
Moderator
(D2O)
117
(5)
FIGURE 12.9 Breakdown of the energy and exergy losses in the nuclear reactor of one PNGS unit. Material streams are represented by solid lines and
heat flows by broken lines. The heavy solid line encloses the part of the nuclear reactor considered in the present analysis. Exergy (in parentheses) and
energy flow rates are indicated for streams, and exergy consumption rates (negative values in parentheses) for devices. Flows of heat Q at points in the
reactor at different values of temperature T are shown. All values are in MW. PHT, denotes primary heat transport.

and for PNGS are: l Since D2O is modeled as H2O, the chemical exergy of
D2O is neglected. Neglecting the chemical exergy of
2267  64  476MW D2O does not significantly affect the exergy analysis
h 100% 95%
1763 14MW results here because, since the D2O is contained in the
closed PHTL of the steam generation section and used
862  18  96MW
j 100% 42% only as a heat-transfer medium, it is only the physical
1763 14MW exergy of the D2O stream that is of interest.
The steam generation sections of NGS and PNGS appear
significantly more efficient on an energy basis than on an 12.6.5.3 Losses in Steam Condensers
exergy basis. Physically, this discrepancy implies that
In the condensers:
although 95% of the input energy is transferred to the
preheated water, the energy is degraded as it is transferred. l A large quantity of energy enters (775 MW for each
Exergy analysis highlights this degradation. NGS unit and 1125 MW for each PNGS unit), of which
Two further points regarding PNGS are noted: close to 100% is rejected
l A small quantity of exergy enters (54 MW for each NGS
l The step in which heat is generated by fissioning
unit and 44 MW for each PNGS unit), of which 25% to
uranium (also shown for completeness in Figure 12.9)
50% is rejected and 50 to 75% is internally consumed.
is, by previous assumption, outside the boundary of the
nuclear reactor considered here. The energy and exergy Thus, energy-analysis results lead to the erroneous conclu-
efficiencies calculated for PNGS could be significantly sion that almost all losses in electricity-generation potential
different if this step was considered. In this case, the for NGS and PNGS are associated with the heat rejected by
energy and exergy of the fresh and spent nuclear fuel the condensers, while exergy analyses demonstrate quanti-
would be required. The question of what are the exer- tatively and directly that the condensers are responsible for
gies of nuclear fuels is not completely resolved. little of these losses (Figure 12.8). This discrepancy arises
Researchers usually only deal with the heat delivered by because heat is rejected by the condensers at a temperature
nuclear fuels, and most argue that the exergy of nuclear- very near that of the environment.
derived heat is equal or nearly equal to the exergy The characteristics of condensers can be seen more clearly
because the heat can potentially be produced at very by considering the net station condenser heat (energy)
high temperatures. rejection rate Renergy, and the net station condenser exergy
280 Exergy

rejection rate Rexergy. Following the expressions for these without the need for a transport step in NGS. Also, most
quantities in Equations 12.28 and 12.29, respectively, it can be heat transfer in the steam generator of the coal-fired
shown for each coal-fired unit that: station occurs from a gas to a solid, whereas the more
746 MW efficient liquid-to-solid heat transfer predominates in
Renergy 1:46 the nuclear station.
524  13 MW
l Thermal neutrons are absorbed and moderated for
and necessary operating and control processes in PNGS.
11 MW This process, which is somewhat analogous to wasting
Rexergy 0:0215 fuel, is not present in the coal-fired station.
524  13 MW
l The potential of the used form of the fuel (spent
and for each nuclear unit that: uranium for PNGS and combustion gases for NGS) is
1107 MW much greater for the nuclear station, where the spent
Renergy 2:10 fuel is highly radioactive and releases significant
545  19 MW
quantities of thermal energy for many years. These
and factors impact the exergy- and energy-related perfor-
21 MW mances of the stations, and should be taken into account
Rexergy 0:0399 in efforts to improve efficiencies.
545  19 MW
The R values indicate that the exergy rejected by the In comparing the thermodynamic characteristics of coal-
condensers is less than 4% of the net exergy produced, fired and nuclear electrical generating stations, several
while the energy rejected is approximately 150% to 200% illuminating insights into the performance of such stations
of the net energy produced. have been acquired. First, although energy and exergy effi-
ciencies are the same for PNGS and similar for NGS, energy
analyses do not systematically identify the location and
12.6.5.4 Miscellaneous Losses
cause of process inefficiencies, and exergy analyses do. That
In the power production and preheating sections of the NGS is, energy losses are associated with emissions (mainly heat
and PNGS units, energy losses were found to be very small rejected by condensers) and exergy losses are associated
(less than 10 MW total), and exergy losses were found to be primarily with consumptions (mainly in the reactors) and
moderately small (100 to 150 MW in the power production little with cooling water and stack gases. Second, since
section and 20 to 25 MW in the preheating section). The devices with the largest thermodynamic losses have the
exergy losses are almost completely associated with largest margins for efficiency improvement, efforts to
internal consumptions. increase the efficiencies of coal-fired and nuclear electrical
generating stations should focus on the combustion and
12.6.5.5 Environmental Impact nuclear reactors, respectively. For instance, technologies
and Sustainability capable of producing electricity without combustion
(e.g., fuel cells) or utilizing heat at high temperatures could
The environmental and sustainability insights gained increase efficiencies significantly. This comment is, of
through the use of exergy analysis are described for NGS in course, overly simplistic, as such decisions require consid-
Section 4.4 of this book. eration of other technical and economic factors, in addition
to efficiency. Third, the use of heat rejected by condensers
only increases the exergy efficiencies by a few percent.
12.6.6 Comparison and Summary
Cogeneration systems, which produce heat at useful
The thermodynamic behavior of the coal-fired and nuclear temperatures at the expense of reduced electrical output, can
generating stations considered are similar in all areas, have greater efficiencies than conventional electrical
except the steam generation sections. Those differences generating stations, but the merit of cogeneration systems
significantly affect the efficiencies, losses, and performance must be determined using exergy analyses because energy
in these sections. Some of the differences are as follows: analyses tend to overstate performance.
l The temperatures associated with heat generation are
constrained to lower values for PNGS than NGS, 12.7 IMPROVING STEAM POWER PLANT
leading to lower efficiencies for the nuclear station.
EFFICIENCY
l The heat-generation and heat-transfer mechanisms vary
greatly between the stations. For PNGS, heat is gener- Electrical generating utilities usually strive to improve the
ated in the calandria and transported to the steam efficiency (or heat rate) at their existing thermal electric
generator, while heat is generated in the steam generator generating stations, many of which are over 25 years old
Chapter | 12 Exergy Analysis of Steam Power Plants 281

and mature. Often, a heat rate improvement of only a few l An alternative thermodynamic approach to designing
percent appears to be desired as it is thought that the costs steam power plants has been suggested, and the use of
and complexity of such measures may be more manageable pinch technology in steam power plant design has
than more expensive options (Rosen and Dincer, 2003aed). been studied.
At other times, major efficiency improvements are sought.
Exergy can play an important role in developing strategies
Exergy methods are helpful in all cases.
and in providing guidelines for more effective use of energy in
Modifications to increase the efficiency of thermal
the existing steam power plants. Exergy analysis also helps in
electrical power generation often strive to carry out one or
improving plant efficiency by determining the origin of
more of the following:
exergy losses, and hence providing a clearer picture. Exergy
l Increase the average temperature at which heat is helps identify components where high inefficiencies occur,
transferred to the working fluid in the steam generator and where improvements are merited. The thermodynamic
l Decrease the average temperature at which heat is cycle can often be optimized by minimizing the irreversibil-
rejected from the working fluid in the condenser ities. At full load of the cycle, the steam temperature and
l Reduce component inefficiencies and losses pressure of the boiler should be at their upper limits. However,
l Improve the integration of process flows so that would- at off-design loads, the temperature and pressure should be
be wastes are utilized, where possible decreased. An exergy evaluation of a supercritical steam
turbine showed that high exergy losses occur in the heat
Many methods and technologies have been reported in the
recovery steam generator and in the steam turbine. Another
literature for improving power-plant efficiency or reducing
exergy analysis led to a great reduction in power cost. Orig-
irreversibilities.
inally, in a power plant facility, 77 MW of fuel and 2.2 MW of
In this section, some of the more significant thermo-
power were needed. After improvement by exergy analysis,
dynamic methods to improve the efficiency of electricity
the fuel consumption was cut down to a value between 45 to
generating steam power plants (particularly coal-based) are
60 MW (Gaggioli et al., 1991).
surveyed and examined. We focus on minor practical
improvements, which can be undertaken with limited effort
and cost. 12.7.2 Computer-Aided Design, Analysis,
Also possible are improvements of a longer term and and Optimization
broader nature. These include replacing combustors with
gasifiers and fuel cells, developing technologies capable of Many efforts to improve coal-fired steam power plants by
utilizing heat at increased temperatures, raising significant providing computer-aided tools for simulation, analysis,
metallurgical temperature limits, and integrating processes and optimization have been reported. Some of these efforts
so that the wastes from one process become the feeds to have focused on processes using Rankine cycles as part or
another. all of a power plant, and have not integrated exergy
concepts. Other works have directed the computer tool at
12.7.1 Exergy-Related Techniques addressing exergy considerations or at ensuring a focus on
exergy, which is a central thrust. Such computer tools can
To assist in improving the efficiencies of coal-to-electricity aid in developing and evaluating potential improvement
technologies, energy analysis is normally used. A better measures.
understanding is attained when a more complete thermody-
namic view is taken via exergy methods. Through the better
understanding developed with exergy analysis, the efficien- 12.7.3 Maintenance and Control
cies of devices and processes can usually be improved, often
Numerous measures related to maintenance and controls
cost-effectively. Consequently, exergy analysis is particularly
are possible to reduce losses. These include: (1) reducing
useful for: (1) designing better new facilities and (2) retro-
leaks of steam, gas, air, and other substances in lines,
fitting or modifying existing facilities to improve them. The
valves, joints, and devices; (2) utilizing improved and
latter use is the focus of the present section. Some examples of
more automated controllers, both to ensure design spec-
how exergy methods can provide meaningful insights that can
ifications are adhered to and to detect parameter varia-
assist in increasing efficiency and achieving optimal designs
tions, which may indicate future problems; (3) improved
for thermal power plants are detailed below:
maintenance to ensure minor breaks are repaired and
l Exergy-based costing and thermoeconomic analysis actual operating parameters match design specifications,
have been investigated and applied. for example, minor modifications to the reheat steam
l A means of evaluating thermal power plants using an temperature in a thermal power plant can be implemented
alternative second law-based efficiency measure based on to improve overall efficiency; and (4) periodic overhauls
a modified coefficient of performance has been proposed. of devices.
282 Exergy

12.7.4 Steam Generator Improvements absorption in the lower furnace and decrease superheater
attemperation spray flows. Fluidized bed combustion
Steam generator efficiency has a significant effect on (FBC) also leads to heat transfer improvement. In FBC,
overall plant efficiency. The main energy processes within crushed coal particles are injected in a bed of fine inert
the steam generator are combustion and heat transfer. particles (e.g., sand, ash, limestone) fluidized by combus-
tion air. Water tubes submerged in this fluidized combus-
12.7.4.1 Combustion-Related Improvements tion zone achieve high rates of heat transfer. FBC also
In the combustion portion of the steam generator, fuel allows for relatively low combustion temperatures
energy is converted to heat at appropriate conditions while (820 Ce870oC) that are well below the ash fusion
minimizing losses from combustion imperfections. Efficient temperature, so firesides slagging is minimized. The higher
combustion requires temperatures sufficiently high to ignite efficiencies for FBC compared with normal combustion are
the constituents, mixing to provide good oxygenefuel in large part due to the high volumetric heat release rates
contact, and sufficient time to complete the process. For and high heat transfer coefficients in the combustion zone.
practical applications, more than the theoretical amount of However, as the flame temperature tends to increase with
air is needed for near complete combustion. However, load, the exergy-efficiency difference between FBC and
excess air increases the quantity of stack gases and the normal combustion decreases as load increases (Rosen and
associated waste emission. Also, irreversibility occurs Dincer, 2003aed).
during combustion even when it is complete and without Increasing the average temperature at which heat is
excess air because the chemical reaction, which the fuel and added to the power cycle by increasing the steam generator
air undergo, is irreversible due to the uncontrolled electron operating pressure normally raises cycle energy efficiency.
exchange between the reacting components. However, this measure can increase moisture content and
One means of improving combustion efficiency thus turbine blade erosion in the last turbine stages.
involves the coal feeding system. For example, the aero- Increasing the average temperature at which heat is
dynamic separation of coal particles in coal stoker-fired added to the power cycle by superheating causes the net
boilers creates a more porous coal layer that is distributed work output, the heat input, and the energy efficiency to
onto a traveling fire grate, which can result in a 2%e4% increase, while decreasing steam moisture content at the
increase in combustion efficiency by reducing incomplete turbine exit. However, superheat temperatures are con-
combustion and the losses from coal powder penetration strained by metallurgical temperature limits and other
through the grate. One recently designed coal grate has factors.
a bottom section with a comb shape that is adjustable, so
that the depth of the furrows in the coal layer formed on the 12.7.4.3 Other Steam Generator Improvements
grate can be easily changed. This device can result in Some other steam generator-related efficiency-improve-
a 2%e4% increase in combustion efficiency through ment measures are worth considering: (1) the amount of
changes in the distribution of primary and secondary air, excess air supplied to the combustor can be reduced to
restrictions in the usage of excess combustion air, and decrease the exergy losses with stack gases and (2) heat can
reductions in the losses from incomplete combustion be recovered from the spent combustion gases, before they
(Rosen and Dincer, 2003aed). exit the flue, to reduce fuel consumption.
Combustion losses may also be reduced by improving Other research efforts related to the steam generator
combustion efficiency, usually through minor adjustments focus on understanding the exergy losses in the combustion
to the combustion chamber and related devices. Larger process, burner retrofits, improving the steam generator and
reductions in combustion losses are likely attainable if the heat recovery devices within it, and improving steam
metallurgical temperature limits for materials used in traps.
the processes are improved so that high temperatures
are permitted in the combustion chamber and related
devices. 12.7.5 Condenser Improvements
Lowering condenser operating pressure lowers the
12.7.4.2 Heat Transfer-Related Improvements
temperature of the steam within the condenser and thus the
Several methods are used in industry for improving heat temperature at which heat is rejected from the plant.
transfer inside a steam generator. Soot blowers can be used However, there is a lower limit on the condenser pressure
to keep heat exchanger surfaces in steam generators clean corresponding to the temperature of the cooling medium
and thus to achieve increased efficiencies through improved needed for effective heat transfer. Also, lowering the
heat transfer effectiveness. Specifically, coal flow dampers condenser pressure can cause such problems as air leakage
and soot blowers can reduce slagging to improve heat into the condenser, as well as decreased turbine efficiency
Chapter | 12 Exergy Analysis of Steam Power Plants 283

and increased turbine blade erosion due to increased simple and inexpensive and have good heat transfer char-
moisture content in the steam in the last turbine stages. acteristics. Closed feedwater heaters are more complex due
to their internal piping, and have less effective heat transfer
than open heaters since the two streams do not come into
12.7.6 Reheating Improvements direct contact. The irreversible losses associated with heat
Reheating can affect overall plant energy efficiency and the transfer and other system processes are greater for closed
average temperature at which heat is added to the steam heat exchangers, since the extracted steam for each heater
generator. However, exergy destruction in the steam is throttled to the corresponding pressure for each low-
generator, which usually accounts for more than half of the pressure heater (for details, see Rosen and Dincer, 2003).
exergy destruction in the power plant, is only affected in Incorporating heat regeneration in a steam power plant
a limited way by reheat pressures. Heat rate can be increases the energy efficiency mainly by reducing the
improved through reheating, depending on the respective irreversible losses in the steam generator. As the number of
final feed temperature for either single or double reheat feedwater heaters increases, the percentage improvement
cycles. Increasing reheat temperature reduces leakage and provided by each additional heater decreases. It is reported
blading losses and increases cycle available energy. (Rosen and Dincer, 2003aed) that the energy-related
Some report that the most economical gain occurs when optimum distribution for n feedwater heaters occurs when
the peak reheat temperature is no more than 30 K above the the total feedwater enthalpy rise experienced by feedwater
saturated temperature corresponding to the steam pressure is divided evenly among the heaters, and that the optimum
of the high-pressure turbine exhaust, but that the influence of ratio of ultimate feedwater enthalpy rise to total enthalpy
reheat pressure on cycle performance is not great. The rise is approximately given by:
maximum improvement in energy efficiency and irrevers- hB  hn =hB  h0 n 11 (12.30)
ible losses for single-reheat cycles appear to be attained
when reheat pressures are about 19% of steam generator where h denotes the specific enthalpy of feedwater, and the
pressure. When a second-reheat stage is incorporated with subscripts B, n, and 0, respectively, denote the saturated
a pressure ratio of approximately five between the first and liquid state corresponding to the boiler pressure, the
second reheat stages, the energy efficiency and irreversible optimal feedwater condition, and the saturated liquid state
losses can be further improved. The optimum value of this corresponding to the condenser pressure.
pressure ratio is affected by reheat temperature, number of The optimum number of feedwater heaters is usually
reheat stages, and feedwater configuration. Improvements in determined from economic considerations, as the use of an
plant exergy efficiency with increased reheat pressure are additional feedwater heater is normally justifiable when the
usually due to improvements in the turbine-cycle unit. When fuel savings it generates are sufficient relative to its cost.
the optimum pressure is set for either the first or second stage Incorporating reheating in a regenerative cycle can
reheat, a wide range of pressures are possible for the other further improve its energy efficiency and the total irrevers-
reheat stage that cause only minimal deviations from the ible losses. These improvements increase at a decreasing
maximum energy efficiency and the minimum total irre- rate as the number of the feedwater heaters increases.
versibility rate. However, there is an upper limit on the first Although reheating and regenerative feedwater heating each
reheat pressure due to boiler feedwater temperature and air lead to efficiency improvements, the improvements are less
heater constraints, and a lower limit on the second reheat when these measures are applied simultaneously than the
pressure due to the possibility of superheated exhaust at part sum of the improvements from applying the measures
load increasing the low-pressure turbine inlet temperature separately. One reason for this observation is that reheating
and leading to temper embrittlement in the low-pressure results in higher extraction steam temperatures and subse-
rotor steel (Silvestri et al., 1992). quently larger temperature differences between the feed-
water and the extraction steam, causing regenerative
12.7.7 Regenerative Feedwater Heating feedwater heating to be less beneficial (Silvestri et al., 1992).
Improvements
Regenerative feedwater heating using bleed steam from the
12.7.8 Improving Other Plant Components
turbines increases energy efficiency by increasing the Measures to improve other plant components using exergy
average temperature at which heat is added to the cycle. analysis have been examined. For example, the use of
The additional work that the bleed steam could have exergy analysis to improve compression and expansion
produced by expanding further in the turbines is foregone. processes has been reported. Also, the optimization of heat
Heat is transferred from the steam to the feedwater exchangers using exergy-based criteria has been carried out
either by mixing the fluids in an open heater or without in general, and specifically for feedwater heaters (Rosen
mixing in a closed heater. Open feedwater heaters are and Dincer, 2003aed).
284 Exergy

Some other practical measures that can reduce the more 12.4 Which component in a steam power plant has the
significant losses in coal-fired electricity generation include greatest exergy destruction? What are the causes and
the following. Heat-transfer losses can be reduced by using how can the exergy destruction be reduced or
smaller heat-exchange temperature differences and more minimized?
efficient heat exchangers. This measure also involves 12.5 Define the exergy efficiency of a steam turbine. Is
ensuring that heat flows of appropriate temperatures are the definition of isentropic efficiency the same as
used to heat cooler flows. Further, expansion-process losses that for the exergy efficiency? Explain. Which effi-
can be reduced by improving the efficiencies of expanders. ciency is typically greater?
This measure may include reducing condenser pressures. 12.6 An engineer performs an exergy analysis of a steam
Also, losses can be reduced by ensuring that no uncon- power plant and determines the exergy efficiencies
strained throttling (which is highly irreversible) occurs. The of the turbine and pump to be 90% and 65%,
use of sliding pressure operations to avoid throttling is one respectively. The engineer claims, based on these
practical example that has significant potential to reduce results, that improving the performance of the pump
exergy losses. will increase the net power output more than
improving the performance of the turbine. Do you
12.8 CLOSING REMARKS agree with the engineer? Explain.
12.7 How can you compare the exergy efficiencies of
Exergy analysis is shown in this chapter to be able to help steam power plants using as fuel (a) coal, (b) natural
understand the performance of steam power plants and gas, (c) oil, and (d) uranium?
identify and design possible efficiency improvements. In 12.8 What are the effects on the exergy efficiency of
addition, exergy methods are useful in assessing which a steam power plant of (a) boiler pressure, (b) boiler
improvements are worthwhile, and should be used along temperature, and (c) condenser pressure? Explain
with other pertinent information to guide efficiency using the exergy destruction concept.
improvement efforts for steam power plants. Of course, 12.9 Compare the exergy efficiencies of steam power
measures to improve efficiency should be weighed against plants and combined cycle plants.
other factors and implemented only where appropriate. 12.10 Identify and describe several methods for increasing
the exergy efficiency of steam power plants.
12.11 Obtain a published article on exergy analysis of
PROBLEMS
steam power plants. Using the operating data
12.1 How are the energy and exergy efficiencies of steam provided in the article, perform a detailed exergy
power plants defined? Which one is typically analysis of the plant and compare your results to
greater than the other? Explain. those in the original article. Also, investigate the
12.2 Explain the difference between the energy and effect of varying important operating parameters on
exergy efficiencies for (a) a geothermal power plant the system exergetic performance.
and (b) a conventional steam power plant. 12.12 Obtain actual operating data from a steam power plant
12.3 Identify the sources of exergy loss in steam power in your area and perform a detailed exergy analysis.
plants and propose methods for reducing or mini- Discuss the results and provide recommendations based
mizing them. on the exergy results for improving the efficiency.

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