Optimize the Operational Parameters through Simulation to Increase the Efficiency of Combined Cycle Power Plants

ABSTRACT 

Electric power generation is one of the important factors for the development of peoples and can take an advantage of energy extraction technology of combined cycle in Sudan, which is highly effective in the States instead of remote power generation and combined cycle power plant also be economically feasible for use in sugar refineries in Sudan. . The purpose of this study is to find the maximum efficiency and minimum cost of power generation in combined cycle power plant by simulate GARRI (1) combined cycle power plant by using ASPEN HYSYS. It aims to conduct a detailed thermodynamic analysis for combined cycle power plant and optimization to attained maximum efficiency by dissertating different scenarios of operating parameters. The study examined the operational side by passing through all the components of the combined cycle power plant and the mechanism of the system. Block 1 in GARRI (1) combined cycle power plant is used. The efficiency obtained from ASPEN HYSYS simulator is 31.89% and that find by mat lab code is 31.42% while the actual of GARRI (1) is 27.4%. The effect of each operating parameter on the efficiency and power output was extracted by using Microsoft excel in form of graphical charts resulted from the thermodynamic analysis done by using ASPEN HYSYS simulator. The maximum efficiency in the optimum operating parameters is about 33.88% by using different scenarios. Reference to the results the Parameters that have a significant impact on the overall efficiency and the power output of the plant and it has and economic effect on the results are the fuel mass flow rate and compressor pressure ratio. The study verified and chooses the values to give optimum efficiency and power output under a minimum cost. Research found that air (ambient/outdoor) temperature has a major impact factor effect on the overall efficiency and net power output.

Table of Contents

Subject Page

Acknowledgements I

Abstract in English II

Abstract in Arabic III

Table of Contents IV

List of Figures IX

List of Tables XII

List of Abbreviations XIV

CHAPTER I

Introduction

1.1 Introduction 1

1.2 Problem Statement 2

1.3 Objectives 2

1.4 Scope of Work: 2

1.5 Research Methodology 3

CHAPTER II

Literature Review & Theoretical Background

2.1 Literature Review 5

2.2 Theoretical Background 6

2.2.1 Preface 6

2.2.2 Gas Turbine Classification 7

2.2.3 Components of Gas Turbine Stations 7

2.2.4 Advantages and Disadvantages 10

2.2.5 Classification of gas turbines 11

2.2.6 Uses of Gas turbines to generate electric power 11

2.2.7 Problems with gas turbines 12

2.2.8 Types of gas turbines used in power plants 13

2.3 Steam cycles 26

2.3.1 Preface 26

2.3.2 Rankine cycle Analysis 27

2.4 Combined cycle 31

2.4.1 Preface 31

2.4.2 Combined cycle power plant advantages 31

2.4.3 Types of combined cycle 32

2.4.4 Electricity market requires power plants to be 35

2.4.5 combined cycle arrangement Systems 35

2.4.6 Thermal efficiency of combined cycle 35

2.4.7 Heating water feeding steam heat exchanger drain 37

CHAPTER III

Garri Combine Cycle Power Plant

3. Preface 38

3.1.1Combined Cycle Principle of Operation 38

3.1.2 Design Configuration 39

3.1.3 Plant Configuration 39

3.1.4 Combined Cycle Power Plant –How it work 40

3.1.5 Operating Scheme of the CCPP 40

3.1.6 Gas Turbine 42

3.1.7 Water/Steam Cycle 47

3.1.8 HRSG and Its Auxiliary System 48

3.2.9 Instrument and Service Compressor Air System 50

3.1.10 Condenser Air Evacuation System 50

3.1.11 HRSG Low Pressure Circulating System 50

3.1.12 LPG Heating Steam System 50

3.1.13 Heat Recovery Steam Generator (HRSG) 51

3.1.14 LPG Fuel 52

3.1.15 Boiler Heating Surfaces Thermodynamic Properties (for Design Condition) 54

3.1.16 Boiler Performance Features 55

3.2 Simulation of Combined Cycle Plant 56

3.2.1 Preface 56

3.2.2 ASPEN HYSYS® Simulation Software 57

3.2.3 Cyclepad Simulation Software 57

3.3 GARRI Station of Sudan Power Plant 58

3.3.1 Actual Data of GARRI Station Process 58

3.4 Simulation of Combined Cycle Power Plant with HYSYS® Simulator 61

3.4.1 Type of Simulation 61

3.4.2 Assumptions 61

3.4.3 Constraints 61

3.4.4 Fluid Packages 61

3.4.5 Components of the Fluid Package 63

3.4.6 Combustion Reaction 63

3.4.7 Input Parameters 64

3.4.8 Results of the Steady-State Simulation with HYSYS 69

3.5 Simulation of Combined Cycle Power Plant with CyclePad Simulator 70

3.5.1 Starting Cyclepad 70

3.5.2 Adding Devices to the Design 70

3.5.3 Analyzing Design 72

3.5.4 Result of Simulation of Combined Cycle Power Plant By Using Cyclepad Software 76

3.6 Comparison Results of the Two Simulated Plants 78

3.7 Mat lab Code for combined Cycle 79

3.7.1 Checking result of Simulations by Mat lab Code 79

3.7.2 Mat-lab program input 79

3.7.3 Mat-lab program Output 80

3.8 Economic analyses for the study 81

CHAPTER IV

Result & Discussions

4.1 Optimization 0f Combined Cycle Power Plant: 82

4.2 Effect of different parameters on plant thermal efficiency: 83

4.3 Result of Optimization: 88

4.4 Economic Analyses & Discussion: 89

CHAPTER V

Conclusion & Recommendations

5.1 Conclusion: 93

5.2 Recommendation 95

CHAPTER VI

References & Appendices

References: 96

Appendices 99