Energy Conversion and Management 106 (2015) 1230–1241

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Energy Conversion and Management

journal homepage: www.elsevier.com/locate/enconman

Energetic and exergetic analysis of a steam turbine power plant

in an existing phosphoric acid factory
Fathia Hafdhi a,⇑, Tahar Khir a, Ali Ben Yahyia b, Ammar Ben Brahim a
a
Applied Thermodynamic Research Unit UR11ES80, National Engineering School of Gabes, Tunisia
b
Tunisian Chemical Group (TCG), B.P. 72, Gabes 6000, Tunisia

a r t i c l e i n f o a b s t r a c t

Article history: An energetic and exergetic analysis is conducted on a Steam Turbine Power Plant of an existing
Received 28 July 2015 Phosphoric Acid Factory. The heat recovery systems used in the different parts of the plant are also con-
Accepted 15 October 2015 sidered in the study. Mass, energy and exergy balances are established on the main compounds of the
Available online 11 November 2015
plant. A numerical code is established using EES software to perform the calculations required for the
thermal and exergy plant analysis considering real variation ranges of the main operating parameters
Keywords: such as pressure, temperature and mass flow rate. The effects of theses parameters on the system perfor-
Energy investigation
mances are investigated.
Exergy analysis
Steam turbine
The main sources of irreversibility are the melters, followed by the heat exchangers, the steam turbine
Phosphoric acid factory generator and the pumps. The maximum energy efficiency is obtained for the blower followed by the
Heat recovery system heat exchangers, the deaerator and the steam turbine generator. The exergy efficiency obtained for the
heat exchanger, the steam turbine generator, the deaerator and the blower are 88%, 74%, 72% and 66%
respectively.
The effects of High Pressure steam temperature and pressure on the steam turbine generator energy
and exergy efficiencies are investigated.
Ó 2015 Elsevier Ltd. All rights reserved.

1. Introduction Energy and exergy analysis may be constituted as a key

methodology for thermal system design and optimization. It is
The phosphate sector is one of the important key vectors for the used to locate and determine the magnitude of irreversibility rates
Tunisian economy balance, both in terms of employment and in occurring in the streams and components of any energy system.
terms of the trade balance. The annual production of Phosphoric Many works were developed on energy and exergy optimiza-
Acid is about 500,000 tonnes. Globally, the Tunisian phosphate tion of industrial plants.
industry occupies the 5th place among the largest international Vučković et al. [1] established an exergy analysis and exergoe-
operators in this activity. Indeed, phosphate and its derivatives conomic investigation of a real industrial plant constituting a part
(phosphoric acid, DAP, TSP, DCP, etc.) are currently exported to of a rubber factory. This plant is used to supply production unites,
about fifty countries in the five continents. While the industry is services and working spaces by steam, compressed air and cooling
very important for the economy, it is considered among the largest and hot water. The exergy efficiency and the exergy destruction
energy consumers. rate of the main components of the plant are determined. The
Many national programs are conducted in Tunisia in the possibilities of plant performance improvement are suggested.
purpose to improve the energy efficiency of the industrial sector, Kaushik et al. [2] presented a review on energy and exergy anal-
especially in the heavy industry factories such as the chemical ysis of thermal power plant. A comparison between thermal power
industry field. plant stimulated by coal and gas was made. For coal based thermal
This study focuses on the analysis of a Steam Turbine Power power plant, obtained results show that the highest energy loss is
Plant with heat recovery systems used in Phosphoric Acid Factory. located in the boiler. While for gas fired combined cycle thermal
power plant the maximum losses are located in the combustion
chamber.
⇑ Corresponding author at: National Engineering School of Gabes, Omar Ibn Ray et al. [3] developed an exergy analysis for proper operating
Khattab Street, 6029 Gabes, Tunisia. and maintenance decisions in a 500 MW steam power plant. The
E-mail address: hafdhi.fathia@gmail.com (F. Hafdhi). study is conducted considering design and off-design conditions

http://dx.doi.org/10.1016/j.enconman.2015.10.044
0196-8904/Ó 2015 Elsevier Ltd. All rights reserved.
 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241 1231

Nomenclature

AC additional condenser Subscripts

Bl blower 0 reference state
cp specific heat at constant pressure (kJ/kg K) CT condenser of turbine
CU concentration phosphoric acid unit D destruction
De deaerator De deaerator
DU distillation unit da dry air
E_ exergy (kW) e energy
h specific enthalpy (kJ/kg) ex exergy
HP high pressure steam Ge gear
LP low pressure steam ha humid air
MP medium pressure steam in inlet
m_ mass flow rate (kg/s) out outlet
PAP unit of phosphoric acid Pm pump
Ph. A phosphoric acid sw seawater
R gas constant (kJ/kmol K) v water vapor
SMM Sulfur melting and maintenance val valve
STGI Steam Turbine Generator I
STGII Steam Turbine Generator II Greek letters
T temperature (°C) e specific exergy (kW/kg)
Tb turbine g efficiency
TC turbine condenser x air humidity ratio

for various values of superheat and reheats sprays. Obtain results cogeneration cycle and using the same fuel mass flow rate.
constitute guide procedures for exergy, economy and maintenance Therefore, different arrangements of recovery and cogeneration
scheduling similar power plants. systems are adopted for the investigated CHP power plants. The
Aljundi [4] performed an exergy and energy analysis of a steam main comparison criteria are based on the power production.
power plant with a capacity of 396 MW. The effect of the reference According to analytic study, the authors confirm that it is possible
environment temperature variation on the exergy analysis of the to improve the efficiency of the existing power of about 8.5% by
consider power plant has been studied. The results showed that using the most efficient prosed CHP system.
the exergy efficiency of the power cycle was about 25%. The rate A comparison between nine coal-fired power plants in Turkey is
of exergy destruction and the exergy efficiency, of each compo- conducted by Erdem et al. [8]. For each plant a calculation model is
nent, changed with reference environment temperature. The main proposed and the mass, energy and exergy balances are estab-
conclusion indicates that the boiler is the major source of irre- lished. That permits to determine the energy and exergy efficiency
versibility in the system. Indeed the exergy destruction in the boi- as well the exergy destruction rate of each component. A compar-
ler system is about 77% of the fuel exergy input. The exergy ison is then accomplished between the considered power plants.
destruction in the turbine, condenser and all heaters and pumps The obtained results may constitute helpful tools for further inves-
are respectively about 13%, 9% and 2%. tigations in the field of energetic and exergetic industrial power
An exergy analysis for thermal power plant is conducted by Hou plant analysis.
et al. [5] using Aspen plus software. The effects of main operating Ghannadzadeh et al. [9] developed a general methodology for
parameters such as combustion exes air coefficient, steam temper- exergy balance in chemical and thermal process integrated in the
ature and pressure and combustion temperature on the exergy effi- ProSimPlus code. In order to fully automate exergy analysis, the
ciency are analyzed. The obtained results reveal that the boiler whole exergy balance of the system is presented under the form
engenders the maximum irreversibility rates followed by the tur- of single software. The essential elements for exergy analysis are
bine. Furthermore the authors suggest that the increase of the provided that can be applied for every process or utility system.
combustion temperature as well as the steam pressure and tem- An energy and exergy investigation of a cement plant was car-
perature leads to improvement of exergy efficiency. ried out by Atmaca et al. [10]. In order to assess the performance of
Regulagadda et al. [6] performed a thermodynamic analysis of a the whole factory and their components, the authors are applied a
subcritical boiler–turbine generator for a 32 MW coal-fired power mass, thermal as well as the exergy balances taking into account
plant. Energy and exergy equation governing the cycle are estab- the variation of operating parameters. A set of performance criteria
lished. A parametric study is conducted for a range of operating are defined in the aim to conduct this analysis.
variables. That permits to define the optimum parameters leading Molés et al. [11] conducted a thermodynamic analysis of a com-
to the best plant performances. The boiler and turbine engender bined organic Rankine cycle and vapor compression cycle system
the maximum exergy destruction rates in the power plant. The using two different fluids with low Global Warming Potentials
identification of the exergy losses in the different cycles has per- GWP for each cycle. System performances are determined for
mitted to develop an environmental impact and sustainability ranges of operating conditions variations. Results show that the
analysis. combined cycle COP varied between 0.30 and 1.10 while the com-
In the purpose to analyze the opportunities to improve the puted electrical COP is varied between 15 and 110. Furthermore,
energy efficiency of existing lignite thermoelectric power plant of for vapor compression system the selection of working fluid does
300 MW, Koroneos et al. [7] was performed a comparative study not affect significantly the thermal and electrical efficiencies.
between the indicated plant and three proposed combined Whereas, for ORC the working fluid has an important effect,
heat and power systems CHP, working according to Rankine especially on electrical efficiency.
1232 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241

Hajabdollahi et al. [12] established a soft computing based An energy and exergy optimization of a drying plant is carried
multi-objective optimization of steam cycle power plant using out by Taner [17] in the purpose to define the optimum energy
Non-dominated Sorting Genetic Algorithm (NSGA-II) and Artificial and exergy efficiencies. Real measurements are accomplished on
Neural Network (ANN). The main cycle parameter at the inlet and the drying plants taking into consideration the different accuracies
outlet of the different components are considered for the optimiza- of the experimental devices. That permits to conduct an exergy
tion design. The maximization of the thermal efficiency and the analysis and defined the optimum mass and thermal values lead-
minimization of the total cost rate are taken as objective function ing to the best system efficiencies. As result of the optimization
is chosen in the purpose to optimize the running conditions of the study, a significant improvement in the energy and exergy efficien-
power plant. Obtain results reveal an increase of the thermal effi- cies of about 41% and 43% respectively are obtained.
ciency of about 3.76% and a decrease of the total cost rate of about Keçebasß et al. [18] carried out a conventional and advanced
3.84%. exergy analysis on a real geothermal power system of 6.35 MW
Keçebasß [13] carried out a thermal, exergo-economic and envi- and located in Denizli, Turkey. The studied system is constituted
ronmental investigation of an existing geothermal district heating by two-level and binary power plant using water for cooling. Real
systems installed in Afyon, Turkey. Based on data collected from operating parameter values are used to accomplish this investiga-
the plant, authors conduct an analysis in order to evaluate the tion. The investigated analysis method has permitted to identify
heating system performance, the energy and exergy efficiencies, the system components that should be improved in the purpose
the specific exergy index as well as the exergy destruction. to enhance the exergy efficiency. The proposed modifications lead
Obtained results show an energy and exergy efficiencies of the to an increase in exergy efficiency of about 18.26%.
overall heating system of about 34.86% and 48.78%, respectively. An energy and exergy analysis of subsea power system working
Authors suggest that the main exergy destruction rates are due according to Rankine cycle is investigated by Yuan et al. [19]. The
to fluid reinjection, losses in heat exchangers and pipe lines, natu- working fluids selected to perform the system analysis are
ral direct discharge and the pump losses. Others advantages of the Water–steam, CO2, C9H2O, C10H22 and C12H26. Simulation results
system are pointed out by authors such as positive effects on the show that the Water–steam gives the best energy and exergy effi-
environment and low investment costs. ciencies as well as high turbine power output. However this sys-
Adibhatla et al. [14] carried out an exergetic analysis of a tem requires higher supply energy. While for CO2 system high
600 MWe coal fired thermal power plant at three operating loads energy and exergy efficiencies are obtained with low energy input,
(100%, 80% and 60%) and under different running conditions: con- but lower turbine power output is produced. Moreover the boiler
stant pressure and at pure sliding pressure operation. The energy, and condenser engender the most important exergy destruction
and exergy efficiencies as well as the exergy destruction rates are rate.
determined for each component of cycles at the indicated condi- Peng et al. [20] carried out an exergy investigation on solar
tions. The highest exergy destruction rate is obtained for the boiler hybrid coal fired power plant of 330 MW. Solar system is used to
followed by the turbine. At constant pressure, the exergy destruc- heating feed water at temperature below 300 °C in the purpose
tion rate in the turbine decreases sensibly when the operating load to substitute the steam extraction from steam turbine. That per-
passes from 100% to 80%. While for the operating loads off 80% and mits to improve the net electrical power generated by the steam
60% the exergy destruction rate is practically the same. For pure turbine. A thermal and economic comparison study is also estab-
sliding pressure operations, the exergy destruction rate in the tur- lished between solar-only and solar-hybrid coal-fired power
bine decreases significantly with the load condition. plants. According to the analysis results lower irreversibility rates
According to an energy and exergy analysis, Edge et al. [15] are are achieved in the solar feed water heater and the steam turbine.
conducted a study on the uncertainty of parameter defining the An enhancement in exergy efficiency and solar energy conversion
power plant performances. The study is performed on a lignite are obtained. Also the hybrid coal-fired power plant seems to be
fired power plant cycle with load conditions varying from 100% economically beneficial than the solar-only thermal power plant.
to 40%. A sensitivity analysis is also carried out in the purpose to Three methods are considered by Memon [21] to conduct an
determine the effect of the main parameter on the overall power analytic study on a combine cycle power plant: exergoeconomic,
uncertainty efficiency. The performed study is based on real mea- thermo-environmental and statistical. The energy, exergy and eco-
surements of the operating parameters by appropriate sensors nomic balances are established. The influence of operating param-
with known accuracies, installed in the different components of eters on the energy and exergy efficiencies, generated power and
the plant. According to obtained result, the accuracy in determin- CO2 emission are analyzed. These performance criteria are corre-
ing the Low Heating Value of the used coal constitutes the main lated according to operating parameters in order to define the opti-
cause of uncertainty. That affects the performance criteria mum values. Exergoeconomic analysis is also developed taking the
determination. maximization of exergy efficiency and the minimization of total
An exergetic and exergoeconomic analysis for solar thermal cost as objective functions. Analytic results show that the optimum
power plant is developed by Elsafi [16]. Two steam power cycles operating conditions giving best cycle performances, suitable eco-
are studied, with and without reheating system. Exergy and nomic balance and minimum gas release are obtained for a Gas
economic balances are established for each component of the Turbine Inlet temperature of 1500 K.
cycle. The obtained results show that the main sources of exergy Exergy analysis of a combined reheat regenerative steam tur-
destruction are the solar field followed by the condenser, the LP bine is performed by Gogoi [22]. The system consists of a based
turbine and the HP turbine. From thermo-economic point of power cycle and a Water-LiBr vapor absorption refrigeration sys-
view and based on the total cost rate, the most expensive tem VARS. Exergetic efficiency and exergy destruction rate in the
component is the solar field followed by the LP turbine, HP different elements of the system are determined as well as the
turbine and the condenser. Authors analyzed the effect of steam whole system energy utilization factor. The influence of the main
reheat degree at the inlet of the LP turbine on the system operating parameters on the system performance is examined.
performances. They observe that an increase in reheat degree Obtained results indicate that the optimum performances are
of about 100 K leads to an increase of 9.1% in vapor fraction at achieved for a boiler pressure of 150 bars. Also the optimum tem-
the turbine outlet and a decrease of 1.5% in energetic and perature values in the each component of VARS are determined.
exergetic efficiencies. Unfortunately an increase in electricity The maximum Exergy destruction rate for the power cycle is
cost of about 2% is obtained. located in the cooling tower followed by the gas stream in the
 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241 1233

boiler outlet and the boiler. While for the VARS the generator rep- connection with the Tunisian Society of Electricity and Gas (STEG)
resents the most important irreversibility followed by the absor- is established in the purpose to ensure a continuous plant
ber, condenser and the evaporator. operation.
An optimization procedure of the multi-step regenerative irre- The schematic diagram flow of the thermal power plant of the
versible Brayton cycle is conducted by Ahmadi et al. [23]. Energetic PAP factory is shown in Fig. 1. This power plant is mainly consti-
analysis coupled with NSGA II algorithm is used in order to opti- tuted by two steam turbine cycles STGI and STGII used to provide
mize the thermal efficiency and the normalized power output of about 14 MW as total net electrical power required for the differ-
the Brayton cycle. Furthermore the decision-making approaches ent units. The required High Pressure steam (HP) mass flow rate
TOPSIS, LINMAP and Fuzzy are used to compare the obtain results at about 40 bars and 410 °C is provided by the Evaporator Boiler
with the real one. Precision analysis is also applied to determine Pre-superheater Superheater group (EBPS).
the deviation from ideal state. The first steam turbine cycle is with extraction and
Sadatsakkak et al. [24] performed thermo-economic optimiza- condensation, while the second one is with back pressure
tion of irreversible regenerative closed Brayton cycle. Ecological turbine. The net electrical power generated by each cycle is
objective function is considered as optimization criteria. An about 7 MW.
equivalent system is defined based on thermodynamic first and Furthermore, to supply the other different units, a quantity of
second laws. Using NSGA-II method developed multi objective HP steam is expanded through expansion valve to obtain Medium
evolutionary approaches are applied to accomplish the analysis. Pressure steam (MP) at 12 bars and 280 °C and Low Pressure steam
Thermo-economic criterion, ecological function and power output (LP) at 6 bars and 230 °C.
are taken into consideration, in the same time, for the optimization In the steam turbine cycle, The HP steam is expanded through
procedure. the steam turbine STG I to reach the Low pressure level at point
Energy and exergy analysis study of a combined cycle power 4 where an appropriate quantity is extracted. The remained LP
plant is carried out by Ganjehkaviri et al. [25]. The combine cycle steam amount is expanded through the last stage of the turbine
is with dual pressure heat recovery steam generator HRSG. Energy, to reach 0.09 bar (point 5). The condensation occurs in the seawa-
exergy and economic balances are defined for the different cycle ter condenser (TC). The obtained liquid is transferred to the storage
components. Optimization is conducted taking into account the tank (CT).
quality of steam turbine outlet. The energy and exergy efficiencies Furthermore sufficient quantities of process water are injected
of the different elements are determined for three values of outlet in points 10 and 13 for steam desuperheating. That permits to
vapor quality. The optimum operating conditions are obtained for decrease the temperatures of MP and LP streams until 190 and
outlet vapor quality of 88%. From economic point of view results 165 °C respectively.
show that the improvement of the steam cycle quality leads to a In the second cycle, about 82 t/h of HP steam is expanded
decrease of the cycle total cost. through the steam turbine STGII. An extraction may be performed
Manesh et al. [26] developed an exergoeconomic and exergoen- optionally at medium pressure MP (point 15) according to working
vironmental analysis on the coupling of a gas fired steam power condition requirements. The remained stream is expanded to reach
plant with a total site utility system. The main purpose of the study the LP level.
is to analyze the incorporation of a steam power plant as an energy The Turbo-blower is supplied by about 12 t/h of HP steam and
supply source for a site utility system. An appropriate method is used to provide the compressed air flow rate required for the sulfur
used to optimize the integration of a steam power plant and a site combustion process. From the Turbo blower the steam is con-
utility effect on the whole plant performances. The obtain results densed in CTb and then transferred to the same storage tank CT.
show that this proposed design is a beneficial way leading to an A Boiler MP is also used as additional energy source when an
enhancement of energy and exergy efficiencies as well as good important quantity of MP steam is required.
environmental impacts. Moreover this integration leads to a The MP and LP streams are used to supply the units (AC, CTb,
decrease of the total annualized cost of the whole system com- CU, De, DU, SMM and TC).
pared with initial base design. The condensate streams issued from all the indicated units are
Taillon et al. [27] proposed new graphs for thermal power plant transferred to the storage tank (CT) and then the deaerator (De). A
exergy efficiency determination. These graphs permit to determine water treatment is then performed in the purpose to supply the
the efficiency ranks compared with the normally obtained values boilers.
for the industrial systems. Temperatures, pressures and mass flow rates are measured in
In the present study an energetic and exergetic analysis is the inlet and outlet of each component by appropriate sensors.
conducted on a thermal power plant installed in an existing The ranges of the operating parameters are indicated on Table 1.
industrial chemical factory. The operating mode of the factory
and the power supply streams are presented. Mass, thermal
3. System analysis
and exergy balances are established on the main compounds. A
code is established in the purpose to perform all calculations
Energy and exergy analysis of power plant are conducted con-
required for the exergetic analysis. The effects of the operating
sidering the following assumptions [28]:
parameter variations on the power plant performance are
analyzed.
– All process are assumed as steady-state and steady flow.
– The kinetic, potential and chemical exergy are neglected.
2. System description
– The dead state was considered as P0 = 1.013 bar and
T0 = 293.15 K.
The Phosphoric Acid Plant (PAP) is one of the important indus-
– No chemical reaction is occurred in the different processes.
trial factories owned by the Tunisian Chemical Group (GCT) and
installed in the industrial area of Gabes (South East – Tunisia).
The plant is intended for the production of Phosphoric Acid. The 3.1. Mass and energy balances
mean daily production is about 1500 t/day. For the operating of
the different units, the PAP plant consumes a meaningful electrical Energy analysis is based on the first law of thermodynamics,
power generated by two steam turbine power plants. Moreover a which is related to the conservation of energy [29].
1234 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241

45 Coupling with PAP

EBPS

HP Steam 1 2

14 b 3
8 6 WTb
11
44 Bl
Boiler MP STG II Tb STG I

15 9 4
17 a 5
16 12 7
10
LP Steam
13
MP Steam
18 19 24’ 24 27
21
36 33
38 37 h SMM d/f CTb AC TC
ST DU CU 35 34 32
g c/e
Y 20 26 Y Y
28 29
23 22 25’ 25 P2
30 P7 P3 P1
P4
42 P6
De
P9
CT 31
43 41
P8
39
40 P5 To PAP 3 Sea water

EBPS: Evaporator_Boiler_Pre-superheater_Superheater, STGI/II: Steam Turbine Generator I/II, Tb: Turbine, SMM: Sulfur Melting and
Maintenance, CTb:Turbo-blower Condenser, DU: Distillation Unit, CU: Concentration Unit, TC: Turbine Condenser, CT: Condensate Tank,

De: Deaerator, AC: Additional Condenser, Bl: Blower, ST: Storage Tank

Fig. 1. Schematic flow diagram of steam turbine power plant.

X X
Table 1 X_ heat  W
_ ¼ _ out eout 
m _ in ein þ E_ D
m ð3Þ
Operating parameter ranges.

Operating parameters Range/value where the exergy transferred by heat is given by : X_ heat
HP steam temperature 385–400 °C X 
T0 _
HP steam pressure 37–39 bar ¼ 1 Q ð4Þ
MP steam temperature 187–190 °C
T
MP steam pressure 11.5–12 bar
LP steam temperature 165 °C and the specific exergy is showed as : ei
LP steam pressure 5.7–6 bar ¼ ðhi  h0 Þ  T 0 ðsi  s0 Þ ð5Þ
HP steam mass flow rate 179 t/h
MP steam mass flow rate 18 t/h Then the governing equations including energy and exergy bal-
LP steam mass flow rate 135 t/h
Seawater temperature 15–32 °C
ances for each component of the cycle showed in Fig. 1 are
Seawater salinity 0.039 kg/kg expressed as follows:
Total Net power generated 14 MW
(a) HP steam production

For an open system the mass and energy balances are given by The HP steam used in thermal power plant of phosphoric acid
X X factory is provided from the Evaporator Boiler Preheater and
_ in ¼
m _ out
m ð1Þ Superheater unit (EBPS). A connection with HP steam network of
other factory is provided.
X X
Q_  W
_ ¼ _ out hout 
m _ in hin
m ð2Þ From EBPS unit

Energy supply : Q_ EBPS ¼ m

_ 1 ðh1  h45 Þ ð6Þ
3.2. Energy and exergy analysis
Exergy flux : E_ EBPS ¼ m
_ 1 e1 ð7Þ
The exergy of a system is the maximum work obtainable as Coupling with PAP III
the system comes to equilibrium with the surroundings. Exergy
Energy supply : Q_ cp ¼ m
_ 2 h2 ð8Þ
analysis predicts the thermodynamic performance of an energy
system and the efficiency of the system components by accurately
quantifying the entropy generation of the components [30]. It Exergy flux : E_ cp ¼ m
_ 2 e2 ð9Þ
permits to identify the causes, locations and magnitudes of (b) Steam Turbine Generator I (STGI) [4,8]
inefficiencies process [31]. Energy balance : _ STGI ¼ m
W _ 3 ðh3  h4 Þ þ ðm
_ 3m
_ 4 Þðh4  h5 Þ
For an open system and taking into account the indicated
assumptions, the exergetic balance can be expressed as flow: ð10Þ
 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241 1235

_ STGI ¼ m
Exergy balance : W _ 3 ðe3  e4 Þ þ ðm _ 4 Þðe4  e5 Þ  E_ D;STGI
_ 3 m (e) Turbo-blower
ð11Þ The turbo-blower is used to supply the drying tower by ambient
air. This group is constituted by steam turbine, Gear and blower as
presented in Fig. 2. The steam turbine converts the thermal energy
Exergy destruction : E_ D;STGI ¼ m
_ 3 ðe3  e4 Þþðm _ STGI
_ 4 Þðe4  e5 Þ W
_ 3 m
to mechanical torque used to drive the gear and then the blower
ð12Þ shaft. The steam at the turbine outlet is transferred into the seawa-
ter condenser. Energy and exergy balance in each component of
_
W the turbo-blower can be expressed as follows.
Energy efficiency : ge;STGI ¼ _ STGI
_ 4 h4  m
_ 5 h5
ð13Þ
m3 h3  m Steam Turbinek

Energy balance : _ ST ¼ m
W _ 6 ðh6  h7 Þ ð25Þ
W_ STGI
Exergy efficiency : gex;STGI ¼
_ 3 ðe3  e4 Þ þ ðm_ 3m_ 4 Þðe4  e5 Þ
m _ Tb ¼ m
Exergy balance : W _ 6 ðe6  e7 Þ  E_ D;Tb ð26Þ
ð14Þ
(c) Steam Turbine Generator II (STGII) [4,8] Exergy destruction : E_ D;Tb ¼ m _ Tb
_ 6 ðe6  e7 Þ  W ð27Þ
Energy balance : _ STGII ¼ m
W _ 14 ðh14  h15 Þ þ ðm
_ 14  m
_ 15 Þðh15  h16 Þ
ð15Þ _
W
Energy efficiency : ge;Tb ¼ _ Tb
ð28Þ
m6 ðh6  h7 Þ
_ STGII ¼ m
Exergy balance : W _ 14 ðe14  e15 Þ þ ðm _ 15 Þðe15  e16 Þ  E_ D;STGII
_ 14  m
_
W
ð16Þ Exergy efficiency : gex;Tb ¼ _ Tb
ð29Þ
m6 ðe6  e7 Þ
Exergy destruction : E_ D;STGII ¼ m
_ 14 ðe14  e15 Þ þ ðm _ STGII
_ 15 Þðe15  e16 Þ  W
_ 14  m
Blower
ð17Þ
Energy balance : _ Bl ¼ W
W _ Tb g ¼ m
_ air ðhb  ha Þ ð30Þ
Ge

W_ STGII
Energy efficiency : ge;STGII ¼
_ 15 h15  m
_ 14 h14  m _ 16 h16
ð18Þ Exergy balance : _ Bl ¼ m
W _ air ðea  eb Þ  E_ D;Bl ð31Þ
m

W _ STGII Exergy destruction : E_ D;Bl ¼ m _ Bl

_ air ðea  eb Þ  W ð32Þ
Exergy efficiency : gex;STGII ¼
_ 14 ðe14  e15 Þ þ ðm
m _ 15 Þðe15  e16 Þ
_ 14  m
The humid air at the blower inlet is a mixture of dry air and
ð19Þ water vapor; the total exergy is expressed as [32]:
   
(d) Turbine Condenser (TC) [4,8] T T P
The energy balance of the turbine condenser gives the heat
eha ¼ ðcpda þ xcpv ÞT 0  1  ln þ ð1 þ x
~ Þ Rda T 0 ln
T0 T0 P0
transferred to the cooling fluid and the exergy balance gives the  
1þx ~0 x
~
exergy destruction as: þ Rda T 0 ð1 þ x
~ Þ ln þx ~ ln ð33Þ
1þx ~ x
~0
Energy balance : _ 5 ðh5  h29 Þ þ m
0¼m _ 32 ðh32  h33 Þ  Energy loss
with x
~ ¼ 1:608x.
ð20Þ Through the Turbo-Blower, the humidity ratio is considered as
constant. Consequently the above equation becomes:
Exergy balance : 0¼m _ 32 ðe32  e33 Þ  E_ D;TC
_ 5 ðe5  e29 Þ þ m ð21Þ    
T T P
eha ¼ ðcpda þ xcpv ÞT 0  1  ln þ ð1 þ x
~ Þ Rda T 0 ln ð34Þ
Exergy destruction : E_ D;TC ¼ m
_ 5 ðe5  e29 Þ þ m
_ 32 ðe32  e33 Þ ð22Þ T0 T0 P0

_ ðh (f) Condenser of Turbo-blower [4,8]

m h Þ
Energy efficiency : ge;TC ¼ _32 33 32
ð23Þ Energy balance : _ 7 ðh7  h26 Þ þ m
0¼m _ 35 ðh35  h36 Þ  Energy loss
m5 ðh5  h29 Þ
ð35Þ
_ 32 ðe33  e32 Þ
m
Exergy efficiency : gex;TC ¼
_ 5 ðe5  e29 Þ
ð24Þ
m Exergy balance : 0¼m _ 35 ðe35  e36 Þ  E_ D;CTb
_ 7 ðe7  e26 Þ þ m ð36Þ

Air Outlet Exergy destruction : E_ D;CTb ¼ m

_ 7 ðe7  e26 Þ þ m
_ 35 ðe35  e36 Þ ð37Þ
b HP Steam _ ðh
m h Þ
Energy efficiency : ge;CTb ¼ _35 36 35
ð38Þ
6 m7 ðh7  h26 Þ
WST
Wbl Gear
Steam m_ ðe  e Þ
Blower Turbine Exergy efficiency : gex;CTb ¼ _35 36 35 ð39Þ
m7 ðe7  e26 Þ
a (g) For expansion valve
7
Energy balance : _ 8 h8 ¼ m
m _ 9 h9 ð40Þ
Air Intlet
35
Seawater Intlet Condenser
36 Exergy destruction : E_ D;val ¼m_ 8 ðe8  e9 Þ
Seawater Outlet ð41Þ
_
¼ m8 ½ðh8  h9 Þ  T 0 ðs8  s9 Þ
26
Condensate
(h) Deaerator [12,17]
The condensate streams from the different units are transferred
Fig. 2. Turbo-blower unit. into the deaerator where oxygen O2 is extracted by LP steam
1236 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241

injection. Obtained treated water will be used to feed boiler. acid 28% P2O5 is injected in the circuit through the filter in order
The energy and exergy balances are established according to the to prevent the solid crusts. After that the filtered acid is evacuated
following equations: by circulation pump to the Graphitic Block Heat Exchanger (GBHE)
_ 20 h20 þ m
_ 23 h23 þ m
_ 30 h30 þ m
_ 41 h41  m
_ 42 h42  m
_ 43 h43 where it is heated by LP steam. Both streams, LP steam and phos-
Energy balance : 0 ¼ m
phoric acid, circulate in cross flow through the GBHE as indicated
ð42Þ in Fig. 4. Then the heated acid is evacuated to the boiler operating
under vacuum in the order to reduce the acid evaporation temper-
Exergy balance : E_ D;De ¼ m
_ 20 e20 þ m
_ 23 e23 þ m
_ 30 e30 þ m
_ 41 e41  m
_ 42 e42  m
_ 43 e43
ature. The vacuum in the boiler is created by seawater jet permit-
ð43Þ ting the condensation of steam and gas from the boiler by direct
contact. A concentrate phosphoric acid 54% P2O5 is so obtained in
_ h
m _ h
þm the boiler that leaves gravitationally by overflow to be stored in
Energy efficiency : ge;De ¼ _ 42 42
_ 23 h23 þ m
43 43
_ 30 h30 þ m
_ 41 h41 Þ
ðm20 h20 þ m appropriate tanks.
ð44Þ In the concentration unit the energy supply is only used in the
GBHE. For this study the exegetic analysis is exclusively performed
_ 42 e42 þ m
m _ 43 e43 on the vapor streams. Consequently the energy and exergy bal-
Exergy efficiency : gex;De ¼ _
ðm20 e20 þ m
_ 23 e23 þ m
_ 30 e30 þ m
_ 41 e41 Þ ances are established for the graphitic block heat exchanger as
follows:
ð45Þ
Energy balance : _ 24 ðh24  h25 Þ þ m
0¼m _ c ðhc  hd Þ  Energy loss
In the other hand the amount of LP steam used to feed the
desalination unit (stream 23, Fig. 1) is considered, for the present ð54Þ
study, as useful energy. An extended exergetic analysis of the
desalination unit will be performed in future investigations. Exergy balance : 0¼m _ c ðec  ed Þ  E_ D;GBHE
_ 24 ðe24  e25 Þ  m ð55Þ

(i) Pumps _ ðh  h Þ
m
Energy efficiency : ge;GBHE ¼ _ c d c
ð56Þ
m24 ðh24  h25 Þ
For each pump used in the different units of the steam turbine
power plant, the energy and exergy balances can be expressed as _ ðe  e Þ
m
Exergy efficiency : gex;GBHE ¼ _ c d c ð57Þ
[4,8]: m24 ðe24  e25 Þ
Energy Balance : _ Pm ¼ m
W _ Pm ðhout  hin Þ ð46Þ
4. Results and discussion
Exergy Balance : E_ D;Pm ¼ E_ in  E_ out þ W
_ Pm ð47Þ
The thermal power plant was analyzed for real operating condi-
E_ in  E_ out tions during whole year. The main operating parameters are the
Energy efficiency : ge;Pm ¼ _ Pm
ð48Þ
W turbine supply flow rate, HP steam temperature and pressure. In
the other hand the seawater temperature varies sensibly for the
E_ in  E_ out different seasons in the local region. That may affect the perfor-
Exergy efficiency : gex;Pm ¼ _ Pm
ð49Þ mances of power plant components supplied by seawater. Hence
W
all the indicated parameters will be taken into consideration for
(j) Sulfur melting and maintenance unit (SMM) the following analytic study.
The melting of the Solid Sulfur is occurred in the melter using A numerical code is established using EES software to perform
MP steam as shown in Fig. 3. Obtained liquid is transferred by grav- the calculations required for the thermal and exergy plant analysis.
ity to the pit. After filtration the sulfur liquid is stored and main- The values of the different operating parameters for real working
tained at suitable temperature in an appropriate tank equipped conditions are indicated in Table 2.
by a heating coil. In the other hand, the exergy losses due to drains or leaks are
Melter determined according to mass balances established on the relevant
Energy balance : _ 18 ðh18  h180 Þ þ m
0¼m _ e ðhe  he0 Þ  Energy loss components. These exergy loss rates are indicated in the bottom of
Table 2.
ð50Þ
The Exergy destruction rates of the different power plant com-
ponents, determined for real operating conditions are presented in
Exergy balance : 0¼m _ g ðeg  eg0 Þ  E_ D;Ml
_ 18 ðe18  e180 Þ þ m ð51Þ Fig. 5. The minimum irreversibility rates are obtained for the con-
Storage tank densers (0.5 MW), the deaerators (0.4 MW) and the blower
(1.5 MW) followed by the pumps and steam turbines. The heat
_ 19 ðh19  h190 Þ þ m
Energy balance : ð0 ¼ m _ P  Energy loss
_ h ðhg00  hh Þ þ W exchangers present an irreversibility rate of about 5 MW. The max-
ð52Þ imum of irreversibility rates is obtained for the melters due to the
important heat losses during open melting process.
Exergy balance : _ 15 ðe15  e150 Þ þ m
0¼m _ P  E_ D;St
_ d ðec00  ed Þ þ W The energy and exergy efficiencies are shown in Fig. 6. The max-
su
imum energy efficiency is obtained for the blower (98%) followed
ð53Þ
by the heat exchangers (97%), the turbine (93%), the deaerators I
(k) Phosphoric acid Concentration Unit (CU) and II (94–92%), and Steam Turbine Generators II and I (87–74%).
This unit is used to obtain phosphoric acid with 54% P2O5 from The minimum energy efficiencies are obtained for the melters
the phosphoric acid with 28% P2O5 by evaporation. The main com- (30%) and the condensers (57–68%). The exergy efficiency obtained
ponents of this unit are: boiler, condenser, heat exchanger and bas- for the heat exchanger, the STGII, the deaerator II and the blower,
ket filter. are 88%, 74%, 72% and 66% respectively. The minimum exergy effi-
The acid loop (Boiler, Filter and GBHE) is initially filled by phos- ciencies are obtained for the melters (28%) and the condensers
phoric acid 54% P2O5. Then an adequate quantity of phosphoric (24–27%).
 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241 1237

MP Steam 18
18’
Steam condensate

Filter
19 BP Steam
Solid Sulfur 19’
g
Steam condensate
g’
Melter Pit
g'’
Liquid sulfur

Storage Tank
h

Fig. 3. Sulfur melting and maintenance unit.

Seawater

Gas & Steam

Boiler

Condenser
Direct
Ph. A 54% P2O5
Ph. A 54% P2O5
d

24 Basket filter
GBHE

25
LP Steam Condensate Ph. A 28% P2O5 To sewers

Pump

Fig. 4. Diagram flow of Phosphoric Acid concentration unit.

The variation of the power generated by the steam turbine gen- For the back pressure steam turbine STGII, the variation of the
erator STGI according to HP steam mass flow rate is presented in exergetic efficiency power according to HP steam mass flow rate
Fig. 7 for different value of condensate rate. The extraction mass is presented in Fig. 10. The exergetic efficiency increases sensibly
flow rate in STGI (see point 4, Fig. 1) is defined according to oper- with mHP to reach a maximum value of about 75.5% for a mass flow
ating conditions required for the desired production rates. That rate of about 73 t/h. That can be considered as an optimum value
affects the generated net power of the turbine. In fact, the gener- for the STGII supply.
ated power increases gradually with HP steam mass flow rate. Fig. 11 illustrates the variations of steam turbine generator
For HP steam mass flow rate less than 35 t/h, the generated power energetic and exergetic efficiencies according to HP steam temper-
is relatively low and is not significantly affected by the condensate ature. The efficiencies increase linearly with THP. For a rise of 30 °C,
rate especially for 8, 12 and 20 t/h. While for HP steam flow rate the energy efficiency increases of about 2% for STGI and 8.8% for
above 40 t/h the condensate rate affects sensibly the generated STGII. The exergy efficiency is also enhanced of about 1.61% for
power. Indeed, in this range, increasing the condensate rate leads STGI and 8.3% for STGII.
to the enhancement of the net generated power. A maximum net The effects of HP steam pressure on steam turbine generator
power of about 6 MW is obtained for 20 t/h of condensate mass energetic and exergetic efficiencies are presented in Fig. 12. For
flow rate. the explored High pressure range, the energy efficiency increases
For the back pressure steam turbine STGII, the variation of the of about 2.1% for STGI and 8.9% for STGII. While an improvement
generated power according to HP steam mass flow rate is pre- in exergy efficiency of about 2.4% and 7.5% are obtained for STGI
sented in Fig. 8. The generated power increases linearly to achieve and STGII respectively.
about 7 MW for a mass flow rate of about 82 t/h. According to above results, one can see that for the variation
The total power generated by the two Steam turbines is widely ranges of THP and PHP, practically the same increase of the energy
sufficient for the power plant requirements. The generated power efficiency is obtained for the two steam turbine generators. While
over than the plant supplies is transferred to the national electric- the exergy efficiencies of STGI and STGII are slightly affected by the
ity network. variations of HP steam temperature and pressure that agrees with
The variation of the exergetic efficiency of steam turbine STGI the difference in exergy destruction rates between the two steam
according to HP steam flow rate is presented in Fig. 9 for different turbine generators obtained for studied case as showns in Fig. 5.
values of condensate flow rate. The exergy efficiency increases As result of exergy efficiency increase, the irreversibility rates
with m _ HP to reach maximum values of about 49%, 51%, 52% and through the steam turbine generators decrease with THP as shown
54% for condensation flow rates of 8, 12, 18 and 20 t/h respectively. in Fig. 13. The irreversibility rate of STGII is more affected by THP
The optimum m _ HP values leading to the indicated maximum exergy increase. These results can be explained by the fact that irre-
efficiencies are respectively 55, 46, 52 and 54 t/h. versibility decrease with temperature rise.
1238 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241

Table 2
Thermodynamic and exergetic data of different streams for real operating conditions.

Stream Mass flow rate (kg/s) Temperature (°C) Pressure (bar) Enthalpy (kJ/kg) Entropy (kJ/kg K) Exergy (kW)
No. Material
1 Steam 34.17 397 38 3210 6.786 40,699
2 Steam 15.55 389 39.65 3188 6.734 18,426
3 Steam 18.05 386 37.5 3185 6.754 21,226
4 Steam 12.5 220 5.64 2895 7.086 9031
5 Steam 5.55 43 0.09 2338 7.422 720.07
6 Steam 3.33 392 37.7 3199 6.772 3946
7 Steam 3.33 50 0.12 2542 7.937 601.9
8 Steam 0.84 386 37.5 3185 6.754 979.7
9 Steam 0.84 350 5.8 3166 7.562 763.1
10 Water 1.39 27 6 113.7 0.395 0.7334
11 Steam 3.34 392 37.7 3199 6.772 3946
12 Steam 3.34 360 12 3186 7.579 3104
13 Water 1.66 27 12.5 114.3 0.395 1.966
14 Steam 22.77 392 37.7 3199 6.772 26,967
15 Steam 0 0 0 0 0 0
16 Steam 22.77 250 5.7 2958 7.206 18,536
17 Steam N.O. N.O. N.O. N.O. N.O. N.O.
18 Steam 3.88 190 12 2790 6.534 3920
19 Steam 3.34 165 5.7 2773 6.281 3015.35
20 Water 7.22 99 1 417.4 1.302 168.8
21 Steam 1.39 165 5.7 2773 6.281 1654
22 Water 8.34 54 3 226.1 0.7543 48.72
23 Water 5 49 2.8 205.2 0.6901 34.15
24a Steam 6.95 120 1.1 2715 7.42 3542
240 Steam 7.78 121 1.2 2716 7.383 4041
25a Water 6.95 97 0.92 406.2 1.272 219.1
250 Water 7.78 96 0.9 402 1.261 239.1
26 Water 3.33 40 0.08 167.4 0.5719 4.906
27 Steam N. O. N. O. N. O. N. O. N. O. N. O.
28 Water N. O. N. O. N. O. N. O. N. O. N. O.
29 Water 5.55 41 0.08 171.6 0.5852 9.35
30 Steam 1.95 165 5.7 2773 6.819 1447
31 Water 521.41 27 1.013 113.2 0.3951 14,162
32 Water 341.91 29 2.7 121.7 0.4228 171,100
33 Water 341.91 33 1.5 138.3 0.4777 171,100
34 Water 341.91 33 1.5 138.3 0.4777 171,100
35 Water 151.01 29 2.7 121.7 0.4228 42,526
36 Water 151.01 37 1.5 155 0.5318 159,782
37 Water 28.49 29 2.7 121.7 0.4228 8024
38 Water 21.37 50 1.5 209.3 0.703 91.64
39 Water 38.33 97 1.5 406.3 1.272 1212
40 Water 6.95 99 4 415 1.295 233
41 Water 31.38 99 4 415 1.295 1052
42 Steam 0.55 104 1.1 2683 7.336 278
43 Water 45.55 104 1.2 435.7 1.350 1178
44 Water N. O. N. O. N. O. N. O. N. O. N. O.
45 Water 37.5 104 75 443.5 1.351 1697
a Air 66.92 27 1.013 67.26 5.842 5.27
b Air 66.92 61 1.331 245.9 6.331 1048
ca Phosphoric Acid L.I 478.5 73 3.2 100 0.311 3482
da Phosphoric Acid L.I 478.5 82 0.3 119.3 0.366 4849
ea Phosphoric Acid L.II 739 72 3.3 97.88 0.304 5165
fa Phosphoric Acid L.II 739 81 0.4 117.1 0.359 7232
g Sulfur Solid 5.59 27 1.013 1.346 0.001 108,064
h Sulfur Liquid 5.59 155 1.013 179.19 0.0014 29,983
Losses
Stream Mass flow rate (kg/s) Exergy losses (MW)
HP steam 1.39 1654.65
MP steam 1.11 940.1
LP steam 1.39 14.97
a
Two heat exchangers, two melters.

Fig. 14 depicts the variation of the condenser exergy Tsw to reach maximum values of about 35% and 45% for the
efficiency according to seawater temperature. It can be seen turbine condenser and the turbo-blower condenser respectively.
that increasing the seawater temperature from 12 to 24 °C leads Although the indicated rise of the exergetic efficiency the
to an increase of the exergy efficiency of about 4 times for the obtained values are very low especially in cold seasons when
turbo blower condenser and 14 times for the turbine condenser. the seawater temperature is less than 15 °C. These results agree
For Tsw above 25 °C the exergy efficiency increases slightly with with Aljundi investigations [4] on energy and exergy analysis of
 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241 1239

Power (MW)
6

3
40 45 50 55 60 65 70 75 80 85
mHP (t/h)

Fig. 8. Variation of STGII net power with HP steam flow rate.

Fig. 5. Exergy destruction rates of thermal power plant components.

0,6

0,5
η S TGI

0,4
20 t/h
18 t/h
12 t/h
0,3 8 t/h

0,2
20 25 30 35 40 45 50 55 60 65 70
mHP (t/h)

Fig. 9. Variation of exergetic efficiency of steam turbine STG I according to HP

Fig. 6. Energetic and exergetic efficiency of main components. steam flow rate.

7 0,8
6,5 20 t/h
18 t/h
6
12 t/h
5,5 8 t/h 0,76
5
Power (MW)

4,5
η S TGII

0,72
4
3,5
3
0,68
2,5
2
1,5
0,64
1 40 45 50 55 60 65 70 75 80 85
20 25 30 35 40 45 50 55 60 65 70
m HP (t/h) mHP (t/h)

Fig. 10. Variation of exergy efficiency of STGII according to HP steam flow rate.
Fig. 7. Variation of STGI net power with HP steam flow rate.

a steam power plant. In fact the authors obtained the same between the two streams decreases, therefore the irreversibility
values of condenser exergy efficiency in similar operating condi- rate due to temperature gradient IDT decreases. That improves
tions. Indeed if the Tsw increases the temperature difference significantly the exergetic efficiency.
1240 F. Hafdhi et al. / Energy Conversion and Management 106 (2015) 1230–1241

0,95 0,5

0,9 ηe,STG II
0,4 ηcdTb
0,85

0,8 ηex,STG II

Condenser
0,3 ηcdT
Turbine

0,75
ηe,STG I
0,2
η

0,7

η
0,65 ηex,STG I
0,1
0,6

0,55 0
375 380 385 390 395 400 405 410 415 10 15 20 25 30 35
THP (°C) Tsw (°C)

Fig. 11. Energetic and exergetic efficiency variations according to THP. Fig. 14. Variation of exergy efficiency of condensers according to seawater
temperature.

balances are established on the main compounds of the factory.

0,95
The effects of the key operating parameters such as seawater
ηe,STG II
0,9
temperature, and mass flow rate on the cycle performances are
investigated. The obtained results can be presented as follows.
0,85 For the explored ranges of HP steam temperature and pressure,
the same increase of the energy efficiency is obtained for the two
ηex,STG II
Turbine

0,8 steam turbine generators. While the exergy efficiencies of STGI

and STGII are slightly affected by THP and PHP variations. About
0,75 steam mass flow rate effect, obtained results show that for STGI
η

ηe,STG I
and considering condensation mass flow rates of 8, 12, 18 and
0,7
20 t/h, the optimum HP steam folw rate values leading to the
0,65
maximum exergy effeciencies are respectively, 55, 46, 52 and
ηex,STG I
54 t/h. While for STGII a maximum exergetic efficiency of about
0,6 _ HP of 73 t/h.
75.5% is obtained for m
36 37 38 39 40 41 42 The seawater temperature affects significantly the exergy effi-
PHP (°C) ciency of the condensers. That should by taking into consideration
for the operating condition in cold seasons.
Fig. 12. Energetic and exergetic efficiency variations according to PHP. The obtain results constitute helpful tools to analyze the real
performances of industrial plants and permit to better undertake
the future perfections that can be carried out on the different
streams in order to improve the efficiency and reduce the energetic
4500 losses.
IrSTGI
4000
Acknowledgments
IrTurbine (kW)

3500
This work is conducted with cooperation of Tunisian Chemical
3000 Group. The authors would like to thank the collaborators for their
support and the interest given to this work.
2500 IrSTGII

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