May 2018 Semester

CCB 4323 : Energy and Process Utility Engineering

Lecturers : Dr. Shuhaimi Mahadzir

Lecture Time : Wednesday 8:00 – 10:00 pm

: Thursday 11:00 am – 1:00 pm

Venue : 04-02-02

Dr. Shuhaimi Mahadzir

Lecture 7: Heat and Power Utilities

Dr. Shuhaimi Mahadzir

Usage of Steam:

Definition:

What is NOT steam.

Steam is water in gas phase.

Colorless and not visible.

Steam is formed when water is heated over its boiling point at specific pressure.
(419 kJ of energy needed to convert 1 kg water into steam at 1 atm)

Dr. Shuhaimi Mahadzir

Usage of Steam:

Process requirement for steam

• Indirect process heating (heaters)

• Live steam injection (for direct process heating)

• Vacuum ejectors

• Agent for stripping in separation process

• Diluent in reactors (to reduce partial pressure)

• Flare atomization

• Power generations (steam turbines)

Dr. Shuhaimi Mahadzir

Usage of Steam:

Vacuum Ejector Flare Atomization

Atomizer schematic
Dr. Shuhaimi Mahadzir
Steam Network

Steam for Process Heating and as Prime Movers

 Steam normally distributed at several pressure levels (LS, MS, HS, HHS).

 Steam condition usually saturated, T(P), i.e. each pressure has a

corresponding saturated temperature.

 Letdown valves control the steam header pressure (with BFW injection for de-
superheating)

 Maximum steam header distribution at 40 bar – Why? Check critical point.

 Heat losses in steam distribution system can be ~ 10% - 20% of fuel.

 Lowest point of steam header usually fitted with steam traps.

Dr. Shuhaimi Mahadzir

Steam Network

Typical Steam Network

Dr. Shuhaimi Mahadzir

Steam Network

Cogeneration Network

Dr. Shuhaimi Mahadzir

Steam Network

Boiler Designs

 Lancashire boiler

Horizontal, Stationary,
Fire tube, Internally fired,
Low Pressure

 Stirling boiler

Vertical, Stationary,
Water tube,
Externally fired,
Low pressure

Dr. Shuhaimi Mahadzir

Steam Network

Steam Traps - Installation

 Traps intervals on a steam line about 30 to 50 meter apart.

 Install traps upstream of Pressure Reducing Valves and Control Valves

 At the Bottom of Vertical Lifts or Drops

Dr. Shuhaimi Mahadzir

Steam Network

Steam Traps

 Need steam traps to allow condensate (water) to pass out but prevent steam
from leaving the system

 Typical steam trap operations

 Mechanical
Bucket
 Thermostatic
 Thermodynamic

Free
moving
Disc
Question:
What is the problem
Metal disc of having condensate
(liquid) in steam line?

Dr. Shuhaimi Mahadzir

Steam Network

Furnace/Boiler Efficiency

Qprocess
hboiler =
Qfuel

CP (TTFT – Tstack)
=
CP (TTFT – To)

(TTFT – Tstack)
=
(TTFT – To)

Dr. Shuhaimi Mahadzir

Example:

Liquid hydrocarbon fuel is fed with air into a burner and generates 150 kW of heat for a
steam boiler. Boiler feed water (BFW) at a flow rate of 130 kg/h and temperature 150 oC is
supplied to the boiler, which generates steam at 40 bar,450 oC.
Determine the efficiency of the boiler.

Solution :

Qprocess = DH =hsteam – hBFW

From the Steam Table:

hsteam (40 bar, 450oC) = 3378 kJ/kg (note that steam produced at superheated level)
hBFW (150oC) = 632 kJ/kg (note that BFW is liquid)
Qprocess = DH = 2746 kJ/kg = 99.2 kW

Qfuel = 150 kW fuel

h = Qprocess / Qfuel = 66%

Dr. Shuhaimi Mahadzir

Example:

A fuel gas comprising pure methane is burned with 15% excess air inside a furnace. Both
fuel and air is at 25oC and 1 atm. The air is wet having a relative humidity of 60%.
Determine the efficiency of the furnace if the stack temperature is 100 oC.

Solution :

Find the composition of fuel and air inlet into the furnace:

Fuel is pure methane, CH4.

Air is 21 mol% O2, 79 mol% N2, and some H2O.

At 25oC (298K), saturated water vapor pressure = 0.002832 MPa = 0.032 bar
Partial pressure of H2O in air, p’H2O = 0.6×0.032 bar = 0.019 bar.
Composition of H2O in wet air at 1 atm, yH2O = 0.019/1.01325 = 0.019 mol H2O/mol air

Dr. Shuhaimi Mahadzir

(solution Contd.)
Basis 1 kmol fuel,
Complete combustion, stoichiometric dry air:
CH4 + 2(O2 + 3.76N2)  CO2 + 2H2O + 7.52N2

With15% excess air, dry:

CH4 + 1.15×2(O2 + 3.76N2)  CO2 + 2H2O + 0.3O2 + 8.65N2

With15% excess air, wet:

CH4 + 2.3(O2 + 3.76N2 + mH2O)  CO2 + 2H2O + (2.3m)H2O + 0.3O2 + 8.65N2
kmol mol frac.
O2 2.3 Combine O2+N2 makes 0.981 mol/mol air
N2 8.65
H2O m 0.019 mol/mol air

Solving for m = 0.019 × 11.16 kmol = 0.21 kmol H2O in wet air.

Dr. Shuhaimi Mahadzir

(solution Contd.)
Basis 1 kmol fuel,
CH4 + 2.3O2 + 8.65N2 + 0.21H2O  CO2 + 2H2O + 0.21H2O + 0.3O2 + 8.65N2

Both the fuel and wet air enter the burner at 25oC so that DHinlet = 0.
DHoC = -889,000 kJ/kmol.
1 kmol CO2
2.21 kmol H2O
The outlet composition (combustion product) is:
0.30 kmol O2
8.65 kmol N2
1st Guess Toutlet = TFT = 2000oC
Dhoutlet = {[1×54.85] + [2.21×43.67] + [0.3×35.27] + [8.65×33.47]} × [TFT – 25]
= 451.5 × [TFT – 25]

Solving Energy Balance: –889000 + 451.5 × [TFT – 25] = 0

TFT = 1993oC (Accept the TFT value)

Dr. Shuhaimi Mahadzir

(solution Contd.)
Furnace Efficiency:
TFT = 1993oC
Tstack = 100oC
To = 25oC
For 1 kmol fuel
Qfuel = 451.5 × (1993-25) = 888,552 kJ
Qprocess = 451.5 × (1993-100) = 854,690 kJ

h =
96.2%

Dr. Shuhaimi Mahadzir

Steam Network

Gas Turbines

A heat engine that gives propulsive power to generate electricity in a power plant
or power to an aircraft.

6
5

3
1 2

There are 6 main components of a GT system:

(1) intake, (2) fan, (3) compressor, (4) burner, (5) turbine and (6) exhaust
Dr. Shuhaimi Mahadzir
 Steam Network

Gas Turbines
COMPONENTS/PROCESSES:
DENERGY
1
INLET: 0 – 2 2 V0 2
COMPRESSOR: 2 – 3
4 COMBUSTOR: 3 – 4 DhCOMPRESSOR
COMPRESSOR
TURBINE: 4 – 5 qADDED
3 MAX AVAIL
OUTPUT POWER: 5 – AMB
DhCOMPRESSOR*

5
DhEXPANSION
2
T

Dr. Shuhaimi Mahadzir

Steam Network

Open Cycle

Consider a steady flow, isentropic process

W=∆H
Taking air as ideal gas with constant Cp

W = ∆ H = CpDT

Compressor work (1)  (2): W12 = h2 – h1 = Cp(T2 –T1)

Turbine work (3)  (4): W34 = h3 – h4 = Cp(T3 –T4)

Heat input (2)  (3): Q23 = h3 – h2 = Cp(T3 –T2) ISENTROPIC

Dr. Shuhaimi Mahadzir

Steam Network

Open Cycle

2’

4’

REAL PROCESS

Dr. Shuhaimi Mahadzir

Steam Network

Isentropic compression and expansion,

(T2) (T3) (g – 1)/g (g – 1)/g

(P2)
= = = r
(T1) (T4) (P1)

where r = pressure ratio P2/P1, g = Cp/Cv = constant

For a simple cycle (e.g. Bryanton Cycle, air only), thermal efficiency:

hth =
Wnet Qin – Qout Cp (T4 – T1)
= = 1-
Qin Qin Cp (T3 – T2) …………Equation (1)

Can you derive 1 (g – 1)/g

=1-
Eq.(2) starting r …………Equation (2)
from Eq.(1)?
Dr. Shuhaimi Mahadzir
Example:

A simple gas turbine cycle operates with a pressure ratio P 2/P1 = 10:1. The temperature
of the air entering the compressor is 30oC and the maximum permissible temperature in
the turbine is 760oC. Calculate the efficiency of the simple gas turbine cycle for g = 1.4.

Solution :

1 (g – 1)/g
hT = 1 -
r

(0.4/1.4)
1
=1- = 0.482 or 48.2%
10

Dr. Shuhaimi Mahadzir

Example:

Suppose both the compressor and turbine in the previous example operate adiabatically

at 85% efficiencies. Determine the thermal efficiency of the power plant.

Solution :
Thermal efficiency of the power plant 2’
2
Workturbine - Workcompressor
hth =
Heat Input
1
Calculate compressor work,
For Isentropic compression, T2/T1 = (P2/P1)(g-1)/g
T2 = 303(10)(0.4/1.4) = 585 K

Also, from compressor efficiency, (585 – 303)/(T2’ – 303) = 0.85

Therefore, T2’ = 635 K

And Compressor Work = Cp(635-303) = 332Cp kJ/kg

Dr. Shuhaimi Mahadzir
(solution Contd.)
3
Calculate turbine work,
For Isentropic expansion, T3/T4 = (P2/P1)(g-1)/g = (10)(0.4/1.4) = 1.93
T4 = (760+273.15)/1.93 = 535 K
4’
4
Also, from turbine efficiency, (1033 – T4’)/(1033– 535) = 0.85
Therefore, T4’ = 610 K and Wturbine = Cp(1033 – 610) = 423Cp
Qin 3

Wnet = 423Cp - 332Cp 2’

Qin = Cp (T3 – T2) = Cp (1033 – 635) = 398Cp
4’

Finally, Thermal Efficiency = Wnet/Qin = 91Cp/398Cp 1

= 22.9%
The thermal efficiency of a real cycle is much lower than the ideal cycle (~48%)

Dr. Shuhaimi Mahadzir

Steam Network

Steam Turbines

A steam turbine utilize high velocity steam flows through a fixed nozzles to
cause motion of blades that in-turns rotate a shaft. In a typical power plant, the
shaft is connected to a dynamic system that generates electricity.

Dr. Shuhaimi Mahadzir

Steam Network

Types of Steam Turbine

• Condensing
Steam Turbine
• Back-pressure
Steam Turbine

• Extraction
Steam Turbine

Dr. Shuhaimi Mahadzir

Steam Network

Steam Turbines

Mechanism of Steam Turbine

~ 75% Efficiency ~ 85% Efficiency

Dr. Shuhaimi Mahadzir

Steam Network

Steam Turbines

Steam Cycle on TS diagram

Heating
(Phase Change,
Steam Generation, P1 > P 2
Superheating)

Isentropic Expansion
Pumping
(Shaft Work,
Heating
Power Generation)

Condensation
(Phase Change)

Dr. Shuhaimi Mahadzir

Steam Network

Steam Turbines

Steam Cycle on TS diagram

P1 > P 2

Actual Expansion
(nonisentropic)
(Shaft Work,
Power Generation)

Condensation
(Phase Change)

Dr. Shuhaimi Mahadzir

Steam Network

Steam Turbines

Definition of isentropic efficiency

On the H-S diagram

Real Process ∆H H1 – H 2
his = = =
Ideal Process ∆ H’ H1 – H 2’

Dr. Shuhaimi Mahadzir

Steam Network

Steam Turbines

Enthalpy of saturated steam

Saturated steam is a mixture of liquid and vapor (hence saturation)

Define x = quality of steam

(i.e. the dry fraction in saturated steam)

Then enthalpy of saturated steam:

hfg = xhg + (1 – x)hf

It follows that entropy of saturated steam:

sfg = xsg + (1 – x)sf

N.B.:
x = dry fraction
sf = entropy of saturated liquid
sg = entropy of saturated vapor
Dr. Shuhaimi Mahadzir
Example:

A steam turbine operates with inlet steam at 7 bar, 320oC and is expanded to 1 atm.
If the isentropic efficiency is 75%, determine the shaft work generated by 1 kg steam.

Solution :

Consider isentropic expansion Then by interpolation:

= H1 – H2 @ DS = 0 H21.01325 bar, isentropic = 2680.7 kJ/kg

Let real expansion = H1 – H2’

From steam table,
H17 bar, 320C = 3100.1 kJ/kg
∆H H1 – H2’real
S17 bar, 320C = 7.3672 kJ/kg-K his = = = 0.75
∆ His H1 – H2isentropic
At 1 atm = 1.01325 bar,
S21.01325 bar = 7.3672 kJ/kg-K Solve for H2’real = 2785.6 kJ/kg
So that DS = S1 – S2 = 0,
S21.01325 bar(7.3672) > S1 atm, saturated(7.3541), Therefore, Ws = 314.5 kJ
which means exhaust steam not saturated.
Dr. Shuhaimi Mahadzir
Example:

A steam cycle consists of a turbine with a rated capacity of 24 MW, which operates with
inlet steam at 86 bar, 500oC and is exhausted to 0.1 bar.
If the efficiency of the turbine is 75%, determine:
a) the state of the exhaust steam (isentropic),
b) the flow rate of the steam, and
c) the thermal efficiency if the turbine

Solution :
From steam table (by interpolation),
H186 bar, 500C = 3392 kJ/kg
For isentropic expansion
S186 bar, 500C = 6.6868 kJ/kg-K
= H1 – H2 @ DS = 0
From steam table, At 0.1 bar = 10.1325 kPa,
Steam enthalpy at 86 bar, 500oC; S20.1 bar = 6.6868 kJ/kg-K (Isentropic)
Superheated Steam at T = 500oC
S20.1 bar = 8.1461 kJ/kg-K (saturated vapor
Pressure 8 MPa 8.6 MPa 9 MPa
from steam table)
h (kJ/kg) 3399.5 3387.4
S20.1 bar < S0.1 bar, saturated(7.3541),
S (kJ/kgK) 6.7266 6.6603
which means the state of exhaust steam is
saturated. Dr. Shuhaimi Mahadzir
(solution Contd.)

Dry fraction of the saturated steam exhaust can be determined by:

S20.1 bar = xSg + (1 – x)Sf
6.6868 = 8.1461x + (1 – x)0.6512

Solving for dry fraction gives x = 0.980 (98.0% dry steam)

Then enthalpy of saturated steam exhaust,

H20.1 bar = xHg,0.1 bar + (1 – x)Hf,0.1 bar
= 0.98(2584.1) + 0.02(192.5)
= 2536 kJ/kg
DHis = 3392 – 2536 = 856 kJ/kg

Let real expansion = H1 – H2’

H2’actual = 2750 kJ/kg

∆H 3392 – H2’actual
his = = = 0.75
∆ His 856 Therefore, Ws,actual = 642 kJ/kg
Dr. Shuhaimi Mahadzir
(solution Contd.)

To calculate the flowrate of steam, actual power of turbine is required, i.e.,

Ws = 24000 kJ/s = msteam×DH
where DH = 642 kJ/kg

Solving for flow rate of steam gives msteam = 37.4 kg/s or 134.6 t/h steam flowrate

To find the thermal efficiency of the steam cycle,

Energy into the cycle is energy input to raise steam from liquid at 0.1 bar to
superheated steam at 86 bar, 500oC. Then from steam tables

H0.1 bar,f = 192.5 KJ/kg Ein = DH = 3200 kJ/kg

H0.1 bar,g = 2584.1 KJ/kg Eout = DH = 642 kJ/kg
H186 bar, 500C = 3392 kJ/kg
Then, hth = Eout/Ein = 0.20 or 20%

Dr. Shuhaimi Mahadzir

Steam Network

Steam Balance

 To determine fuel consumption / efficiency in boiler

 To account for steam losses

 To size the boiler

 To determine steam quantity needed for a given steam turbine

 To assess potential for steam/power for import / export

 To assess potential for Power import / export

 To size up let down valves and deaerator

 To determine the requirement for boiler feed water (BFW) and fresh water make-up

Dr. Shuhaimi Mahadzir

Example:

Find power generated by extraction of 40 bar, 4400C steam to 10.5 bar steam and
the flow rate of steam from 40 bar, 4400C header to 2 bar header in turbine T1.

Dr. Shuhaimi Mahadzir

Solution :

40 bar, 440oC to 10.5 bar  DHis = 350 kJ/kg (from steam table)

W1 = 350 kJ × 81,100 kg × h × 0.55 = 4.3 MW

kg h 3600 s

Using the isentropic efficiency of 55%, it is possible to find

WT = W1 + W2 = 6 MW

 W2 = 1.7 MW

10.5 bar to 2 bar  DHis = 623 kJ/kg (from steam table)

m2 = 1700 kJ × 1 kg × 1 = 17861 kg/h
s 623 kJ 0.55

Dr. Shuhaimi Mahadzir

Example:

Do a steam balance on the given network below to determine flow rates m 1 to m7.

Utility
Boilers
Process Blowdown 5%
P = 40 bar Blowdown 5% m1
5 t/h
T = 350oC
h = 3094 kJ/kg 15 t/h
Process
Process m2
P = 4 bar 10 t/h Blowdown 5%
T = 150oC
h = 2753 kJ/kg 20 t/h
m3 Vent 5% Process
m4
Deaerator 2683 kJ/kg
m5
T = 105oC
h = 439 kJ/kg m6 m7
Treated Water Condensate Return 70%
T = 25oC T = 80oC
h = 105 kJ/kg h = 336 kJ/kg

Dr. Shuhaimi Mahadzir

Solution :

A guess of m3 = 5 t/h solves the steam balance as follows:

Utility
Boilers
Process Blowdown 5%
P = 40 bar Blowdown 5%
5 t/h 25 t/h
T = 350oC
h = 3094 kJ/kg 15 t/h
Process 15 t/h
Process
P = 4 bar 10 t/h Blowdown 5%
T = 150oC
h = 2753 kJ/kg Vent 20 t/h
Guess m3 = 5 t/h
0.3 t/h Process
Deaerator
42 t/h

Treated Water Condensate Return

9.3 t/h 28 t/h

Dr. Shuhaimi Mahadzir

 (solution Contd.)
Check guess by doing a balance around deaerator:
m3 Vent 5%
m4 You only need
2683 kJ/kg
Deaerator
to solve energy
m5 m7 balance
T = 105oC Condensate Return 70%
h = 439 kJ/kg m6 T = 80oC
h = 336 kJ/kg
Treated Water
T = 25oC
h = 105 kJ/kg

Overall mass balance: Overall energy balance:

m3 + m 6 + m 7 = m 5 + m 4 m6h6 + m7h7 = m5h5 – m3h3 + m4h4

m6h6 + m7h7 = m5h5 – m3h3 + 0.05m3h4

m4 = 0.05m3, so that
m6 = m5 – m7 – 0.95m3 105m6 + 336m7 = 439m5 – m3(2753 – 0.05*2683)
…(1)
105m6 + 336m7 = 439m5 – 2618.8m3
…(2)
Dr. Shuhaimi Mahadzir
(solution Contd.)
Combining equations (1),(2) and solving for m3

m6 = m5 – m7 – 0.95m3
105m6 + 336m7 = 439m5 – 2618.8m3

334m5 – 231m7 334(42) – 231(28)

m3 = = = 3.0 t/h e = 40%
2519 2519

Since the discrepancy between guessed and calculated values of m 3 is large,

need to iterate steam balance calculations until convergence is achieved
(e < 5% is acceptable)

2nd guess, m3 = 3 t/h

Dr. Shuhaimi Mahadzir

(solution Contd.)

A new guess of m3 = 3 t/h solves the steam balance again:

Utility
Boilers
Process Blowdown 5%
P = 40 bar Blowdown 5%
5 t/h 23 t/h
T = 350oC
h = 3094 kJ/kg 15 t/h
Process 13 t/h
Process
P = 4 bar 10 t/h Blowdown 5%
T = 150oC
h = 2753 kJ/kg 3 t/h Vent 20 t/h
0.15 t/h Process
Deaerator
24.2 + 5.3 + 10.5 = 40.0 t/h

Treated Water Condensate Return

10.6 t/h 26.6 t/h

Dr. Shuhaimi Mahadzir

(solution Contd.)
Solving for m3 from mass and energy balance around deaerator
334m5 – 231m7 334(40) – 231(26.6)
m3 = = = 2.9 t/h e = 3.3%
2519 2519

Therefore the steam balance solution is now acceptable.

Dr. Shuhaimi Mahadzir