Steam Generation Unit Research Articles

Analysis of the regional potential and prospects for converting MSW into hydrogen based on TPPS (using the example of the Ural Federal District)

The need to increase the level of municipal solid waste (MSW) utilization, combined with an increased focus on low-carbon energy, leads to an increase in interest in technologies for producing hydrogen from MSW, not only at the industrial level, but also at the state level. The availability of free space and excess generation capacity makes thermal power plants (TPPs) the most suitable objects for introducing such installations. The aim of the study is to analyze the potential and prospects for converting MSW to hydrogen based on TPPs using the example of the Ural Federal District. During the study, an assessment was carried out of the potential volume of hydrogen production and use of MSW, the parameters of a thermal power plant were calculated that could serve as a basis for introducing an MSW hydrogen installation. The expected change in technical and economic indicators of a thermal plant was analyzed, and recommendations were made on the choice of a site. Thus, under the conditions of the Ural Federal District, total hydrogen production can range from 11 to 31 tons per hour. At the same time, production of hydrogen will require water vapor ranging from 63 to 137 tons per hour and cooling water ranging from 32 to 7233 tons per hour. And it will lead to a decrease in electric power from 58 MW to 125 MW (while maintaining the load on steam-generating equipment constant), an increase in conventional fuel consumption from 6 tons per hour to 12 tons (with an increase in load on the steam generator), and an increase of 18 MW thermal capacity of thermal plants to 84 MW when disposing of waste heat generated by the MSW (hydrogen) installation. The expected margin profit change will vary from −32 thousand rubles per hour with a decrease in turbine power and utilization of hydrogen waste heat, or from +29 to −21 thousand rubles with an increase in steam generation unit fuel consumption and use of hydrogen production waste heat.

Energy Performance of Steam Generation Unit with Using Non-Renewable Fossil Fuel Like Imported (Indonesian) Coal at Spectrum Dyes and Chemicals Private Limited, Palsana-Surat

Now a day’s competition to became power fuel nation is increase industrialization and develop various process or methods for Energy sector. Due to increases energy demand with suitable use of Energy is important for any developing nation. The current case study work is an account of Energetic performance of steam generation unit like Boiler in the Spectrum Dyes and Chemicals Private Limited. The capacity of the Boiler for the steam generation 10 T/Hr. (2 Unit) and 6 T/hr. (1 Unit) coal fired boiler supplied by Rajdeep Boiler, Sachin. After completing the whole 1st law analysis of the Boiler plant has been presented The analysis carried out by using first law for a particular steam generation unit. There are useful assumption is required to analysis during calculations which is introduced in these performance calculations. Microsoft Excel is used for computer programs are developed for performance calculation energetic analysis of a steam generation plant. The PIE chart is graphical represent to energy flow in the system and the losses in the various components during normal operating condition have been identified. The analysis shows that the 1st law efficiency of Boiler Plant with solid Imported (Indonesian) coal fired boiler is 81.43%.

Effect of steam quality on the oil recovery factor of the Karazhanbas field

Background: The injection of the thermal agent as "steam" reduces the viscosity of the oil and the mobility ratio, which increases the displacement and coverage factor, and ultimately significantly increases the oil recovery factor. This statement was the basis for determining the effect of steam enthalpy on the oil recovery factor, as well as for reliably determining the flow rate of flared gas, as a result of which the existing gas pipeline will be reconstructed, the required amount of fresh water will be calculated, and the distribution of steam pumping in the entire Karazhanbas field.
 Aim: The purpose of the article is to consider the influence of the quality of steam produced at the steam generator units of the Karazhanbas field on the oil recovery factor. The main parameter that determines the quality of steam is dryness, which was calculated using the actual values of the boiler (pressure, temperature, gas flow), flue gas tests on a special device, as well as laboratory tests to determine the heat value of the combusted gas.
 Materials and methods: This work used materials from GHM (geological and hydrodynamic modeling), results of studies of boiler flue gases and heat balance.
 Results: The calculation showed a low quality of the produced steam, which negatively affects the recovery factor.
 Conclusion: Evaluation to determine the optimal value of saturated steam parameters (steam dryness, temperature in terms of development efficiency) showed that the higher the temperature and dryness of steam at the wellhead and bottom hole of the injection well, the higher the oil recovery factor at the Karazhanbas field.

Conceptual Design of Experimental Test Rig for Research on Thermo-Flow Processes During Direct Contact Condensation in the Two-Phase Spray-Ejector Condenser

Abstract The paper presents the conceptual design of a prototype experimental facility for mixing jet-type flow condensers investigations when the steam in exhaust gases is condensed on the water jet in the presence of CO2. The proposed experimental test rig was designed to give abilities to investigate the effectiveness of jet condensers experimentally as part of the CO2 capture phase and especially to investigate Spray-Ejector Condensers (SEC) developed as the combination of ejector and condenser devices. The paper presents the design and key features of the prototype installation components. The basic design was developed based on the simulation results, and for this purpose, model of installation, including characteristics of individual components, was built. The developed model helps to evaluate the main performances of the conceptual test rig and supports the test-rig design process. The main components and the features of the steam generation unit, CO2 supply and mixing with steam, process water preparation, and H2O and CO2 separation subsystem are discussed. The measuring system was designed to test the efficiency of compression and condensation processes of the SEC fed by the CO2/H2O gas mixture. The performances of the two-phase jet condensers can be analyzed by experimental investigation and calculation of heat transferred to the cooling water during direct contact condensation with the presence of CO2. The paper presents the results of heat flowrates and their uncertainties for the selected period of the experimental test, confirming the application of the novel developed test rig.

Machine learning-assisted tri-objective optimization inspired by grey wolf behavior of an enhanced SOFC-based system for power and freshwater production

In recent years paying attention to the generation of clean and sustainable power and fresh water along with having lower cost and emission has increased. In the present research, a novel scheme for generating efficient power using the flame-assisted fuel cell is introduced, which has higher efficiency than ordinary fuel cells due to increased hydrogen concentration in the flame-rich combustion chamber. The waste heat is then introduced to a multi-effect desalination unit through a heat recovery steam generation unit to generate fresh, drinkable water. In order to make the system have higher efficiency, lower cost, and lower emission, the machine learning techniques are applied to optimize the operational conditions of the system, and find out the best solution point based on the cutting-edge algorithm of the grey wolf. Also, a complete techno-economic analysis and a parametric study are necessary to figure out the best solution point based on the TOPSIS method. The results indicate that the maximum value of exergy efficiency and drinkable water generation is 67.5% and 3.4 kg/s, respectively, while the minimum energy cost is 90.1 $/MWh. Moreover, results show that for the second optimization scenario considering the drinkable water production, energy cost, and pollution index as the objectives, the net produced power, energy efficiency, exergy efficiency, and water mass flowrate improve by around 1059 kW, 5.1%, 1.3%, and 1.6 kg/s than the design condition. Besides, energy cost and emission index are reduced by about 22 $/MWh and 51.9 kg/MWh, respectively.

Performance of hydrogen and power co-generation system based on chemical looping hydrogen generation of coal

An integrated hydrogen and power co-generation system based on slurry-feed coal gasification and chemical looping hydrogen generation (CLH) was proposed with Shenhua coal as fuel and Fe 2 O 3 /MgAl 2 O 4 as an oxygen carrier. The sensitivity analyses of the main units of the system were carried out respectively to optimize the parameters. The syngas can be converted completely in the fuel reactor, and both of the fuel reactor and steam reactor can maintain heat balance. The purity of hydrogen produced after water condensation is 100%. The energy and exergy analyses of the proposed system were studied. Pinch technology was adopted to get a reasonable design of the heat transfer network, and it is found pinch point appears at the hot side temperature of 224.7 °C. At the given status of the proposed system, the hydrogen yield is 1040.11 kg·h −1 and the CO 2 capture rate is 94.56%. At the same time, its energy and exergy efficiencies are 46.21% and 47.22%, respectively. According to exergy analysis, the degree of exergy destruction is ranked. The gasifier unit has the most serious exergy destruction, followed by chemical looping hydrogen generation unit and the heat recovery steam generator unit. • A hydrogen and power co-generation system is proposed and simulated. • Slurry-coal gasification is integrated with chemical looping hydrogen and combined cycle. • Assessing hydrogen production based on chemical looping conversion of fossil fuels. • Pure hydrogen can be achieved with high carbon capture efficiency through process integration.

Development of Maintenance Management Strategy Based on Reliability Centered Maintenance for Marginal Oilfield Production Facilities

The present work adopted Reliability Centered Maintenance (RCM) methodology to evaluate marginal oilfield Early Production Facility (EPF) system to properly understand its functional failures and to develop an efficient maintenance strategy for the system. The outcome of the RCM conducted for a typical EPF within the Niger Delta zone of Nigeria provides an indication of equipment whose failure can significantly affect operations at the production facility. These include the steam generation unit and the wellhead choke assembly, using a risk-based failure Criticality Analysis. Failure Mode and Effect Analysis (FMEA) was conducted for the identified critical equipment on a component basis. Each component of the equipment was analyzed to identify the failure modes, causes and the effect of the failure. The outcome of the FMEA analysis aided the development of a robust maintenance management strategy, which is based on an optimized mix of corrective, preventive and condition-based monitoring maintenance for the marginal oilfield EPF.

Design and development of solar hybrid distillation system for essential oil extraction from turmeric

The present study was conducted to design and develop the solar hybrid essential oil extraction system from turmeric at Department of Processing and Food Engineering, PAU, Ludhiana, Punjab. The developed system has six solar parabolic trough concentrator, steam generation unit, steam distillation unit, condensing unit and essential oil separator. A prototype of solar hybrid essential oil extraction system of 10 kg was designed and developed. The volume of steam distillation unit was 0.061m3 and volume of steam generation was 0.057 m3. The essential oil was extracted by using three turmeric grates size that is, 14.50 mm, 15.620 mm and 17.53 mm size. The smallest particle size (14.50 mm) having the highest essential oil yield (45 ml/kg) obtained from turmeric grates (P2, L42). The developed system was supplied additional 2 kW energy to extract oil from the turmeric grates. The results obtained from the study indicated that smallest grates size (14.50 mm) has the highest oil yield as compared to the largest grates size (17.53 mm). The steam generation and steam distillation unit has efficiency of 60 and 55.17%, respectively while the condensing unit having the efficiency of the 47.22%. The solar parabolic trough concentrators ensured energy saving of 21.53% and required 6.20 h extraction time. Developed system can be effectively helps in energy saving, reduced time required for oil extraction which makes the system more economical. Novelty impact statement In the developed solar hybrid essential oil extraction system, the oil extraction was performed by the steam diffusion mechanism, as there is no such technology available for the essential oil extraction through the steam diffusion from turmeric. The developed hybrid system ensures 21.53% saving of electrical energy and 17.33% saving of the overall extraction time for the essential oils from turmeric grates. It can be installed and operated on a rooftop, so no additional space is needed. The developed system act as a tool for the generation of the extra income for the farmers in term of value addition.

Impact of recent district heating developments and low-temperature excess heat integration on design of industrial energy systems: An integrated assessment method

One of today’s biggest challenges is taking effective measures to mitigate negative effects and consequences of human-made climate change such as sector coupling and excess heat valorization. In this work, sector coupling of residential and industrial heat supply are considered in an optimization-based design and operation evaluation for industrial energy supply systems with the aim of minimizing costs and determining the impact of on-going developments and progresses in district heating systems. The developed method is applied to a use case with a superstructure for the industrial energy system including a biomass-fired steam generation unit, two heat pumps and various thermal storages, generic industrial load profiles for steam, hot water and excess heat and simulation-based district heating load profiles. The most relevant results reveal that depending on the district heating setting total annual costs, including fuel costs and annualized investments, increase between 2 and 39% compared to no additional district heating supply by the industrial energy supply system. However, the lowest cost increase does not coincide with the lowest additional energy amount. Thus, synergies such as corresponding temperature levels between energy supply for all domains have been identified as crucial criteria for economic success. Also, unit integration for excess heat recovery occurs always combined with thermal storages adapting the temporal occurrence of excess heat. Results for the evaluated use case highlight the importance and relevance of combined considerations for sector coupling measures. Thus, methods, as presented in this work, can contribute crucial information for future assessments. However, further development of the model, e.g. a larger set of generation technologies, and further use cases with other temperature levels, demand profiles are identified as relevant next steps.

A natural gas-based eco-friendly polygeneration system including gas turbine, sorption-enhanced steam methane reforming, absorption chiller and flue gas CO2 capture unit

Poly-generation systems have attracted a lot of attention due to the increment of efficiency as well as reducing energy penalties, costs and pollutants. Extensive research has been done on these systems in recent years. The current work is done with the aim of simulating an environmentally friendly poly-generation system in the power plant of Shahrood city in Iran. In this way, a poly-generation system is simulated in Aspen Plus software which consists of: I) a gas turbine (GT) for power generation with natural gas fuel of Shahroud power plant, that its flue gas is utilized to supply heat for other cycles and streams, II) a sorption-enhanced chemical looping reforming (SECLR) which simultaneously generates H2 by steam methane reforming (SMR) and uptakes produced CO2 by calcium adsorbent during the carbonation/calcination reactions. In this section, there is also a chemical looping combustion (CLC) based on redox reactions of Ni/NiO to provide heat of the reactors, III) a NH3/H2O absorption refrigeration system to yield the cooling demand, IV) a high-pressure steam generation unit and V) a MEA-based post-combustion CO2 capture unit (PCC) for flue gas. In this system, an attempt has been made to prevent heat loss by internal streams, especially gas turbine exhaust gas, so that energy loss is minimized. Moreover, environmental issues are also prioritized to reduce the CO2 emissions as much as possible. The proposed process is capable of producing 133.3 MW power, 9.875 MW cooling, 50 kg/s high-pressure steam and 0.384 kg/s hydrogen. The mass flow rates of CO2 captured in the SECLR and PCC sections are 2.6 kg/s and 15.35 kg/s, respectively. Moreover, the total energy efficiency of the integrated system is 68.74%. Ultimately, a sensitivity analysis was performed to identify the key parameters and their influence on the process performance.

Plant system study of France–Japan common concept on Sodium-cooled Fast Reactor

This paper provides an overview of plant system studies to establish a common technical view for Sodium-cooled Fast Reactor (SFR) concept (the common SFR concept) between France and Japan based on ASTRID 600 and the new concept with downsized output (ASTRID150). One of important issues on a reactor structure design is to enhance seismic resistance to be tolerable against strong earthquake such that postulated in Japan. A concept of High Frequency Design (HFD) is shared, in which the natural frequency of the reactor structure should be higher than that of peak acceleration of vertical floor seismic response with a horizontal seismic isolation system. The design options related to HFD have been examined and design recommendations are established. ASTRID 600 adopted a gas power conversion system to strictly eliminate the chemical reaction risks due to the proximity of sodium and water in the steam generator units. On the other hand, a steam generator (SG) is thought to be a concept with high technical readiness level and is a reference option in Japan and a backup option in France. Then, design comparison of the SG with single-walled helical coil tubes was mainly conducted in this study from the viewpoint of safety and so on. A common concept of a decay heat removal system is discussed to achieve practical elimination of loss of decay heat removal function. A fuel handling system studies are performed to eliminate and ex-vessel storage of spent fuels in sodium to reduce a construction cost. An adequate confinement system is investigated to achieve practical mitigation of large radiological release to the environment even under the condition of core destructive accident.

Multi-objective optimization of power, CO2 emission and exergy efficiency of a novel solar-assisted CCHP system using RSM and TOPSIS coupled method

In this study, the waste energy from exhausted gases of a gas turbine was recovered in a novel combined cooling, heating, and power system integrated of a gas turbine power plant, Kalina cycle, single-effect LiBr–H2O absorption chiller, parabolic trough collectors, heat recovery steam generator unit, and domestic hot water provision. This system utilized solar energy to preheat the air inlet to the combustion chamber and alleviated the emission of carbon dioxide resulted from consuming methane. An unparalleled algorithm was introduced to determine an optimum configuration of solar collectors. The results indicated that there were six optimum points with respect to maximum net power, minimum carbon dioxide emission and maximum exergy efficiency. The best optimum point was recognized using technique for order preferences by similarity to ideal solution method. The findings showed that compression ratio of 11.66, pinch point temperature difference in the air preheaters-1 of 11.96 K, inlet temperature of gas turbine-1 of 1470 K, and inlet temperature of combustion chamber of 900 K were the best multi-objective optimum conditions. In that condition, the net power, the system emission and the exergy efficiency were 61.73 MW, 52.87 g/MJ and 44.22%, respectively.

INSTALLED BASE SAFETY UPGRADE AT POWER GENERATION STATION

The study case power-generation plant comprises four steam generation units, commissioned in the 1990's, it is one of the largest in Italy and one of major in Europe, contributing to base load demand to the country south region. Age and limited availability of replacement parts for original medium voltage air magnetic circuit breaker, now in obsolete life cycle phase, is an operation concern on such mission critical equipment, as well as racking operation procedure on original 50kA rated installation not internal arc classified. The owning Utility strategy drives energy transition towards an increasingly sustainable model and the plant electrical installed base modernization, focusing on efficiency, health and safety as the three key elements. Innovative retrofit solutions have been designed and fully type tested to enable original installed base modernization with latest circuit breaker technology, providing withdrawable motorized execution for safety and easy maintenance. The benefits in terms of safety upgrade and installation are described. Furthermore, operation benefits such as standardization of spare parts, replacement of mechanical to electrical signalling and easiness of racking procedure is discussed.

Assessment of the economic efficiency of occupational safety and health measures

The issue of occupational safety is studied by assessing working conditions and calculating the economic effect of labor protection measures. The paper describes criteria for improving the economic efficiency by increasing the level of labor protection. It describes measures aimed to ensure the occupational safety and health of workers. The economic efficiency of measures aimed to improve working conditions and ensure the safety is calculated on the example of a steam generation unit. The methodology for calculating technical, economic and social indicators of labor protection takes into account the costs of improving safety and calculating the economic damage caused by accidents. The methodology can be used to evaluate the effectiveness of industrial measures, and takes into account the social effect of labor protection and envi ronmental protection measures. To calculate the effectiveness, the cost of losses, damage, localization costs, environmental damage, and measures is calculated. The occupational safety assurance measures can reduce the cost of production due to the increased labor productivity and improved quality of working capacities in favorable working conditions. An objective assessment of the measures aimed to improve safety conditions contributes to the development of recommendations and can justify management decisions made to ensure the occupational safety.

Difference oxidation behaviors of Ni8Al and Ni25Cr coatings in air with water vapor at 650∘

The oxidation behaviour of Ni8Al and Ni25Cr coatings produced by high velocity oxygen fuel spray (HVOF) which were deposited on Fe-based alloys (CB2) was investigated. We simulated the service environment of the steam generator unit, and put the samples in a thermostatic tube furnace at 650[Formula: see text] in air with 20 wt.% water vapor for 1000 hours of cyclic oxidation. The formation mechanism are explained using SEM, XRD, and EDX. There were no spallations and obvious cracks in both coatings. Ni25Cr coating generated a better protection oxides scale than that scale on Ni8Al. The behavior and mechanism of the oxide scale formation had an important influence in coatings and we have discussed these phenomenons in the study.

Influence of Pre-Ratcheting Fatigue on Tensile Behavior of Modified 9Cr-1Mo Steel at Ambient Temperature

Modified 9 Cr-1Mo steel is a material of prime significance in power plants used for components of steam generation units. The phenomenon of ratcheting involves aggregation of plastic strain in each cycle during asymmetric cyclic stressing. In the present study, the role of prior ratcheting has been studied on tensile behavior of this steel at ambient temperature. Cyclic tests were performed under uniaxial stress under the three parameters namely mean stress (σm), stress amplitude (σa) and stress rate $$(\dot{\sigma })$$ for 200 cycles. Tensile behavior of the pre-ratcheted samples was evaluated at ambient temperature at a strain rate of 10−4 s−1. It was found that pre-ratcheting enhanced the yield strength (SYS) and tensile strength (SUTS) but reduced the ductility. The results are discussed in terms of cyclic hardening resulting from the pre-ratcheting under different variables, and the internal microstructural changes are revealed by transmission electron microscopy.

A novel triple pressure HRSG integrated with MED/SOFC/GT for cogeneration of electricity and freshwater: Techno-economic-environmental assessment, and multi-objective optimization

In the present study, a novel integrated energy system comprising a multi-effect desalination unit (MED) and a solid oxide fuel cell (SOFC) integrated with a gas turbine (GT) is presented for power and freshwater production. Thus , SOFC fuel cell's waste heat is exploited by a novel design of the steam generator unit to run a triple pressure steam cycle. Using MATLAB software, the performance of the proposed system is investigated from energy, exergy, economic, and environmental aspects. A parametric study is conducted to assess the influence of key parameters. Moreover, dual- and tri-objective optimizations are performed to determine the best-operating conditions considering exergy efficiency, levelized cost of energy, and normalized emission as objectives. The results indicate that the proposed integrated system can enhance the system power generation, the exergy efficiency, and the normalized emission by 6.5%, 8.42%, and 5.8%, compared to the solid oxide fuel cell integrated with a gas turbine standalone. The results also show that the proposed integration leads to daily freshwater production of 1141 m3 at a constant value of levelized cost of energy. According to the exergy analysis, solid oxide fuel cells influence the system's overall enhancement considerably because of the highest exergy destruction value. By employing two-objective optimization, results showed that the exergy efficiency and levelized cost of energy can improve by 18.8% and 11% compared to the base case. Although normalized emission was not considered as an objective function, 16.5% improvement was observed. 3D Pareto front of three-objective optimization revealed a linear correlation between the exergy efficiency and normalized emission.

Overall performance of steam system used in garment industries in Bangladesh: a case study–based approach

The fabric or garments production activities starting from raw material preparation to the finishing process are energy-intensive. Steam generation and distribution system is part of all the major processes involved here. Therefore, this study aims to assess the overall performance of the steam system used in the textile or garment industry in Bangladesh. The quantity of heat loss through different sources both at steam generation and distribution unit was computed. The amount of in-process heat energy consumption was also determined. Current practices in steam system management were investigated, and opportunity for improvement was addressed. Finally, the genetic algorithm approach was used to optimize the process parameters of steam generation unit thermodynamically. The average efficiency of the steam generation units used in the fifteen studied factories was found 76%. The dyeing and ironing processes were found as the most heat energy–intensive process. Among the sources of heat losses, maximum loss was found occurring through the dry flue gas during steam generation. At distribution unit, most heat is lost through the steam line and in-process distribution. Based on the analysis, daily 694 GJ heat passes away through a steam system resulting in 13 tons and 31 tons of fuel wastage and greenhouse gas emission, respectively. Considering the occurring losses, the remedial measures were focused on excess air and stack temperature control, improvement in boiler operating condition, steam leakage and trap maintenance, insulation enhancement, etc. Moreover, by optimizing the thermodynamic process parameters, it is possible to increase energy efficiency by almost 3.0%.

Experimental Results of Pressing and Cold Deformation for the Development of New Pipe Products

This article discusses the use of experimental results obtained by the Laboratory of drawing and pressing, RD cold-deformed pump and compressor pipes and respective couplings from 110CrNi alloy; cold-deformed pipes from Ti–3Al–2.5V titanium alloy; and long length cold-deformed pipes from 03Kh18N13S2AM2VFBR-Sh steel for nuclear steam generator unit of new generation. This article discloses the features of commercial technologies meeting the exclusive engineering requirements inherent to each of the mentioned pipe products.

Conventional and Advanced Exergy and Exergoeconomic Analysis of a Spray Drying System: A Case Study of an Instant Coffee Factory in Ecuador

Instant coffee is produced worldwide by spray drying coffee extract on an industrial scale. This production process is energy intensive, 70% of the operational costs are due to energy requirements. This study aims to identify the potential for energy and cost improvements by performing a conventional and advanced exergy and exergoeconomic analysis to an industrial-scale spray drying process for the production of instant coffee, using actual operational data. The study analyzed the steam generation unit, the air and coffee extract preheater, the drying section, and the final post treatment process. The performance parameters such as exergetic efficiency, exergoeconomic factor, and avoidable investment cost rate for each individual component were determined. The overall energy and exergy efficiencies of the spray drying system are 67.6% and 30.6%, respectively. The highest rate of exergy destruction is located in the boiler, which amounts to 543 kW. However, the advanced exergoeconomic analysis shows that the highest exergy destruction cost rates are located in the spray dryer and the air heat exchanger (106.9 $/h and 60.5 $/h, respectively), of which 47.7% and 3.8%, respectively, are avoidable. Accordingly, any process improvement should focus on the exergoeconomic optimization of the spray dryer.