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New procedure for optimal design of cogeneration system with considering environmental impacts and total cost

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Abstract

In this paper, a new procedure is introduced for optimal design of utility system in process industries. This method is based on the development of the R-curve concept and cogeneration targeting through estimating costs, environmental impacts, and exergoeconomic analysis. This new method can be applied for the synthesis of site utility system in process industries with considering total cost, environmental impacts, and exeregoeconomic analysis. In this regard, the powerful and accurate cogeneration targeting method is provided. The procedure which is proposed here provided a consistent, general procedure for determining mass flowrates and efficiencies of the applied turbines. Also, the new graphical representations are proposed. These curves can be easily constructed and simply understood. In addition, the optimal design of site utility is carried out in two case studies, in which the usefulness of this method is clearly demonstrated.

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Abbreviations

\( \Phi_{k} \) :

Maintenance factor (–)

\( \eta_{\text{cogen}} \) :

Cogeneration efficiency (%)

\( c_{{{\text{p}}.{\text{import}}}} \) :

Price of importing power ($/kWh)

\( c_{\text{f}} \) :

Price of fuel ($/kWh)

\( c_{p} \) :

Specific heat of saturated water (MWh/tC)

\( C_{\text{D}} \) :

Cost rates of exergy destruction ($/h)

\( C_{\text{F}} \) :

Fuel cost ($/h)

\( C_{{{\text{F}},k}} \) :

Cost rates of fuel in the kth component ($/MW)

\( C_{\text{GT}} \) :

Capital investment for gas turbine system (MM$)

\( C_{\text{i}} \) :

Initial investment cost (MM$)

\( C_{\text{P}} \) :

Product cost ($/h)

\( C_{{{\text{P}},k}} \) :

Cost rates of product in the kth component ($/MW)

\( C_{\text{ST}} \) :

Capital investment for steam turbine system (MM$)

CFP:

Carbon footprint (m2)

\( {\text{CRF}}_{{\left( {i,n} \right)}} \) :

Capital recovery factor (–)

\( {\text{ED}} \) :

Exergy destruction (MW)

EF:

Equivalence factor for forests (–)

EMFP:

Emission footprint (m2)

EFP:

Energy footprint (m2)

\( F_{{{\text{CO}}_{2} }} \) :

Fraction of CO2 absorbed by the oceans (kgCO2 m−2 y−1)

H :

Specific enthalpy (kJ/kg)

\( \overline{\Updelta H}_{\text{is}} \) :

Isentropic enthalpy change between the steam turbine inlet and outlet (MWh/t)

\( M_{{{\text{CO}}_{2} }} \) :

Product specific emission of CO2 (kgCO2)

\( m_{{{\text{exhaust}}.{\text{GT}}}} \) :

Flow rate of gas turbine exhaust (kg/s)

\( m_{\hbox{max} } \) :

Maximum steam flow rate of steam turbine (t/h)

\( \dot{m}_{i}^{\text{DEM}} \) :

Mass flow of process steam demand (t/h)

\( \dot{m}_{i}^{\text{GEM}} \) :

Mass flow of process steam generation (t/h)

N :

Slope of the Willan’s line for steam turbine (MWh/t)

P :

Pressure (bar)

\( {\text{PW}} \) :

Present worth (MM$)

\( {\text{PWF}}_{{\left( {i,n} \right)}} \) :

Present worth factor (–)

s :

Specific entropy (kJ/kg K)

\( S_{n} \) :

Salvage value (MM$)

\( S_{{{\text{CO}}_{2} }} \) :

Sequestration rate of CO2 by biomass (kgCO2 m−2 y−1)

\( T_{{{\text{exhaust}}.{\text{GT}}}} \) :

Exhaust temperature of gas turbine (°C)

\( T_{{{\text{s}},{\text{ave}}}} \) :

Average saturation temperature between the turbine inlet and outlet (°C)

\( T_{{{\text{s}},{\text{in}}}} \) :

Saturation temperature of steam turbine inlet (°C)

\( T_{{{\text{s}},{\text{out}}}} \) :

Saturation temperature of steam turbine outlet (°C)

\( \Updelta T_{\text{s}} \) :

Saturation temperature difference between the inlet and outlet (°C)

TAC:

Total annualized cost (MM$)

\( q_{\text{in}} \) :

Heat content in the inlet (MWh/t)

\( q_{\text{out}} \) :

Heat content in the outlet (MWh/t)

\( Q_{\text{fuel}} \) :

Fuel consumption (MW)

\( Q_{{{\text{fuel}}.{\text{GT}}}} \) :

Fuel consumption of gas turbine (MW)

\( Q_{\text{heat}} \) :

Heat demand of steam (MW)

\( Q_{{{\text{heat}}.{\text{HRSG}}}} \) :

Heat content in the steam generated from HRSG (MW)

W :

Power demand (MW)

\( W_{{{\text{GT}}.\hbox{max} }} \) :

Maximum power generation of gas turbine (MW)

\( W_{\text{import}} \) :

Importing power (MW)

\( W_{\text{loss}} \) :

Internal loss of steam turbine (MW)

WFP:

Water footprint (t)

\( \dot{Y} \) :

Environmental impact rate (Pts/h)

\( \dot{Z}_{k} \) :

Capital cost rate of unit k ($/h)

\( Z^{\text{CI}} \) :

Cost rates associated with capital investment ($/h)

\( Z^{\text{OM}} \) :

Cost rates associated with operating and maintenance ($/h)

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Acknowledgments

The authors thank Iran Power Plant Project Management Company (MAPNA Group) for data and financial support. This work is also supported by K. N. Toosi University of Technology.

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Authors and Affiliations

  1. Energy & Process Integration Research Center, Faculty of Mechanical Engineering, K. N. Toosi University of Technology, P.O. Box 19395-1999, No. 15-19, Pardis St., Mollasadra Ave., Vanak Sq., Tehran, Iran

    M. H. Khoshgoftar Manesh, P. Navid, M. Amidpour & M. H. Hamedi

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  1. M. H. Khoshgoftar Manesh
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  2. P. Navid
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  3. M. Amidpour
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  4. M. H. Hamedi
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Correspondence to M. H. Khoshgoftar Manesh or M. Amidpour.

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Khoshgoftar Manesh, M.H., Navid, P., Amidpour, M. et al. New procedure for optimal design of cogeneration system with considering environmental impacts and total cost. Clean Techn Environ Policy 15, 893–919 (2013). https://doi.org/10.1007/s10098-012-0576-0

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