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Optimal design of cogeneration system based on exergoenvironmental analysis

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Abstract

In this article, a new procedure was introduced for the optimal design of utility system in process industries. This method was based on the development of the R-curve concept and a new cogeneration targeting through estimating costs, environmental impacts, exergoeconomic, and exergoenvironmental analyses. In the exergoenvironmental analysis, the environmental impacts obtained by life cycle assessment are apportioned to the exergy streams pointing out the main system components with the highest environmental impact and possible improvements associated with these components. Moreover, exergoenvironmental variables are calculated, and an exergoenvironmental evaluation is carried out. In this regard, correlations for estimating the environmental impacts of cogeneration system have been introduced. In addition, the powerful and accurate cogeneration targeting method was applied. Also, the new graphic representations have been proposed. These curves are based on cost estimation, environmental impacts, and exergoenvironmental analysis. In addition, the optimal design of site utility was carried out in Iran LNG cogeneration plant, in which the usefulness of this method was clearly demonstrated.

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Abbreviations

\( \varphi_{k} \) :

Maintenance factor

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

Cogeneration efficiency (%)

b :

Specific environmental impact per unit of exergy (Pts/GJ)

\( \dot{B} \) :

Environmental impact rate associated with exergy (mPts/s)

c :

Cost per unit of exergy ($/GJ)

\( \dot{C} \) :

Cost associated with an exergy stream ($/s)

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

Price of importing power ($/kWh)

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

Price of fuel ($/kWh)

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

Specific heat of saturated water (MWh/tC)

\( \dot{C}_{\text{D}} \) :

Cost rates of exergy destruction ($/h)

\( \dot{C}_{F} \) :

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 (106 $)

\( C_{i} \) :

Initial investment cost (106 $)

C P :

Product cost ($/h)

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

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

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

Capital investment for steam turbine system (106 $)

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

Capital recovery factor

\( \dot{E}_{\text{D}} \) :

Exergy destruction (MW)

H:

Specific enthalpy (kJ/kg)

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

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

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

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 (106 $)

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

Present worth factor

S :

Specific entropy (kJ/kgK)

\( S_{n} \) :

Salvage value (106 $)

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

Exhaust temperature of gas turbine (°C)

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

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

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

Saturation temperature of steam turbine inlet (°C)

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

Saturation temperature of steam turbine outlet (°C)

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

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

TAC:

Total annualized cost (106 $)

\( \dot{q}_{\text{in}} \) :

Heat content in the inlet (MWh/t)

\( \dot{q}_{\text{out}} \) :

Heat content in the outlet (MWh/t)

\( \dot{Q}_{\text{fuel}} \) :

Fuel consumption (MW)

\( \dot{Q}_{{{\text{fuel}} . {\text{GT}}}} \) :

Fuel consumption of gas turbine (MW)

\( \dot{Q}_{\text{heat}} \) :

Heat demand of steam (MW)

\( \dot{Q}_{{{\text{heat}} . {\text{HRSG}}}} \) :

Heat content in the steam generated from HRSG (MW)

\( \dot{W} \) :

Power demand (MW)

\( \dot{W}_{{{\text{GT}}.\hbox{max} }} \) :

Maximum power generation of gas turbine (MW)

\( \dot{W}_{\text{import}} \) :

Importing power (MW)

\( \dot{W}_{\text{loss}} \) :

Internal loss of steam turbine (MW)

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

Cost rates of total \( \dot{Z}^{\text{CI}} \)  and \( \dot{Z}^{\text{OM}} \) ($/h)

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

Capital cost rate of unit k ($/h)

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

Cost rates associated with capital investment ($/h)

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

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

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Acknowledgments

The authors thank the Iran Power Plant Project Management Company (MAPNA Group) for data and financial supports. This study was 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, Pardis Str., Mollasadra Ave., Vanak Sq., 19991-43344, Tehran, Iran

    Pooya Navid

  2. Division of Thermal Science & Energy Systems, Department of Mechanical Engineering, Faculty of Technology &Engineering, University of Qom, Qom, Iran

    Mohammad Hasan Khoshgoftar Manesh

  3. Department of Process Engineering, Universidad de de Las Palmas de Gran Canaria, Edificio de Ingenierías-Tafira Baja, 35017, Las Palmas, Spain

    Ana Maria Blanco Marigorta

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  1. Pooya Navid
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  2. Mohammad Hasan Khoshgoftar Manesh
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  3. Ana Maria Blanco Marigorta
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Correspondence to Mohammad Hasan Khoshgoftar Manesh.

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Navid, P., Manesh, M.H.K. & Marigorta, A.M.B. Optimal design of cogeneration system based on exergoenvironmental analysis. Clean Techn Environ Policy 16, 1045–1065 (2014). https://doi.org/10.1007/s10098-013-0705-4

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