NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
Problem Solving 1
1] A natural gas-fired fire tube steam boiler utilizes 0.5 m3/s of natural gas as fuel. The boiler operates under the
following conditions: (50 pts)
Natural Gas Supply Pressure: 800 kPa
Natural Gas Supply Temperature: 40℃
Steam Condition: 6 MPa, 480℃
Feedwater Condition: 150℃
Boiler Room Ambient Condition: 1 atm, 25℃
Boiler Rating: 157,000 kg/hr
Heating Surface Area: 5300 m2
Excess Air: 20%
Volumetric Analysis of Natural Gas: Propane = 3%, Methane = 85%, Ethane = 12%
CH4: HHV = 55.5 MJ/kg
C2H6: HHV = 51.9 MJ/kg
C3H8: HHV = 50.4 MJ/kg
Determine: a) Mass Flow Rate of Fuel
b) Volume Flow Rate of Air for Combustion
c) Volume Flow Rate of Flue Gas
d) Boiler Efficiency
Solution:
a. Solving for mass of mixture
𝑚𝑚𝑖𝑥 = 𝑉𝑚𝑖𝑥 𝑥 𝜌𝑚𝑖𝑥
Where:
𝑉𝑚𝑖𝑥 = 0.5 𝑚3 /𝑠
From general Gas Law
𝑃𝑉 = 𝑚𝑅𝑇
𝑚 𝑃
𝑉
= 𝑅𝑇
Then;
𝑃
𝜌𝑚𝑖𝑥 =
𝑅𝑚𝑖𝑥 𝑇
𝑃 = 800𝑘𝑃𝑎
𝑅
𝑅𝑚𝑖𝑥 = 𝑀 → gas constant of mixture
𝑤𝑚𝑖𝑥
𝑅 = 8.3143 𝑘𝐽⁄𝑘𝑚𝑜𝑙 ∙ 𝐾
𝑚𝑚𝑖𝑥
𝑀𝑤𝑚𝑖𝑥 = → 𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑖𝑥𝑡𝑢𝑟𝑒
𝑛𝑚𝑖𝑥
𝑚𝑚𝑖𝑥 = 𝑚𝐶𝐻4 + 𝑚𝐶2 𝐻6 + 𝑚𝐶3 𝐻8
For every 𝑛𝑚𝑖𝑥 = 100𝑘𝑚𝑜𝑙
16 𝑘𝑔 30 𝑘𝑔 44 𝑘𝑔
𝑚𝑚𝑖𝑥 = (85 𝑘𝑚𝑜𝑙) ( ) + (12 𝑘𝑚𝑜𝑙) ( 𝑘𝑚𝑜𝑙 ) + (3 𝑘𝑚𝑜𝑙) ( 𝑘𝑚𝑜𝑙 )
𝑘𝑚𝑜𝑙
𝒎𝒎𝒊𝒙 = 1852 kg
NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
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ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
𝑚𝑚𝑖𝑥 1852
𝑀𝑤𝑚𝑖𝑥 = =
𝑛𝑚𝑖𝑥 100 𝑘𝑚𝑜𝑙
𝑀𝑤𝑚𝑖𝑥 = 18.52 kg/kmol
So;
8.3143 𝑘𝐽/𝑘𝑚𝑜𝑙∙𝐾
𝑅𝑚𝑖𝑥 =
18.52 𝑘𝑔/𝑘𝑚𝑜𝑙
𝑅𝑚𝑖𝑥 = 0.449 kJ/kgK
And;
800 𝑘𝑃𝑎
𝜌𝑚𝑖𝑥 = ( )
0.449 𝑘𝐽/𝑘𝑔∙𝐾 (40+273) 𝐾
𝜌𝑚𝑖𝑥 = 5.692 kg/m3
Therefore:
𝑚𝑚𝑖𝑥 = 0.5 𝑚3 /𝑠 𝑥 5.692 𝑘𝑔/𝑚3
𝒎𝒎𝒊𝒙 = 𝟐. 𝟖𝟒𝟔 𝒌𝒈/𝒔
NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
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b. Solving for the volume flow rate of air
𝑚𝑅𝑇
𝑉𝑎 =
𝑃
𝑤ℎ𝑒𝑟𝑒:
𝑅𝑎 = 0.287𝑘𝐽/𝑘𝑔𝐾
𝑇 = 25 + 273 = 298𝐾
𝑃 = 101.325𝑘𝑃𝑎
From Air Fuel Ratio:
𝑚𝑎 𝐴
=( )
𝑚𝑓 𝐹 𝑎
𝐴
𝑚𝑎 = 𝑚𝑓 𝑥 ( )a
𝐹
𝑚𝑚𝑖𝑥 = 𝑚𝑓 = 2.846 𝑘𝑔/𝑠
𝐴 𝑚 𝑂2 + 𝑚 𝑁 2
( ) =
𝐹 𝑎 𝑚𝐶𝐻4 +𝑚𝐶2 𝐻6 +𝑚𝐶3 𝐻8
To calculate for the AFR we need to perform balance combustion reaction:
0.85CH4 + 0.12C2H6 + 0.03C3H8 + aO2 + 3.76aN2 ⟶ bCO2 + cH2O + 3.76aN2
(fuel) (air) (product)
By material balance
for Carbon,
0.85(1) + 0.12(2) + 0.03(3) = 𝑏(1)
𝑏 = 1.18
for Hydrogen,
0.85(4) + 0.12(6) + 0.03 (8) = 𝑐(2)
𝑐 = 2.18
for Oxygen,
𝑎(2) = 𝑏(2) + 𝑐(1)
𝑎 (2) = (1.18)(2) + (2.18)(1)
𝑎 = 2.27
For the balanced theoretical reaction equation
0.85CH4 + 0.12C2H6 + 0.03C3H8 + 2.27𝑂2 + 8.5352N2 ⟶ 1.18CO2 + 2.18H2O + 8.5352N2
For actual reaction equation with 20% excess air
[0.85𝐶𝐻4 + 0.12𝐶2 𝐻6 + 0.03 𝐶3 𝐻8 ] + 1.20 [2.27𝑂2 + 8.5352 𝑁2 ] ⟶ 1.18𝐶𝑂2 + 2.18𝐻2 𝑂 + 𝑑𝑂2 +
1.20(8.5352𝑁2 )
By material balance
For Oxygen,
NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
COLLEGE OF ENGINEERING
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ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
1.20(2.27)(2) = 1.18(2) + 2.18(1) + 𝑑(2)
𝑑 = 0.454
For balanced actual reaction equation
[0.85𝐶𝐻4 + 0.12𝐶2 𝐻6 + 0.03𝐶3 𝐻8 ] + 2.724𝑂2 + 10.242𝑁2 ⟶ 1.18𝐶𝑂2 + 2.18𝐻2 𝑂 + 0.454𝑂2 + 10.242𝑁2
Then, for fuel air ratio
𝐴 2.724(32) + 10.242 (28)
(𝐹) = 0.85 (16)+0.12(30)+0.03(44)
𝑎
𝐴
( ) = 20.191 𝑘𝑔 𝑎𝑖𝑟/𝑘𝑔 𝑓𝑢𝑒𝑙
𝐹 𝑎
Solving for the mass flow rate of air
𝑘𝑔 𝑎𝑖𝑟
𝑚𝑎 = (2.846 𝑘𝑔 𝑓𝑢𝑒𝑙/𝑠) (20.191 )
𝑘𝑔 𝑓𝑢𝑒𝑙
𝑚𝑎 = 57.465 𝑘𝑔/𝑠
Therefore:
(57.465 𝑘𝑔/𝑠) (0.287𝑘𝐽/𝑘𝑔𝐾) (25 + 273)𝐾
𝑉𝑎 =
(101.325 𝑘𝑃𝑎)
𝑽𝒂 = 𝟒𝟖. 𝟓𝟎𝟓 𝒎3/s
c. Solving for volume flow rate of flue gas
𝑚𝑜𝑙 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠
𝑉𝑓𝑙𝑢𝑒 𝑔𝑎𝑠 = 𝑥 𝑉𝑓𝑢𝑒𝑙
𝑚𝑜𝑙 𝑓𝑢𝑒𝑙
1.18 + 2.18 + 0.454 + 10.242 𝑚𝑜𝑙 𝑓𝑙𝑢𝑒 𝑔𝑎𝑠𝑓𝑢𝑒𝑙 𝑚3
𝑉𝑓𝑙𝑢𝑒 𝑔𝑎𝑠 = ( ) 𝑥 0.5
0.85 + 0.12 + 0.03 𝑚𝑜𝑙 𝑓𝑢𝑒𝑙 𝑠
𝑽𝒇𝒍𝒖𝒆 𝒈𝒂𝒔 = 𝟕. 𝟎𝟐𝟖 𝒎𝟑 /𝒔
d. Solving for the efficiency of boiler
From steam table:
Steam pressure = 6 MPa
Steam temperature = 480 ℃
hs = 3374.3 kJ/kg
Feedwater = 150 ℃
hf = 632.20 kJ/kg
ms = 157,000 kg/hr
𝐻𝐻𝑉𝐶𝐻4 = 55.5 𝑀𝐽/𝑘𝑔
𝐻𝐻𝑉𝐶2 𝐻6 = 51.9 𝑀𝐽/𝑘𝑔
𝐻𝐻𝑉𝐶3 𝐻8 = 50.4 𝑀𝐽/𝑘𝑔
For the higher heating value of fuel mixture
𝑚𝐶𝐻4 𝑚𝐶 𝐻 𝑚𝐶 𝐻
𝐻𝐻𝑉𝑚𝑖𝑥 = ( ) 𝐻𝐻𝑉𝐶𝐻4 + ( 2 6 ) 𝐻𝐻𝑉𝐶2 𝐻6 + ( 3 8 ) 𝐻𝐻𝑉𝐶3 𝐻8
𝑚𝑚𝑖𝑥 𝑚𝑚𝑖𝑥 𝑚𝑚𝑖𝑥
NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
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ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
1360 360 132
𝐻𝐻𝑉𝑚𝑖𝑥 = ( ) (55.5) + ( ) (51.9) + ( ) (50.4)
1852 1852 1852
𝐻𝐻𝑉𝑚𝑖𝑥 = 54.437 𝑀𝐽/𝑘𝑔
Therefore,
𝑘𝑔 1 ℎ𝑟
(157,000 𝑥 )(3374.3 − 632.20) 𝑘𝐽/𝑘𝑔
ℎ𝑟 3600 𝑠
𝑒𝑏𝑜 =
(2.846 𝑘𝑔/𝑠) (54,437 𝑘𝐽/𝑘𝑔)
𝒆𝒃𝒐 = 𝟕𝟕. 𝟏𝟖𝟖%
NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
COLLEGE OF ENGINEERING
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ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
2] A steam condenser for a large power plant has steam condensing at 35℃ on the shell side of a shell-and-tube
exchanger. The condenser vacuum is 70 cm mercury when the barometer reads 75.5 cm of Hg. Water serves
as the coolant on the tube side, entering at 20℃ and leaving at 27℃. The exchanger involves one shell pass
and two tube passes. For a heat transfer rate of 700 MW and overall heat transfer coefficient of 3.4 kW/m2K,
calculate the following: (20 pts)
a) Draw the temperature profile
b) Heat exchanger area required
c) Flow rate of cooling water
d) Vacuum efficiency
e) Condenser efficiency
Solution:
a) For the temperature profile
T
𝑇𝑠𝑎𝑡 = 35 ℃
Steam ∆𝑡𝑚𝑖𝑛 = 8 𝐶°
𝑡𝑜𝑢𝑡 = 27℃
∆𝑡𝑚𝑎𝑥 = 15𝐶°
H2O
𝑡𝑖𝑛 = 20℃
b) For Heat Exchanger Area
𝑄𝑠 = 𝑈𝐴(𝐿𝑀𝑇𝐷) 𝑓𝑙𝑜𝑤
𝑄𝑠
𝐴=
𝑈(𝐿𝑀𝑇𝐷)
700,000 𝑘𝑊
𝐴=
15 − 8
(3.4 𝑘𝑊/𝑚2 𝐾) [ ]𝐾
15
ln ( )
8
𝑨 = 𝟏𝟖, 𝟒𝟖𝟖. 𝟒𝟗𝟎 𝒎𝟐
c) For the flow water of cooling water
𝑄𝑠 = 𝑄𝑤
𝑄𝑠 = 𝑚𝑤 𝐶𝑝𝑤 (𝑡2 − 𝑡1 )
𝑄𝑠
𝑚𝑤 = 𝐶𝑝𝑤 (𝑡2 − 𝑡1 )
700,000 𝑘𝑊
𝑚𝑤 = (4.187 𝑘𝐽/𝑘𝑔𝐾) (27− 20) 𝐾
𝒎𝒘 = 𝟐𝟑, 𝟖𝟖𝟑. 𝟒𝟒𝟗 𝒌𝒈/𝒔
d) For the vacuum efficiency
𝑃𝑎𝑡𝑚 −𝑃𝑐𝑜𝑛
𝑒𝑣 = 𝑃𝑎𝑡𝑚 −𝑃𝑠𝑎𝑡
𝑥 100 %
Where;
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𝑇 = 35℃
𝑃𝑠𝑎𝑡 = 0.005622 𝑀𝑃𝑎
0.101325 𝑀𝑃𝑎
𝑃𝑎𝑡𝑚 = 75.5 𝑐𝑚 𝐻𝑔 𝑥
76 𝑐𝑚 𝐻𝑔
𝑃𝑎𝑡𝑚 = 0.100658 𝑐𝑚 𝐻𝑔
0.101325 𝑀𝑃𝑎
𝑃𝑐𝑜𝑛 = (75.5 − 70) 𝑐𝑚 𝐻𝑔 𝑥
76 𝑐𝑚 𝐻𝑔
𝑃𝑐𝑜𝑛 = 0.006666 𝑀𝑃𝑎
Then;
𝑃𝑎𝑡𝑚 − 𝑃𝑐𝑜𝑛
𝑒𝑣 = 𝑥 100%
𝑃𝑎𝑡𝑚 − 𝑃𝑠𝑎𝑡
0.100658 − 0.006666
𝑒𝑣 = 𝑥 100%
0.100658 − 0.005622
𝒆𝒗 = 𝟗𝟖. 𝟗𝟎𝟏%
e) For the condenser efficiency
(𝑡2 − 𝑡1 )
𝑒𝑐𝑜𝑛 = (𝑡𝑠𝑎𝑡 − 𝑡1 )
𝑥 100%
(27− 20)
𝑒𝑐𝑜𝑛 = (35− 20)
𝑥 100%
𝒆𝒄𝒐𝒏 = 𝟒𝟔. 𝟔𝟔𝟕 %
NUEVA ECIJA UNIVERSITY OF SCIENCE AND TECHNOLOGY
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
3] A superheat Steam Power Plant has 450 kg/s of steam enter and leave the nozzle of an impulse turbine stage
at 2.75 MPa and 260℃, and 1.37 MPa, respectively. The nozzle efficiency is 90 %. The nozzle angle is 20°.
The blade is symmetrical, travels at optimum velocity of 255 m/s and has a velocity coefficient of 0.97. Draw
the velocity diagram and calculate the following. (30 pts)
a) Critical pressure
b) Spouting velocity
c) Blade angle at inlet and outlet
d) Stage power
e) Blade efficiency
The steam expands in the turbine to 0.052 bar. If the mechanical efficiency of the turbine is 98%, alternator
efficiency is 96% and pump efficiency is 77%, calculate the following:
f) Brake Power
g) Actual enthalpy at the exhaust of the turbine
h) Generator Output
i) Pump Brake Power
Solution:
a) For critical pressure
𝑘
2 𝑘−1
𝑃𝑡 = 𝑃1 ( )
𝑘+1
Where;
𝑘 = 1.3 𝑓𝑜𝑟 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑒𝑎𝑚
Then,
1.3
2 1.3−1
𝑃𝑡 = (2.75 𝑀𝑃𝑎) ( )
1.3 + 1
𝑷𝒕 = 𝟏. 𝟓𝟎𝟏 𝑴𝑷𝒂
b) Spouting Velocity
1
𝑉2 = 44.7(ℎ1 − ℎ2 )2
1
𝑉2 = 44.7[(2896.6 − 2753.524) 𝑥 0.9]2
𝑽𝟐 = 𝟓𝟎𝟕. 𝟐𝟑𝟖 𝒎/𝒔
c) Blade angle at inlet and outlet
𝑉2 𝑆𝑖𝑛 𝛼2
𝛽2 = 𝑡𝑎𝑛−1 [ ]
𝑉2 𝐶𝑜𝑠 𝛼2 − 𝑈
(507.238) 𝑆𝑖𝑛 (20)
𝛽2 = 𝑡𝑎𝑛−1 [ ]
(507.238) 𝐶𝑜𝑠 (20) − 255
𝛽2 = 38.092 °
For symmetrical blade,
𝜷𝟐 = 𝜷𝟑 = 𝟑𝟖. 𝟎𝟗𝟐 °
d) Stage or blade power
Solving for relative velocity at inlet
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𝑉2 𝑆𝑖𝑛 𝛼2
𝑉𝑟2 =
𝑆𝑖𝑛 𝛽2
(507.238) 𝑆𝑖𝑛 (20)
𝑉𝑟2 =
𝑆𝑖𝑛 (38.092)
𝑉𝑟2 = 281.210 𝑚/𝑠
Solving for relative velocity at outlet
𝑉𝑟3
𝑘=
𝑉𝑟2
𝑉𝑟3 = 0.97 𝑥 281.210
𝑉𝑟3 = 272.773 𝑚/𝑠
Solving for whirl velocity
∆𝑉𝑤 = 𝑉𝑟2 𝐶𝑜𝑠 𝛽2 + 𝑉𝑟3 𝐶𝑜𝑠 𝛽3
∆𝑉𝑤 = [(281.210 )𝐶𝑜𝑠 (38.092)] + [(272.773 )𝐶𝑜𝑠 (38.092)]
∆𝑉𝑤 = 435.996 𝑚/𝑠
Solving for blade power
𝐵𝐿𝑃 = 𝑚𝑠 𝑥 ∆𝑉𝑤 𝑥 𝑈
1 𝑀𝑁
𝐵𝐿𝑃 = (450 𝑘𝑔/𝑠) 𝑥 (435.996 𝑚/𝑠) 𝑥 (255 𝑚/𝑠) 𝑥 1,000,000 𝑁
𝑩𝑳𝑷 = 𝟓𝟎. 𝟎𝟑𝟏 𝑴𝑾
e) Blade efficiency
2∆𝑉𝑤 𝑈
𝑒𝑏 = 𝑥 100%
𝑉2 2
2(435.996 𝑚/𝑠)(255 𝑚/𝑠)
𝑒𝑏 = 𝑥 100%
(507.238 𝑚/𝑠)2
𝒆𝒃 = 𝟖𝟔. 𝟒𝟐𝟑 %
Or
𝑘 𝐶𝑜𝑠 𝛽3
𝑒𝑏 = 2𝜌 [(𝐶𝑜𝑠 𝛼2 − 𝜌) (1 + )] 𝑥 100%
𝐶𝑜𝑠 𝛽2
Where;
𝑈 255 𝑚/𝑠
𝜌= =
𝑉2 507.238 𝑚/𝑠
𝜌 = 0.5027
𝑘 = 0.97
Then,
(0.97) 𝐶𝑜𝑠 (𝟑𝟖. 𝟎𝟗𝟐 )
𝑒𝑏 = 2(0.5027) {[𝐶𝑜𝑠 (20) − 0.5027] [1 + ]} 𝑥 100%
𝐶𝑜𝑠 (𝟑𝟖. 𝟎𝟗𝟐 )
𝒆𝒃 = 𝟖𝟔. 𝟓𝟓𝟐 %
f) Brake Power
𝐵𝑃
𝑒𝑚 =
𝐵𝐿𝑃
𝐵𝑃 = 𝑒𝑚 𝑥 𝐵𝐿𝑃
𝐵𝑃 = (0.98)(50.031 𝑀𝑊)
𝑩𝑷 = 𝟒𝟗. 𝟎𝟑𝟎 𝑴𝑾
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COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
ME 414 POWER PLANT DESIGN WITH RENEWABLE ENERGY
g) Actual enthalpy at the exhaust of the turbine
From Steam Table
At 𝑃1 = 2.75 𝑀𝑃𝑎, 𝑇1 = 260 ℃
ℎ1 = 2896.6 𝑘𝐽/𝑘𝑔
𝑠1 = 6.4003 𝑘𝐽/𝑘𝑔𝐾
Then,
𝐵𝑃 = 𝑚𝑠 (ℎ1 − ℎ2 ′)
49,030 𝑘𝑊 = (450 𝑘𝑔/𝑠) (2896.6 − ℎ2 ′)
𝒉′𝟐 = 𝟐𝟕𝟖𝟕. 𝟔𝟒𝟒 𝒌𝑱/𝒌𝒈
h) Generator Output
𝐸𝑃 = 𝑒𝑎𝑙𝑡 𝑥 𝐵𝑃
𝐸𝑃 = (0.96)(49.030 𝑀𝑊)
𝑬𝑷 = 𝟒𝟕. 𝟎𝟔𝟗 𝑴𝑾
i) Pump Brake Power
From Steam Table
At 𝑃2 = 𝑃3 = 0.0052 𝑀𝑃𝑎
𝑣3 = 1.005𝑥10−3 𝑚3 /𝑘𝑔
Then,
𝑊𝑃
𝑃𝐵𝑃 =
𝑒𝑃
𝑚𝑓 𝑣3 (𝑃4 − 𝑃3 )
𝑃𝐵𝑃 =
𝑒𝑃
(450 𝑘𝑔/𝑠)(1.005𝑥10−3 𝑚3 /𝑘𝑔)(2750 − 5.2) 𝑘𝑃𝑎
𝑃𝐵𝑃 =
0.77
𝑃𝐵𝑃 = 1612.12 𝑘𝑊
𝑷𝑩𝑷 = 𝟏. 𝟔𝟏𝟐 𝑴𝑾
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