Energy Systems and Turbomachinery

Giornata di studio sui Sistemi EnergeticiFerrara, 7 febbraio 2018

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Università degli Studi di Bergamo

Dipartimento di Ingegneria e Scienze Applicate

Energy Systems and TurbomachineryResearch Group


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Gruppo di ricerca

Personale strutturatoProf. Antonio Perdichizzi

Prof. Giovanna Barigozzi

Prof. Giuseppe Franchini

Prof. Silvia Ravelli

Dottorandi / Assegnisti / Borsisti

2-5 PhD students

2-5 Research fellows


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Turbomachinery

Film cooling in Gas Turbine Vanes and Blades

Ambiti di ricerca

Aero-thermal experimental investigations:

Aerodynamic probesLaser Doppler VelocimetryHot Wire AnemometryParticle Image Velocimetry (PIV)Cold Wire ThermometryThermochromic Liquid Crystals (TLC)Infrared ThermometryPressure-Sensitive Paint (PSP)Oil visualizations

CFD & 1-D optimization codes


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Power Systems:

Combined Cycle Power Plants

Cogeneration Plants

Energy Efficiency in industrial process

Waste to Energy Plants

Ambiti di ricerca

Renewable Energy: Concentrated Solar Power Plants

Solar Cooling & Desalination


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Ambiti di ricercaZero Energy Buildings in hot climates:

Off-Grid & Passive Building Design

Renewable Energy integration

Trigeneration systems

Prediction of PV & batteries operation


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PRODUZIONE DI POTENZA ELETTRICA DA RECUPERI TERMICI: DUE CASI STUDIO IN

CEMENTIFICI ITALCEMENTI


Dipartimento di Ingegneria e Scienze Applicate


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Oggetto dello studio

Recuperi a valle di forni produzione clinker

Valutazione soluzioni impiantistiche

proposte;

Simulazione soluzioni impiantistiche

e verifica prestazioni;

Definizione ciclo termico;

Analisi di soluzioni con recupero a

vapore o ORC;

Simulazione sistema circolazione

fumi.

Suspension Preheaterboiler (PH or SP)

Air Quenching Cooler boiler

(AQC)


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Caso 1: cementificio di Pukrang (Thailand)

Verifica del progetto WHR&PG

Pel = 21 MW

Qth = 187 MW


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Volume flow rate

Tin pin

Nm3/h °C daPa(G)Line #1

AQC1 203200 360SP1k 160000 340 -500SP1c 210000 345 -700

Line #2AQC2 272600 360SP2k 232000 343 -545

SP2c (OFF) 257000 360 -705SP2c (ON) 191047 360

3 diverse condizioni operative:

Case 1 Normal load (designcondition): Line #1 and Line#2 are ON; raw mill is ON.

Case 2a Minimum load:Line #1 is idle and Line #2 isON; raw mill is ON.

Case 2b Most minimumload: Line #2 is idle and Line#1 is ON; raw mill is ON.

Site Altitude + 10 mAmbient pressure 1.012 bar aAmbient average temperature

29.5°C

Wet bulb temperature 28 °C

Verifica del progetto WHR&PG



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AQC boiler 1 AQC boiler 2

SP boiler 1 SP boiler 2



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THERMOFLEX Version 21.0 barigozzi Universita Degli Studi Di Bergamo

Linea #1 1461 File = C:\Italcementi\Phukrang\PUKRANG_V3.tfx 12-01-2011 15:30:16

bar C t/h kJ/kg

SP1c SP1k

AQC1

FromCondenser

ToFLUSHER

ToSteam Turbine

PH-1 Circulation Pump

p bar

T C

m t/h

h kJ/kg

8 9 12 13 14 15 16 17 24 25 26 30 35 36 37 38 39 45 47 48 49 50 51 52 64 77 78 79 93 107

1.012 16.4 1.012 8.4 1.013 8.6 1.012 8.4 1.033 1.014 1.025 7.89 7.89 8.6 12 8.4 8.4 8.6 1.022 7.89 1.028 7.89 1.014 7.89 17 8.4 8.6 8.6 8.4 8.4

83.69 167.1 190.5 172.4 199 173.4 202.1 172.4 345 360 340 314.9 324.5 167.2 168.2 167.1 167.1 167.2 320.1 313.1 326.5 317.3 335.9 343 49.05 167.2 167.2 167.2 168.3 167.1

259.1 60.76 218.5 15.22 259.1 17.99 297.5 19.86 297.5 259.1 218.5 35.08 53.08 17.99 35.08 19.86 15.22 7.68 218.5 19.86 297.5 15.22 259.1 17.99 60.76 35.08 60.76 35.08 35.08 35.08

60.79 707 175 2769.3 181.4 2770.3 186.1 2769.3 345.5 354.1 341.3 3089 3109 707 712 707 707 707 318.7 3085 324.5 3094 327.8 3147 206.7 707 707 707 712 707

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36

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48 50

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9

78

7977

8485

86

3793107

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45

64

64

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35

86

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78

7977

8485

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3793107

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DESIGN MODE : dimensionamento dei componenti per rispettare le proprietà termodinamiche del PFD

THERMOFLEX®



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WHRBs AQC1 SP1k SP1c AQC2 SP2k SP2c Units

Pinch point 27.9 18.1 30.4 16.0 23.7 32.0 °CApproach Temperature 6 °CWaste Gas Exit Temperature 86.6 190.6 202.8 86.5 196.2 204.9 °C

Input Heat transfer rate 25.04 20.43 28.17 33.59 29.95 36.33 MWth.

Recovered Heat transfer rate 20.79 10.08 13.11 27.9 14.41 17.61 MWth.

Feed water mass flow rate 60.75 15.22 19.86 71.36 21.76 26.46 t/h

Feed water temperature at inlet

48.7 167.5 167.5 48.7 167.5 167.5 °C

Superheated steam pressure 7.89 bar a

Superheated steam temperature

343 317.3 313.1 348 316 322.2 °C

Superheated steam mass flow rate

17.99 15.22 19.86 25.8 21.76 26.46 t/h

Thermal Efficiency 83.04 49.36 46.52 83.07 48.10 48.47 %

0 5000 10000 15000 20000 250000

100

200

300

400

Heat Transfer [kW]

Tem

peratu

re [

C]

Mutiple HX T-Q1

E[7]8605

B[10]10303

S[39]1883

THERMOFLEX Version 21.0 Microsoft Universita Degli Studi Di Bergamo

File = 1461 File = C:\Italcementi\Phukrang\Pukrang_v1.tfx 10-19-2011 16:53:14

0 3000 6000 9000 12000150

200

250

300

350

400

Heat Transfer [kW]

Tem

per

atu

re [

C]

Mutiple HX T-Q3

B[9]8712

S[37]1371

THERMOFLEX Version 21.0 Microsoft Universita Degli Studi Di Bergamo

File = 1461 File = C:\Italcementi\Phukrang\Pukrang_v2.tfx 10-19-2011 19:12:54

AQC boiler SP boiler

Diagrams of gas-steam/water temperature profiles vs. heat transfer rate

WHRBs thermal sizing



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Steam Surface Condenser sizing

Heat Transfer Rate 80.493 MWth.

Cooling water inlet temperature

32 °C

Cooling water mass flow rate

10678 t/h

Cooling water temperature rise

6.5 °C

UA 8149 kW/°C

SH steam mass flow 125.9 t/hSH steam pressure 6.89 bar aSH steam temperature 323.3 °CHP turbine efficiency 82.6 %Flusher steam mass flow

0.9 t/h

Flusher steam pressure 1.3 bar aFlusher steam temperature

107.1 °C

LP turbine efficiency 80 %Exit steam mass flow 126.9 t/hExit pressure 0.098 bar aExit temperature 45.44 °CExit steam fraction 0.954 -Mechanical efficiency 97.8 %Generator efficiency 97.4 %Power factor 0.8 -

5.5 6.0 6.5 7.0 7.5 8.0 8.52200

2400

2600

2800

3000

3200

3400

Entropy [kJ/kg-C]

En

tha

lpy

[k

J/k

g]

ST Mollier Chart1

0.95

0.9

0.85

Wilson 0.97

200 C

300 C

400 C6.89 bar

1.301 bar

0.098 bar

THERMOFLEX Version 21.0 barigozzi Universita Degli Studi Di Bergamo

File = 1461 File = C:\ITALCEMENTI\PHUKRANG\PUKRANG_V2.TFX 11-17-2011 16:02:03

Turbine sizing



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WHR&PG Plant PFDDESIGN

simulationUnits

Net Power Output 19.42 19.22 MWe

Total Heat Transfer Rate Input 193.20 176.11 MWth

Heat Transfer Rate Recovered 105.11 103.74 MWth

WHRBs Average Thermal Efficiency 54.4 59.6 %Plant Overall Net Thermal Efficiency 10.05 11.04 %

Case 1 Normal load

WHR&PG Plant PFDOFF-DESIGN simulation

Units

Net Power Output 10.91 10.48 MWe

Total Heat Transfer Rate Input 111.00 101.40 MWth

Heat Transfer Rate Recovered 60.70 59.46 MWth

WHRBs Average Thermal Efficiency 54.7 58.7 %Plant Overall Net Thermal Efficiency 9.83 10.19 %

Case 2a Minimum load

Nr. of h/yr

Energy generated (GWh/yr)

Case 1 4287 82.416Case 2a 1741 18.034Case 2b 1723 11.705Overall 7751 112.155



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Caso 2: cementificio di Ait-Baha (Marocco)

Simulazione impianto ORC-WHR&PG


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Simulazione impianto ORC-WHR&PG

ProgettoSimulazione “Design”

Unità

Q olio diatermico in ingresso ORC 11245 11246 kWt

T olio diatermico in-out 278/140 278/140 °CT acqua torre a secco al condensatore 26/47 26/47 °CPel netta 1597 1596 kWe

hel netto 14.2 14.2 %

Dimensionamento HXsSimulazione “Design”

Unità

UA scambiatore fumi/olio diatermico 160 kW/KUA economizzatore 64.64 kW/KUA evaporatore 71.74 kW/KUA split 35.55 kW/KUA rigeneratore 719.4 kW/KUA condensatore 576.4 kW/K



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Simulazione come strumento diagnostico

Attuale funzionamento dell'impianto non ricostruibile mettendo in off-design il modello costruito sulle

condizioni di progetto

Scambiatore fumi /olio diatermico dimensionato per un valore di UA pari

a 85.75 kW/K (53.6% del valore ottenuto in condizioni di design)

Il calcolo di verifica eseguito da Italcementi ha indicato un valore di UA pari a 85.9 kW/K in accordo col

modello


Dipartimento di Ingegneria e Scienze ApplicateProf. Antonio Perdichizzi

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Energy Systems & TurbomachineryResearch Group

Dip. di Ingegneria e Scienze Applicate

[email protected]@[email protected]

[email protected]

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Energy Systems and Turbomachinery