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Energy Conversion and Management 49 (2008) 20262031

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Energy Conversion and Management


journal homepage: www.elsevier.com/locate/enconman

First and second law analysis of diesel engine powered cogeneration systems
Aysegul Abusoglu, Mehmet Kanoglu *
Department of Mechanical Engineering, University of Gaziantep, 27310 Gaziantep, Turkey

a r t i c l e

i n f o

a b s t r a c t
In this article, the thermodynamic analysis of the existing diesel engine cogeneration system is performed. All necessary data are obtained from the actual diesel engine cogeneration plant located at Gaziantep, Turkey. The exergy analysis is aimed to evaluate the exergy destruction in each component as well as the exergetic efciencies. The thermodynamic performance of a 25.32 MW electricity and 8.1 tons/h steam capacity diesel engine cogeneration system at full load conditions is analyzed. The thermal efciency of the overall plant is found to be 44.2% and the exergetic efciency is 40.7%. The exergy balance equations developed in this paper may also be utilized in the exergoeconomic analysis to estimate the production costs depending on various input costs in a diesel cogeneration system. 2008 Elsevier Ltd. All rights reserved.

Article history: Received 9 July 2007 Accepted 25 February 2008 Available online 8 April 2008

Keywords: Energy Exergy Economy Exergoeconomy Diesel cogeneration

1. Introduction Cogeneration may be dened as a thermal system that produces electrical and heat energy simultaneously from a single source of fuel. For industrial and domestic applications where both kinds of energy are demanded, this turns out to be a very effective energy saving system [1]. It is commonly described as an energy conservation process because of the efciency improvement obtained by the thermal recovery, in opposition to the conventional generation, a practice in which more than one primary energy is consumed to satisfy the energy needs of a process plant. The common way of the providing the necessary energy to the process plant is to purchase the electric energy from the utility grid and to produce the required the thermal energy. In this way, cogeneration can be considered as a diverse mode of energy production [2]. Reciprocating engines are mostly employed in low and medium power cogeneration units. The lower and upper limits are often a function of the fuel in use; these can range from 50 kW to 10 MW for natural gas, from 50 kW to 50 MW for diesel, and 2.5 MW to 50 MW for heavy fuel oil. One of the major advantages of reciprocating engines is their higher electrical efciency as compared to other prime movers. There are four sources of usable waste heat from a reciprocating engine: exhaust gas, engine jacket cooling water, lube oil cooling water, and turbocharger cooling. The exhaust gases from diesel cogeneration plants represent a signicant amount of thermal energy that traditionally has been used for combined heat and power
* Corresponding author. Tel.: +90 342 3601200/2508; fax: +90 342 3601100. E-mail address: kanoglu@gantep.edu.tr (M. Kanoglu). 0196-8904/$ - see front matter 2008 Elsevier Ltd. All rights reserved. doi:10.1016/j.enconman.2008.02.012

applications. In regions of high ambient temperature it may be more appropriate to utilize the waste heat to facilitate indoor climate control or to improve the performance of the prime generation unit [3]. Recovered heat is generally in the form of hot water or low pressure steam (about 2 bar). The high temperature exhaust gas can generate medium pressure steam (about 10 bar), but the hot exhaust gas contains only about one half of the available thermal energy from a reciprocating energy. Generally the hot water and low pressure steam produced by reciprocating engine cogeneration systems is appropriate for low temperature process needs, space heating, potable water heating, and to drive absorption chillers providing cold power, air conditioning, or refrigeration. Compression ignition diesel engines are among the most efcient simple-cycle power generation options on the market. Efciency levels increase with engine size and range from about 30% for small high speed diesels up to 4248% for the large bore, slow speed engines. It is expected that efciencies can improve to a 52% in the near future [4]. According to the studies presented, diesel engines are more efcient than the equivalent ones with gas turbines, since they have a higher electrical performance that the most important parameter is the electricity produced in cogeneration scheme [5]. A serious problem of the diesel fuel and heavy fuel which are used in diesel cogeneration are their high percentage of sulfur and it becomes worse when the high cost of the sulfur elimination in the diesel engine cogeneration is considered [6]. In the present work, the rst and second law analyses are introduced in the actual diesel powered cogeneration system, in Gaziantep. The results from this study will be used in the thermoeconomic performance analysis and optimization of diesel cogeneration

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systems. This is a rst study for Turkey since diesel cogeneration is preferable in the regions in which natural gas is not available as in the case of Gaziantep. The results should provide a realistic and meaningful ground in the performance evaluation of these power systems, which may be useful in the analysis of similar systems. 2. Formulations for energy and exergy analysis Steady ow conditions can be closely approximated by devices that are intended for continuous operation such as turbines, pumps, boilers, condensers and heat exchangers of diesel engine power plants. The governing equations below can be used for these and similar devices once the transient start-up period is completed and a steady operation is established [79]. The conservation of mass principle for a general steady ow system with multiple inlets and exits can be expressed in the rate form as X X _i _e m m 1 where the subscripts i stands for inlet and e for exit. The conservation of energy equation and exergy balance for any control volume at steady state with negligible kinetic and potential energy changes can be expressed, respectively, by X X _ W _ _ i hi _ e he m 2 Q m X X _ heat W _ _ dest _ e ee _ i ei E E m m 3 _ and W _ are the net heat and work inputs, m _ is the mass where Q _ dest is the rate of ow rate of the uid stream, h is the enthalpy, E _ heat is the net exergy transfer by heat at exergy destruction, and E temperature T, which is given by  X T0 _ _ heat E Q 4 1 T The specic ow exergy and the rate of total exergy are given by e h h0 T 0 s s0 _ me _ E 5 6

where the reversible work in this case is the difference between the actual work and exergy destruction. The second-law efciency of the heat exchangers in the power plant is measured by the increase in the exergy of the cold stream divided by the decrease in the exergy of the hot stream. That is, gheat exch; II _ out E _ in _ cold he hi T 0 se si cold m E cold _ in E _ out _ hot hi he T 0 si se hot m E hot 11

_ cold and m _ hot are the mass ow rates of the cold and hot where m streams, respectively. The thermal efciency of the diesel engine is dened as the ratio of the net power generated by the engine to the rate of heat input supplied to the engine, and is expressed as gth; engine _ net _ net W W _ _ fuel qLHV m Q in 12

_ fuel is the rate of fuel input to the engine and qLHV is lower where m heating value of the fuel. Note that in internal combustion engine analysis, the choice of heating value is lower heating value of the fuel since the state of water in the exhaust is generally vapor. For the entire diesel cogeneration system the useful outputs are electricity and process heat, usually in the form of saturated steam. Then, utilization efciency for this cogeneration system may be dened as gu;cogen _ process W _ net Q _ net m _ water he hi W _ in _ fuel qLHV m Q 13

_ process is the rate of process heat used in the cogeneration where Q plant, which is taken equal to the mass ow rate of water times the enthalpy change in the steam production unit. The exergy efciency (i.e., the second-law efciency) of the diesel engine may be expressed as gengine; II _ net _ net W W _ _ m fuel efuel Efuel 14

Similarly, the exergetic efciency for the entire diesel cogeneration system may be expressed as gcogen; II _ process W _ net E _ net m _ water he hi T 0 se si water W _ in _ fuel efuel m E 15 _ process is the exergy rate of where efuel is the exergy of the fuel and E the process heat, which is equal to the exergy increase of the water in the steam production unit. Brzustowski and Brena [10] examined the ratio efuel/qLHV for homologous series of hydrocarbons. They concluded in their analysis that the proportionality constant between fuel exergy and lower heating value is given closely by efuel 1:065 qLHV 16

where the subscripts 0 stands for the restricted dead state and T0 is the dead state temperature. Thermodynamic analysis of a power system usually includes the assessment of individual performances of system components. In diesel engine powered cogeneration systems, turbines, compressors, and heat exchangers are among the components used. The isentropic efciencies of an adiabatic turbine and a compressor can be given, respectively, as gturb gcomp wa hi he ws hi he;s ws he;s hi wa he hi 7 8

where wa and ws are the actual and isentropic works, respectively. The second-law (exergy) efciency of an adiabatic turbine can be dened as a measure of how well the stream exergy of the uid is converted into shaft-work output [8] gturb; II wa hi he wrev hi he T 0 si se 9

where wrev is the reversible work which is the sum of the actual work and irreversibility (i.e., exergy destruction). The second-law efciency of the compressor is dened similarly but in opposing manner as gcomp;II wrev he hi T 0 se si he hi wa 10

In diesel cogeneration systems, the fuel most commonly used is heavy fuel oil, and in many cases the chemical composition is not known with certainty. Also, the composition of this fuel may vary from one particular application to another. The authors of Eq. (16) concluded that this equation is applicable to heavy hydrocarbons of undetermined composition. Thus, we may use this equation to obtain the fuel exergy of heavy hydrocarbons used in diesel cogeneration units after obtaining the lower heating value of the fuel. A detailed exergy analysis of a power system should include calculating the exergy destruction in each component and relating this to the exergy of the fuel and to the total exergy destruction in the system. The exergy destruction in steady ow operation of a component may be obtained using Eq. (3). It may also be calculated from

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_ gen _ dest T 0 S E

17

_ gen is the rate of entropy generation in the component. The where S rate of exergy destruction in a system for the kth component can be compared to the exergy rate of the fuel provided to the overall system as ydest;k _ dest;k E _ fuel E 18

Alternatively, the component exergy destruction rate can be compared to the total exergy destruction rate within the system as y dest;k _ dest;k E _ Edest;total 19

The two exergy destruction ratios are useful for comparisons among various components of the overall system. 3. Diesel engine powered cogeneration plant operation The diesel engine cogeneration plant (SANKO Energy) analyzed in this paper has a total installed electricity and steam generation capacities of 25.32 MW and 8.1 tons/h, respectively. The plant is located in the city of Gaziantep, Third Organized Industrial Region, located in the southeastern Turkey and it started to produce power and steam in 2002. The electricity is generated by three, diesel engine actuated generator sets each having two turbochargers. The schematic diagram of this plant for one engine set is shown in Fig. 1 where only one turbocharger is demonstrated. The engine is four-stroke compression ignition engine with 18 cylinders in a V conguration. Heavy fuel oil is used as fuel for engines. The permissible annual electricity production is 217 GW h and the annual fuel consumption is nearly 45,000 tons at designed operating conditions.

In the process, as shown in Fig. 1, electricity is generated by a diesel engine actuated generator set. When the engine starts, air is charged to the compressor of the turbocharger unit. The turbocharger consists of two machines, a turbine and a compressor, which are mounted on a common shaft. The shaft power obtained by the operation of diesel engine is transferred to the generator for electricity production. The exhaust gases leaving the engine ow through the turbine of the turbocharger unit to produce the necessary shaft work for the compressor. The air leaving the compressor is cooled by water in an intercooler before air enters the engine cylinders. The exhaust gases leaving the turbine enter the exhaust gas boiler unit to transfer heat to the feed water to produce steam for manufacturing facilities in the factory and for preheating of streams in the auxiliary equipments such as fuel forwarding module (FFM) and fuel oil in daily usage tank (FDT). This is to decrease the viscosity of the fuel. The exhaust gas leaving the boiler is sent to the DeSOx (desulphurization) unit in which the SOx emission is lowered to the acceptable legal values. Finally, after the DeSOx unit, the exhaust gases are released to the atmosphere. The water used in the plant is distributed by the collectors to the exhaust gas boiler, airwater radiator (AWR) and the ue gas treatment unit. High temperature water (HT) from AWR with the low temperature water (LT) rst enters through the intercooler (IC) for the cooling of compressed air before entering the engine. High temperature water from intercooler enters through the diesel engine for the cooling application of engine jacket while low temperature water from intercooler entering the lubrication oil cooler (LOC) for the cooling of lubrication oil from engine and then both unmixed water returns back to the airwater radiator unit. Oil is used for lubrication and cooling purposes of the engine components. The fuel used in the cogeneration system is stored in daily usage tanks and is preheated by steam before entering fuel forwarding module. Finally, it is injected to the engine cylinders through the

9 1 7 25 Atmosphere

23 AWR

24

25 6 28 WHB LOT 12 H 27 26 10

8 DeSOx 13 14 SD 11 16

20

IC 3

21

LOC

22

DIESEL ENGINE
30 19 5

15

FWT

FDT

CON 18 Lub oil Fuel oil 4 Exhaust Pool water 17 P


C : Compressor ; T : Turbine;; WHB : Waste Heat Boiler DeSOx: Desulphurization; AWR: Air-Water Radiator. IC: Intercooler; WH: Water Heater; LOC: Lub Oil Cooler LOT: Lub Oil Tank; SD: Steam Drum; FWT: Feed Water Tank; FDT: Fuel oil Day Tank; CON: Condenser; FFM: Fuel Forwarding Module; P: Pump

29 Air Water

FFM

Fig. 1. The schematic of actual diesel engine cogeneration system (DECGS).

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nozzle in the fuel forwarding module. Table 1 lists the temperature, pressure and mass ow rate data and exergy evaluations of the cogeneration plant according to the nomenclature shown in Fig. 1.

Table 2 _ P for the _ F and the exergies of products E Denitions of the exergies of the fuels E components of the actual DECGS Component C (TC) IC LOC DE T (TC) WHB FDT FFM CON P _F E _C E _2 E _3 E _ 27 E _ 28 E _ ch E _3 E _5 E _ 21 E _ 26 E f _6 E _7 E _7 E _8 E _ 15 E _ 16 E _ 17 E _ 18 E _ 18 E _ 19 E _P E _P E _2 E _1 E _ 21 E _ 20 E _ 24 E _ 23 E _ 25 E _ 24 E _6 E _ 22 E _ 27 E _ 31 E _T E _ 13 E _ 12 E _4 E _ 0;FO E _5 E _4 E _ 30 E _ 29 E _ 11 E _ 10 E

4. Results and discussion By using the approach, which is explained in Eq. (16), chemical exergy of a high-molecular weight fuel with an unknown composition may be taken as 1.065 times the lower heating value of the fuel. Then the total exergy input of fuel by considering three engine systems to this cogeneration plant becomes 62,757 kW. The exergy analysis of the diesel engine powered cogeneration system presented in this paper introduces the exergetic efciency as a parameter for evaluating the thermodynamic performance. The exergetic efciency provides a true measure of the performance of an energy system from the thermodynamic viewpoint. In dening the exergetic efciency it is necessary to identify both a product and a fuel for the cogeneration system being analyzed. The product represents the desired result produced by the component or the system. The fuel represents the resources expended to generate the product. Both the product and the fuel are expressed _ F and in terms of exergy and denitions of the exergies of the fuels E _ the exergies of products EP for the components of the existing diesel engine powered cogeneration system is given in Table 2 [11]. Table 3 shows that, 40.35% of the exergy entering the plant is converted to electrical power and 5% of this power is used for parasitic load in the plant that simply is the usage of engine power

State numbers refer to Fig. 1.

through driven of auxiliary components in the plant. Net steam production of the plant is 0.4% of total exergy input. The remaining 59.65% of the exergy input is lost. This corresponds to 37340.4 kW that is the total irreversibility in the plant. The exergetic efciency of the plant according to the Eq. (15) is obtained as 40.72%. Total exergy destruction in diesel engines of the cogeneration plant accounts nearly for 46.0% of the total exergy input and 83.32% of total exergy destruction in the plant. The rate of exergy destructions of the components of the diesel engine powered cogeneration system as compared with total fuel exergy input and net electricity production output is given in Fig. 2 by using values in Table 3. Total exergy destruction in the engine is mostly due to the highly irreversible combustion process in the engine, heat losses from engine and friction.

Table 1 Thermodynamic properties of uids of diesel engine cogeneration system (DECGS) State no. 0 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Fluid Air Water Fuel oil Lub oil Air Air Air Fuel oil Fuel oil Exhaust Exhaust Exhaust Exhaust Water Water Water Water Water Water Water Water Water Water HT water HT water HT water LT water LT water LT water Lub oil Lub oil Lub oil Air Air Pressure P (bar) 1.00 1.00 1.00 1.00 1.00 2.90 2.80 4.30 5.10 2.40 0.80 0.75 1.190 2.40 8.00 8.00 8.00 8.00 8.00 7.80 8.00 4.70 4.60 3.10 3.00 2.80 3.10 3.00 2.90 4.20 3.00 2.90 1.00 0.99 Temperature T (C) 30.0 30.0 30.0 30.0 30.0 172 53.7 81.0 137.5 451 302 247 53.7 88.0 88.0 95.0 170 170 170 70.0 170 60.0 50.0 71.7 81.0 88.0 38.4 44.9 50.3 63.0 78.3 59.7 30.0 51.0 _ Mass owrate, m (kg/s) 18.4 18.4 18.4 0.46 0.46 17.0 17.0 17.0 17.0 0.75 0.75 0.75 0.75 0.55 0.05 0.05 0.15 0.15 0.15 30.0 30.0 30.0 47.2 47.2 47.2 20.0 20.0 20.0 0.30 0.30 Enthalpy, h (kJ/kg) 303.5 125.1 303.5 446.9 313.7 103.5 231.5 739.2 580.9 523.8 327.3 326.1 326.5 397.9 718.6 718.6 718.6 293.0 718.6 250.9 209.1 299.7 338.7 368.1 160.5 187.6 210.2 65.7 97.7 58.9 303.5 324.6 Entropy, s (kJ/kg C) 5.712 0.434 5.712 5.794 5.492 0.316 0.654 6.357 6.428 6.342 5.738 1.050 1.049 1.248 2.041 2.041 2.041 0.953 2.041 0.829 0.702 0.974 1.085 1.167 0.549 0.635 0.706 0.206 0.299 0.186 5.712 5.781 Specic exergy (kJ/kg) 0.0 0.0 0.0 0.0 0.0 118.40 76.80 7.75 33.34 240.20 60.42 29.33 16.02 14.55 15.11 26.31 106.80 106.80 106.80 10.84 106.80 6.20 3.01 11.21 16.37 21.02 0.69 1.68 2.20 3.33 7.05 2.71 0 0.26 Exergy rate (kW) 0.0 2179 1413.1 3.57 15.34 4083.4 1027.1 499 272.3 11.0 11.3 20.0 80.1 58.7 5.4 0.6 16.0 1.0 0.5 336.3 491.1 630.7 32.5 79.5 104.0 66.6 141.0 54.2 0.0 0.1

State numbers refer to Fig. 1 (Data is for one engine set only).

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Table 3 Energetic and exergetic evaluations of the components of actual diesel engine powered cogeneration system (one engine set only) Components C (TC) IC LOC DE T (TC) WHB FDT FFM CON P Overall system _ (kW) Q 0.00 2452.0 790.2 0.00 0.00 970.8 21.3 70.2 6.3 0.00 80.1 _ (kW) W 2640.0 0.00 0.00 8440.0 2692.0 0.00 0.00 0.00 0.00 0.43 8440.0 _ F (kW) E 2640.0 766.0 86.8 22905.14 3056.0 528.1 4.8 15.0 0.5 0.43 20919.0 _ P (kW) E 2180.0 201.8 24.5 13295.1 2692.0 60.1 3.6 11.8 0.1 0.3 8520.1 _ D (kW) E 460.0 564.2 62.3 9610.04 364.0 468.0 1.20 3.20 0.40 0.13 11533.5 y* (%) 3.99 4.89 0.54 83.32 3.16 4.06 0.01 0.03 0.00 0.00 100.0 y (%) 2.200 2.700 0.300 45.940 1.740 2.240 0.006 0.020 0.001 0.000 55.147 ge (%) 82.56 26.33 63.01 40.35 88.10 11.43 79.06 87.43 16.57 96.97 40.72

45.40 % Diesel Engine

2.70 % Intercooler

2.24 % Waste Heat Boiler 2.20 % Compressor 1.74 % Turbine

62757 kW Exergy Input to DECGS 0.30 % Lub Oil Cooler

4.93 % Others

25320kW Net Electricity Production

Fig. 2. The rate of exergy destructions of the components of diesel engine powered cogeneration system (DECGS) as compared with fuel exergy input to the system and net electricity production output.

The exergetic efciencies of the compressor and turbine of the turbocharger are 82.56% and 88.10%, respectively. These rather high values indicate that the performance of turbocharger is in the desirable level. The exergetic efciencies of the waste heat boiler and condenser are calculated as 11.43% and 16.57%, respectively, which make them the least efcient components of the plant. This is due to the high average temperature difference between the streams in condenser and also relatively quite low mass ow rate of saturated steam as compared with exhaust gas in the waste heat boiler. Third least efcient component in the plant is intercooler with 26.33% exergetic efciency. Exergy destructions such heat exchange units in the plant are mostly due to the heat transfer across a high average temperature difference between the two unmixed streams. The percent of exergy loss associated with lubrication oil cooler is very low as seen from Table 3. This is due to the cooling of lubrication oil in the lubrication oil cooler by using low temperature water, which is highly available at desired conditions [8]. The utilization efciency of the overall cogeneration plant is found to be 44.2%. This is very high compared to thermal efciencies of power plants whose sole purpose is the production of electricity and they have efciencies in the range of 3050% [12]. In diesel engine cogeneration plants, the main product is electricity and the steam may be called as byproduct. The exhaust gas from engine is mainly utilized in two sections; it is used in turbine of the turbocharger to produce power to drive compressor and in the boiler for production of steam for the manufacturing facilities and the auxiliary equipments of the plant.

In exergetic efciency of the overall plant, the only input exergy is taken as the chemical exergy of the fuel. The exergy of the fresh treated water at the inlet of the waste heat boiler is negligibly small as compared with exergy of fuel. 5. Conclusions The detailed thermodynamic analysis of the actual diesel engine cogeneration system presented in this paper is well suited for furthering the goal of more effective energy resource use, for it enables the location, cause and true magnitude of waste to be determined. Such information can be used in the design of the new energy efcient systems and for increasing the efciency of existing systems. This detailed analysis provide a powerful and systematic tool for identifying all cost sources and for optimizing the design of diesel engine powered cogeneration systems. References
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