International Journal of Innovative Technology and Exploring Engineering (IJITEE)

ISSN: 2278-3075, Volume-2, Issue-1, December 2012

Plants

Energy Efficiency Improvement in Thermal Power

Genesis Murehwa, Davison Zimwara, Wellington Tumbudzuku, Samson Mhlanga
identification of these loses. Energy analysis evaluates the
Abstract - The purpose of the study outlined
in this
is to identify
energy
generally
on its quantity only, whereas exergy
major energy loss areas in Zimbabwes thermal
power
stations
analysis
assesses
the energy on quantity as well as the quality.
and develop a plan to reduce them using energy and exergy
The aim of the exergy analysis is to identify the magnitudes
analysis as the tools. The energy supply to demand is narrowing
and the locations of real energy losses, in order to improve
down day by day around the world due to the growing demand and
sometimes due to ageing of machinery. Most of the power plants the existing systems, processes or components, (Tekin and
are designed by the energetic performance criteria based not onlyBeyramogle: 1998). This study identifies specific plant
systems and equipment where efficiency improvements can
on the first law of thermodynamics , but the real useful energy loss
cannot be justified by the fist law of thermodynamics, because it be realized either through new installations or modifications,
does not differentiate between the quality and quantity of energy.and provides estimates of the resulting net plant heat rate
The present study deals with the comparison of energy and exergy
reductions and the order-of-magnitude costs for
analysis of thermal power plants stimulated by coal. Our nationalimplementation.
electricity requirement is about 2100MW against 1615MW supply;
1.1 Aim
this is evident of about 21% deficit in terms of power requirements.
The main aim of the study is to identify areas where energy
In view of this situation, the project seeks to increase output from
losses are occurring and develop them for efficient and
the Power Stations (PS) in the process closing down on the power
shortages now and in the future through effective and efficiency effective improvement in a thermal power station.
improvement.
Keywords- Energy, Exergy, Effective, Efficiency, Improvement,1.2 Objectives
Thermal Power Station
The object to satisfy this are

To conduct energy analysis of the overall plant and

I. INTRODUCTION determine the efficiencies and energy losses of all the
major
components on the power plant.
The SADC region including Zimbabwe they
are suffering
Select
and
develop the areas where energy losses are
from critical shortage of power and this has negative impact
being experienced.
on industrial development. The expansion on the demand
Determine
the
costs
and payback periods for the new
side resulted in over stretching of the current electricity
technologies
suggested
for efficiency improvement.
generation capacity coupled with aging thermal plants which
are still utilising old technology. The paper will focus on the
1.3 Scope
energy efficiency improvement in thermal stations.
The study
scope
Thermal Power Stations generate electricity
through
a encompasses three major tasks, energy
analysis
and a
the identification of methods to
thermal power plant; its installed capacityandis exergy
designed
with
reduce the energy losses of power plant and the determination
common range of boilers feeding into ofcommon
steam
their associated
costs involved with the installation of the
possible
measure
to
for the problem. Energy analysis is
receivers from where any of the turbines tape the cater
steam.
to be done on components from the combustor to the
Currently only few boilers are in operation
withgenerator.
an output of
electrical
approximately 1615MW. The power plants use coal1.4asNeed
theJustification
supply in Zimbabwe is becoming a shortage
primary input for generating electricity.dueElectricity
The
plant
use
to increase in demand made up of import displacement,
expanded rural electrification program, new
20-30% of energy value of primary fuelsurban
andexpansion,
the remaining
investments and the need of spinning reserves. The current
70-80% is lost during generation, transmission
and
electricity supply
situation in the country is as shown in Table
distribution of which major loss is in the1 below.
form of heat.
The
Table 1 Power Station in Zimbabwe

heat rate of a plant is the amount of fuel energy input needed

Po wer
Type Of
YearInstalled
Dependabl
Station
Station
Commissioned
Capacity
e Capacity
(Btu, higher heating value basis) to produce
1 kWh
Hwange Thermal
1987 92 of
0MW net
780MW
Kariba Hydro 1970 75 0MW 750MW
12 0MW 25MW
electrical energy
output.
This
study
wasBulawayo
doneThermal
to 1950
identify
Manuscript
received on
December,
2012
Harare
1960 12 0MW 30MW
Genesis Murehwa, National University of Science
and Thermal
Technology,
Mun
yati Ascot,
Thermal
1938 12 0MW 30MW
Industrial
Manufacturin
g Engineering
P O Box
939,
various methods
toandreduce
the
heat rate
ofAC
existing
coal-fired
Bulawayo, Zimbabwe
Zimwara, National
University of Science
and Technology,
power plant in Davison
Bulawayo
by identifying
areas
that cause
the
MW 1 615MW
Industrial and Manufacturin g Engineering P O Box AC
939, 1Ascot,
Table
shows theTOTALS
installed2 030
capacity
against the
Bulawayo,
Zimbabwe
most heat losses and introducing the new
technologies
dependable
capacity, so that
our goal is to work towards
Wellington Tumbudzuku, National University of Science and
increasing
theused
dependable
supply to as close as possible to the
Technology, Energy
Indu strial andand
Manufacturing
Engineering
P O Box is
AC
939,
cater for the losses.
exergy
analysis
for the
Ascot, Bulawayo, Zimbabwe
Industrial and Manufacturin g Engineering P Oinstalled
Box AC capacity.
939, Ascot,Our power plants in the country currently
Samson Mhlanga. National University of Science
and Technology,
provide
about
87.6%
20 of the installed capacity, a situation we
Bulawayo, Zimbabwe

Energy Efficiency Improvement in Thermal Power Plants

intend to increase through efficiency
Outputs
improvement
to the process
of the are combustion products and the
entire power plants.
power generated. Power generated for the year 2011 is as
shown in Figure 1 below.
1.5 Current Supply-Demand Situation
Table 2 shows the current demand supply in Zimbabwe.
Table 2 Current demand
Dependable Capacity
1615MW
Available Maximum Capacity
1615MW
Maximum Demand
2100MW
Our national electricity requirements are about 2100MW
against 1615MW supply; this is evident of about 21% deficit
in terms of power requirements as shown in table 2, the future
supply- demand forecast in Zimbabwe will require an
additional of 1750MW by 2015 to further increase the power
shortage.

Power generated
(MW)
10
20
0
30
Power generated (MW)

1.6 Future Supply-Demand Situation

Figure 1.Power generated for the year 2011
Zimbabwe will require an additional 1750MW by 2015. In
view of this situation, the project seeks to increase output
II. DESCRIPTION OF THE PLANT
from Thermal Power Station (TPS) in the process closing
down on the power shortages now and in the future. Energy A schematic diagram of a plant with its various significant
components is shown in Figure 2. The continuous supply of
efficiency improvement measures provide a win-win
situation by promoting cost-savings, lowering environmentalde-mineralized water is ensured to the condenser hot well for
impacts while at the same time promoting economic growth the normal running of the plant at a constant load. The
and social development. In addition to generating very largecondensate extraction pump (EXP) feeds the feed water to the
annual energy savings, present outlays on energy efficiencyejector from the hot well. After the ejector exit, the feed water
would avoid investment in energy infrastructure that wouldpasses through the gland steam cooler, and the low pressure
otherwise be needed to keep pace with accelerating demand.heater (LP). From the outlet of the low pressure heater (LP)
Efficiency improvement in all power plants can result in the
a condensate enters into the boiler feed pump (BFP) where
the
sustainable gain in terms of electricity supply but this will condensate is pumped from the high pressure heater one
need to be aided by other supply options such as imports and(HP1) to high pressure heater three (HP3). Then the
condensate passes through the economizer, and then enters
commissioning of new plants around the country.
1.7 Methodology
into the boiler drum. There is a continuous circulation of
between
the drum and the water walls and a part of the
The project is going to cover the water
following
areas:
feed
water
is
converted
A description of the facilities and their principal into steam. The steam is separated in
the boiler drum and supplied to the super heater section and
operation on the plant.
the boiler condenser section. The super heated steam
A discussion of all major energy consuming systems.
A description of all recommended Energy Conservation produced in the super heater then enters into the turbine
turbine
stop valve and then rotates the electrical
Measures (ECMs) with their through
specific the
energy
impact.
generator.
After
expansion
in the turbine the exhaust steam is
Energy and exergy analysis of the whole plant.
A review on the implementation costs, benefits and condensed in the condenser and is used for the closed cycle as
payback period.
shown in Figure 2.
Specific conclusions and recommendations.
1.8 Inputs and Outputs
The inputs to the thermal power plant processes at Power
Stations are coal and water. The source of these is Hwange
Colliery Company about 480 kilometres away from
Bulawayo. The coal chemistry is as given in Table 3.
Table 3 Coal chemistry
Total Moisture
Ash
Volatile Matter
Fixed Carbon
Gross Calorific Valve (Specific Energy)
Sulphur

3.6 6.4%
1.5 -12.4%
19.3 - 42%
23.8-66.7%
13.87-32.08MJ/kg
0.15- 4.67%

Figure 2 Schematic diagram of thermal plant

Crucible Swelling Number 0-9+.
Ash Fusion Temperature 1550-1080oC

III. is21
RELATED
LITERATURE
The related literature
Rankine
analysis.cycle,
energy and exergy

International Journal of Innovative Technology and Exploring Engineering (IJITEE)

ISSN: 2278-3075, Volume-2, Issue-1, December 2012
defined as the ratio of energy output to the energy input to
3.1 Rankine cycle
system
al, 1997).
Rankine cycle is the idealized cycle(Jin
foretsteam
power
plants; it is a heat engine with a vapour power cycle (Wiser,
3.3 Exergy analysis
2000). The common working fluid is water, and the cycle
Exergy is a generic term for a group of concepts that define
consists of four processes as shown in Figure 3.
the maximum possible work potential of a system, a stream of
matter or heat interaction; the state of the environment being
used as the datum state. In an open flow s ystem there are
three types of energy transfer across the control surface
namely working transfer, heat transfer, and energy associated
with mass transfer or flow. The work transfer is equivalent to
the maximum work, which can be obtained from that form of
energy (Naterer et al, 2010).
Energy analysis is based on the first law of
thermodynamics, which is related to the conservation of
energy. Second law analysis is a method that uses the
conservation of mass and degradation of the quality of energy
along with the entropy generation in the analysis, design and
improvement of energy systems. Exergy analysis is a useful
method; to complement but not to replace energy analysis,
(Bajan, 2002).
The irreversibility maybe due to heat transfer, through
finite temperature difference, mixing of fluids at different
temperature and mechanical friction. Exergy analysis is an
effective means, to pinpoint losses due to irreversibility in a
real situation (Dincer and Rosen, 2003).
IV. THERMAL POWER PLANT PERFORMANCE
MEASURES
The thermal performance indicator is used to monitor
thermal power station units' efficiency. It is an indication of
the thermal
units' plant
success in meeting thermal design
Figure 3. Rankine cycle representation
of power
capabilities and enables comparison among similar units.
(a) Power plant circuit
Thermal performance indicator =
Process 1-2: Isentropic compression (Pump; during the
x100 .Eqn 1
isentropic compression process, external work is done on
the working fluid by the pumping. Pumping takes place This indicator is used to evaluate operating parameter
deviation from the design values and take appropriate
from low to high pressure.
corrective
whereornecessary.
Process 2-3: Isobaric heat supply
(Steam action
Generator
The following indicators are used to evaluate station
Boiler; heat from the high temperature source is added to
performance on daily, monthly, quarterly and annually basis.
the working fluid to convert it into superheated steam.
Pressurised liquid enters a boiler where it is heatedThese
at indicators can be calculated for the unit or Station
basis.
constant pressure to dry saturated vapour.
Process 3-4: Isentropic expansion (Steam turbine); an Plant Availability
isentropic process, the entropy of working fluid remains
Availability =
x100
constant. The dry saturated vapour expands through a
.Eqn 2
turbine, generating power. The temperature decreases
Plant
load factor
and pressure drops, and condensation can take place may
occur.
Plant load factor= x100
Process 4-1: Isobaric heat rejection (Condenser; An
.Eqn 3
isobaric process, in which the pressure of working fluid
Planned
outage rate
remains constant. The wet vapour then enters a
condenser where it is condensed at a constant
%planned outage rate= x100
temperature to become a saturated liquid, (Kapooria, et
.Eqn 4
al, 2008)
Forced outage rate
transfer across the control surface
namely
working transfer,
3.2 Energy
analysis
%forced outage rate = x100
heat transfer (Qk), and energy associated with mass transfer
In an open flow system there are three types of energy
and/or flow. The temperature (Tk) from the heat source and
..Eqn 5
the network (W) developed by the system are used for the
Reliability
analysis of open flow systems and to analyze plant
It is an indication of how well maintenance management
performance whilst kinetic and potential energy changes areprogrammes are being executed %reliability = 100% - forced
ignored. The energy or first law efficiency of a system isIt is an indication
outage
of how
rate
22 well
.
Thermal
the plant
efficiency
is being
Eqn 6operated as

Energy Efficiency Improvement in Thermal Power Plants

compared to the design characteristics.
The first law efficiency (the energy efficiency) of different
Thermal efficiency =
components is alsox100
calculated and their comparison is
depicted in Figure 4. It is noted that the energy efficiency of
. Eqn 7
the boiler is 70.27%, which upon replacement or retrofitting
Where: MC quantity of coal consumed
can yield 20% more on effi ciency. So, replacing boilers or
CV- calorific value of coalretrofitting makes good sense for reasons like, significant fuel
Overall unit efficiency, = Bo il e r x T urb x Ge n x wr ks
cost savings and improved reliability and safety. The overall
Where: Bo il e r boiler efficiency
plant energy effi ciency is 18.28%, which upon replacement
T u rb - turbine efficiency
or retrofitting of other plant components can result in an
Ge n generator efficiency
increase of about 20%.
wrk s works efficiency
Operational Efficiency
Operational efficiency is the ratio of the total electricity
produced by the plant during a period of time compared to the
total potential electricity that could have been produced if the
plant operated at 100 percent in the period.
Operational efficiency =
x 100 ..Eqn 8
where:
E = energy output from the power plant in the period (kWh)
E10 0% = potential energy output from the power plant
operated at 100% in the period (kWh)
Economic Efficiency
Economic efficiency is the ratio between productions
costs, including fuel, labour, materials and services, and
energy output from the power plant for a period of time.
Economic efficiency=
.. Eqn 9
Figure 5. First law efficiencies of components and plants
V. DISCUSSION OF
RESULTS
The
comparison of exergy losses between the different
From the energy analysis, thecomponents
overall plantofenergy
the plant
loss
areisshown in Figure 6. It is noted that
calculated as 81.72%. The comparison of energy losses the maximum exergy loss occurs in the Boiler (48.92%),
between different components is given in Figure 4. It iswhich is approximately 60% of the total plant exergy losses
observed that the maximum energy loss (47.79%) occurred inoccur in the boiler. This may be due to the irreversibility of
the condenser, this is due to the reason of heat energy the combustion process in the boiler/combustor. The
expulsion from the condenser. Thus the energy analysis percentage of exergy losses for the plant components are
diverts our attention towards the condenser for the plantcompared and shown in Figure 6. The total plant exergy
performance improvement. Approximately half of the totaldestruction is calculated as 81.72%.
plant energy losses occur in the condenser only and theseThe exergy loss in the boiler is mainly due to the
combustion reaction and to the large temperature difference
losses are practically useless for the generation of electric
during heat transfer between the combustion gas and steam.
power. Thus the analysis of the plant based only on the First
Factors that contribute to high amount of irreversibilitys are
law principles may mislead to the point that the chances of
tubes fouling, defective burners, fuel quality, inefficient soot
improving the electric power output of the plant is greater in
blowers, valves steam traps and air heaters fouling.
the condenser by means of reducing its huge energy losses, The exergy loss in the turbines is due to the frictional
which is almost impracticable.Hence the First law analysis effects
pressurecannot
drops across
the turbine blades as well as
(energyand
analysis)
be
the
pressure
and
heat
losses
to
the surroundings. The HPT
used to pinpoint prospective areas for improving the
and
LPT
contribute
6.36%
of
the
total exergy destruction
efficiency of the electric power generation. However, the
which
indicates
a
need
for
reducing
its
irreversibilitys. Other
Second law analysis serves to identify the true power
factors
that
may
contribute
to
the
irreversibilitys
are most
generation inefficiencies occurring throughout the power
likely
due
to
the
throttling,
losses
at
the
turbine
governor
station.
valves, silica deposited at the nozzles. Overhauling the
turbine maybe needed to check the real causes for improving
plant performance.
The of
exergy
in to
thethe
FWH,
the thermodynamic
point
viewloss
are esdue
finitefrom
temperature
difference
between the streams, which interchange heat loss to the
atmosphere and also due to the pressure drop. HP3 shows the
highest exergy loss, so tubes inspection should be
recommended during plant outage to determine the real
cause. Other causes include wrong venting operation, high
percentage of plugged tubes, poor maintenance and wrong
Figure 4.Comparison
components
of energy
operating
losses inwater
the plant
level.and 23

International
Journal
of Innovative
Technology
and Exploring
(IJITEE)
Energy
Efficiency
Improvement
in Thermal
PowerEngineering
Plants
ISSN: 2278-3075, Volume-2, Issue-1, December 2012

recommendation of retrofitting and replacement was done for

the system. On going work in development of intelligent
power plant is expected to improve stability of steam
headers, responsiveness to steam demand, increase power
generation flexibility, minimize operations cost, improve
overall plant efficiency, increase fuel cost savings and reduce
CO2 Emission.

including engineers and journey men left the country for

greener pastures during the era 2007 and 2008 economic
meltdown.
Vandalism of machinery has proven a major challenge as
the security is having a tough time as one cant tell
whether its an internal or external job which is in
operation.
REFERENCES
VII. RECOMMENDATIONS

[1 ] Tekin T. and Bayramoglu M., (1998) Exergy Analysis of the Sugar

The
recommends
that results from this study be
Production Process from Sugar Beets, Int.
J. ofresearch
Energy Research,
Vol
22 ,591-6 01,1998.
used as a guide in determining future process improvement
[2 ] Wiser, Wendell H (200 0), Energy resources:
occurrence,
production,
actions.
Using exergy
analysis, the boiler was found to have
conversion, use .ISBM 0-387-98744-4(alk.paper)
the
highest
percentage
[3 ] Jin H., Ishida M., Kobayashi M., Nunokawa M., (1997), Exergy of exergy destruction (48.92%) of the
Evaluation of Two Current Advanced Power Plants: Supercritical
overall plant (81.66%). To reduce this loss retrofitting and
Steam Turbine and Combined Cycle,0Trans. of ASME, Vol. 119, pp replacement of some boiler elements is necessary for the
250 256, Dec. 199 7.
[4 ] Naterer GF, Regulagadda P, Dincer I.,overall
(2010), plant
Exergyefficiency
analysis of improvement.
a
The
Power
Station
should also include the concepts of an
thermal p ower plant with measured boiler and turbine losses, Applied
intelligent power plant, the concepts include:
Thermal Engineering 2010; 30:970 6.
[5 ] Bejan, (2002 ), Fundamentals of Exergy Analysis,
tropy Generation
Process En
Monitoring,
Optimization and Management
Minimization, and the Generation of Flow Architecture, International
-Real-time
Process
data
collection
Jou rnal of Energy Research, Vo l. 26, No. 7, 200 2, p p. 545 -565.
-Real-time
process
statistics
[6 ] Rosen MA. (2001) Energy and exergy based comparison of coal-fired
-Real-time
process
monitoring
and nuclear steam%power
plants. loss
International
Journal
of Exergy
of exergy
Analysis 2001.
-Schematics visualization and analysis
[7 ] Kapooria R.K, Ku mar S, Kasana K.S,(2008), An analysis of a thermal
-Reports Generation
power plant working onFigure
a Rank ine
cycle: a th eoretical
investigation,
6 Comparison
of exergy
losses
in the power
plant and and Analysis, this should be
Performance
Calculation
Journal of Energy in Southern Africa.Vol.No.1. February 2008.

10
20
30
40
50
60
70
80
90

components done on the following areas: Plant Performance, Unit

The Second law efficiency (thePerformance,
exergy efficiency)
of Energy Balance (Boiler, Turbine,
Mass and
different components is also calculated and their comparison
Feedwater Heater, Condenser, Cooling Tower, Air
is depicted in Figure 7. It is noted that the exergy efficiency
Pre-heater, Feedwater Pump, Condensing Pump,
of the turbine, the feed water heaters and the heat pumps are
Circulating Pump, Induced Draft Fans, Force Draft Fans,
90.07%, 77.23%, and 83.63% respectively. The exergy
and Primary Air Fans).
efficiency of the boiler and the condenser are calculated asEconomical analysis and optimal operation guidance
69.53% and 84.20% respectivel y. The overall plant exergy
- Calculate and compare bet ween the actually controllable
efficiency is 18.28%. Thus the exergy analysis of the plant parameters and expected parameters to obtaining the
pinpoints that the prospective improvement in the combustor energy losses
- Analyze the reasons of deviation by expert system, and
can improve the overall plant efficiency.
providing the operation direction
- Primary Controllable Losses
Main Steam Pressure
Main Steam Temperature
Reheat Steam Temperature
Carbon Content of Fly Ash
- Primary uncontrollable Losses
RH Pressure Loss
Fuel Thermal Value
HP Turbine Efficiency
- Advanced Control Technology, for example:
To optimize the excess air in the combustion process to
Figure 7. Second law efficiency of the plant and component decrease CO emission
Calculate the best relationship between oxygen, air flow,
coal supply, main steam flow and so on
VI.CHALLENGES
Online Performance Test
Coal is very expensive as the
mode Performance
of transport Test
from
Boiler
Hwange Colliery which is about 480 kilometres away is Turbine Performance Test
by road instead of rail transport. Bulawayo is in region
Condenser Performance Test
five geographically meaning water is very scarce and the Air Pre-heater Leakage Test
city council resort to rationing. The industrial hub might Vacuum Leakage Test
be spared the rationing but at the end of the day the cost of
CONCLUSION
the precious liquid has got an effect on the efficiency ofenergy analysis only power plants VIII.
as a performance
measure
the plant.
that
will
help
improve
effi
ciency.
Exergy
analysis
wason
The paper set to show the weakness of depending
Worker morale is very low due to the current economic
undertaken at the thermal power plant which highlighted the
situation of economic recovery in the country.
The
situation
humanwhich
resource
saw base
manyisqualified
areas
another
thattechnical
impending
could bepersonnel
addressed
issue
24 a to improve the efficiency. A
25