A 500 MW IGCC Power Plant Project

Second Report

By Group 2

Name Student ID
Annas Fauzy N18087050
Harikrishnan M K N16087070
Safdar Abbas N36077118
Raza Muhammad Mohsin N16087020
Rusdan Aditya Aji N P46087035
Satishkumar Subendran N16087046

SPECIAL TOPICS IN COMBUSTION

MAY 2020
About IGCC
 One of the promising power plant technologies is an IGCC power plant. IGCC power
plant is an abbreviation of the Integrated combined cycle power plant. It is the power generation
strategy by combining gas and steam turbines. The IGCC power plant will allow the gasification
of a wide range of both solid, liquid, or waste fuel to convert into synthesis gas (Syngas). The
syngas contains a hydrogen and carbon monoxide—this syngas used as fuel of the gas turbine
coupled with a generator to produce the electricity. Coal is the conventional fuel used in the
gasification process.
In the common power plant, Steam turbine and the boiler is a popular choice as an
essential part to generate electricity. In the early beginning of
The objective of this project is to design the produce about 500 MW of gross power
(before subtracting auxiliary power), and process roughly 15300 TPD of pulverized coal. The
plant site was assumed to be under ISO condition of the surrounding (59°F/15°C,
14.7psia/1.013bar, 60% relative humidity) and located at sea level. All other assumptions and
operating data provided in the sections where they are most relevant.

A. Case summary and software description

Figure 1. System full diagram

To predict valuable property in our power plant, we built a model that construct using
ASPEN plus software. Aspen Plus is the process simulation software developed by Aspen Tech
that possible to predict the overall balance and give a good estimation before we decide in the
real situation. The summary of the simplified schematic of the IGCC power plant that we used in
our model. It includes the power generator parts (gasifiers, gas and steam turbine, heat recovery
steam generator, and boiler) and supporting part (pollutant management and water treatment).
In this modelling, we more focus on the energy generation of the work by the gasifiers,
gas turbine, heat recovery steam generator, and boiler. Each part will show the energy and mass
balance inside the simulation result and relate what is the strategy may use to achieve it. We use
a combined cycle between gas and a three-stage steam turbine. Also, the combination of heat
recovery steam generators and the boiler used together to support the three-stages steam turbine
in the maximum power production. The block diagram for Aspen plus software configuration
showed in the figure below.

Figure 2, flow sheet for Aspen Plus Modeling for IGCC

A. COAL PREPARATION

The conversion of this coal to the end goal of electricity is a multifaceted process.
Transportation of coal plays a vital role in designing a power plant. Once unloaded, the coal is
then pulverized into a fine powder by a large grinder. The crushing process is to ensure nearly
complete burning of the coal to maximize the heat given off and to minimize pollutants. The
pulverized coal put to the Gasifier, where gasification occurs, and the coal provides heat to the
power plant as well as the production of syngas.
PROCEDURE
● Raw coal storage and transportation system
The raw coal with size under 35mm and moisture under 15% is conveyed to raw coal
shed by the auto dumper. The raw coal stored in coal sheds load to coal receiving hoppers by the
loader. The raw coal in coal receiving hoppers is fed to the bucket elevator evenly by a speed
adjustable feeding belt conveyor. The raw coal discharged when it is lifted to the required height
and then comes to the powder making system by double-layer airlock valve.
● Pulverized Coal Preparation System:
The raw coal from storage and conveying systems come into air swept coal mills for
grinding. The coal powder mass and heat transfer with 200℃~350℃ hot air. The moisture enters
flue gas from coal. Coal powder is dried by hot air. Then coal powder comes to the powder
separator with airflow for classification. The separated coarse powder comes to a mill for
regrinding. The fine powder comes to a powder collecting system with airflow through coal
windpipe.
● Pulverized Coal Collecting System:
Under the negative pressure of the induced draught fan set after explosion-proof bag
filter, the qualified coal powder discharged from the powder separator and came to the
explosion-proof bag filter by coal windpipe. After it goes to filter bags of dust collector for
filtration, the coal powder is collected and dropped to a coal powder hopper underneath the dust
collector. The filtered and purified flue gas is discharged to the air by funnel through an induced
fan. The pulverized coal storage in the coal powder hopper is discharged to the bucket elevator
by revolving discharger and screw conveyor and then lifted to the top of the coal powder hopper
by bucket elevator. After that, it goes to a coal powder hopper by screw conveyor on the top of
the hopper.
To meet with the demand that is producing power of 500MW deals with a large amount
of coal. As a result of the modelling, coal is fed into the Gasifier for an amount of
578330.4kg/hr. With the coal, the air was also fed at the rate of 10000 TPD for production of
500MW of power.
The coal is fed into the Gasifier around 1038°C, as mentioned in the above paragraph.
The produced syngas is a mixture of Carbon dioxide, Carbon monoxide, Methane, Nitrogen,
Hydrogen, Ash, Carbon, Sulphur, etc. as given below and are obtained from simulation.

Table 1 Syngas composition from the simulation

Syngas Composition Mass Flow Rate (kg/s)

Ar 0.470
CH4 0.028
CO 28.130
CO2 0.743
H2 14.780
H2O 0.061
N2 2.822
Total 47.04
B. . GAS AND STEAM TURBINE

Before we use the Aspen-Plus combine cycle turbine theoretical analysis

Gas Turbine

(1) → (2) Compressor

[( ]
γa−1

W comp =ṁa c p ,air T 1 1+

1 ( r
η AC AC
γa
))
−1 −1

Wcomp : Compressor Power

ηAC : Compressor isentropic efficiency
rAC : Pressure ratio
T1 : Inlet air temperature
ṁa : Mass of air
γa : Specific gas constant ratio
cp,air : Specific heat capacity of air
γa−1

T 2=T 1 1+[ 1
r
η AC AC
( γa
−1 )]
T2 : Compressor exit
(2) → (3) Combustor

T 3=
( FA ) ×CV −(1−η )( FA )× CV
c p ,air + cc

( 1+( FA ))C
p, g

CV : Caloric Value of the fuel

ηcc : Combustor efficiency
T3 : Combustor exit temperature and inlet to the gas turbine
γa −1
P4
( [ (
T 4=T 3 1−ηT 1−
P 2 ( 1−Δ PCC ) ) γa
])
P4 : Pressure at the exit of gas turbine

(3) → (4) Gas Turbine

W ¿ =m g c p , g (T 3−T 4 )
WGT : Gas Turbine Power Output
Mg : Mass of flue gas
Cp,g : Specific heat capacity of flue gas entering the gas turbine
T3 : Temperature of flue gas at the turbine inlet
T4 : Temperature of flue gas at turbine exit
P3=P2 ( 1− Δ Pcc )
ΔPcc : Combustor pressure drop

Steam Turbine
W ST =ṁ w (h 6−h7 )
WST : Steam Turbine Power Output
ṁw : Mass of steam
h6 : Enthalpy of steam turbine inlet
h7 : Enthalpy of steam turbine outlet
h + ṁ (h −h )
h6 = 7 g 4 5
ṁw
h4 : Enthalpy of tail gas inlet HRSG (Heat Recovery Steam Generator)
h5 : Enthalpy of tail gas outlet HRSG (Heat Recovery Steam Generator)
ṁ
h7 =h8 + cw (H 10 −H 11)
ṁw
ṁcw : Mass of cooling water flowing through the condenser
Wp
h 9=h8 +
ṁw
Wp : Pump power

In this section, we will introduce the turbine calculation for our requirement. The gas
turbine in our modelling is a single gas turbine and three-stage steam turbines. The gas turbine
use syngas as a fuel to run the system, while steam turbine uses an HRSG (Heat Recovery Steam
Generator) to produce steam A total mass flow rate of syngas produced from the gasifiers is
obtained to be 47.04 kg/s.
Based on this estimation, we have some comment. The syngas flow rate is too much
compared with the commercially available gas turbine. In the previous report, we proposed to
use the GE 7 F turbine based on the specification below. But after we run our modelling, we
found that the flow rate for the modelling and the design specification did not match very well.
So, we propose to double the commercial turbine that we choose in the simulation to fit with the
design specification.

Table 2 Design specification of gas turbine

Ambient 15oC, 1.013 bar, 60% Relative Humidity

Compressor Pressure ratio 16.2
Air flow to ASU (kg/s) 17.7
Combustor Nitrogen Flow (kg/s) 63.8
Steam Flow (kg/s) 4.3
Turbine Exhaust Flow (kg/s) 550
Turbine Exhaust temperature (oC) 587
Number of turbine stages 3
Performance Gas Turbine Power (MW) 232

The steam turbine used in this simulation is the three stages of the steam turbine. The
specification provided below belongs to steam turbine.

Table 4 Design specification of steam turbine

HP Steam Temperature (oC) 559

Steam Pressure (bar) 124
Steam Flow (kg/s) 98.8
IP Steam Temperature (oC) 559
Steam Pressure (bar) 31
Steam Flow (kg/s) N/A
LP Steam Temperature (oC) 280.7
Steam Pressure (bar) 4.48
Steam Flow (kg/s) 87.9
Performance Steam turbine efficiency (%) N/A
Steam turbine power (MW) 136.5

Result this is the result of the combustion product.

(1) → (2) Compressor
Compressor pressure ratio 16.2
Mass flow rate of air leaving compressor 442.5 kg/s
Polytropic efficiency 86.4 %
Work required for compressor 1.15 MW

(2) → (3)
Mass flow of flue gas 597.22 kg/s
CH4 ≈0
CO ≈0
CO2 34.61 kg/s
H2 ≈0
H2O 112.9 kg/s
AR 0.3
N2 437.063 kg/s
O2 13 kg/s
Temperature of flue gas 1800oC

The CO and H2 is complete consume in this combustor. Nevertheless, the amount of N2 and CO
become dominant. The reason behind this result of N2 and CO2 is due to the huge amount of air
compressed in the combustion chamber with respect to the fuel flow rate-also, the mixture
become lean. Then we need to use carbon capture to

(3) → (4) Gas Turbine

Temperature at the gas turbine exit 1373.37 oC

Pressure 4 bars
Work done 482.993 MW
Mass flow rate of gas turbine exit 597.22 kg/s

By assuming the discharge pressure of gas turbine to be 4 bar, as a result there was an increasing
power production which was found out to be 482.993 MW. The mass flow rate of the gas turbine
was found out to be the same with combustor exit as the mass flow rate remain constant whereas
energy flow rates varies.
(4) → (5) & (9) → (6) Heat Recovery Steam Generator (HRSG)

Temperature at the HRSG inlet (T4) 1373.37oC

Temperature at the HRSG outlet (T5) 1286.76oC
Temperature of water before HRSG (T9) 123oC
Temperature of steam after HRSG (T6) 650oC
Pressure of steam before HRSG (P9) 124 bar
Steam mass flow rate 22 kg/s
The main role of HRSG is to recover the heat from hot flue gases coming out from gas turbine to
produce steam for the steam turbine with desired temperature. The flue gases temperature
reduces from 1373.3oC to 1286.76oC. The water at 74.09oC become steam at 650oC without
change in pressure.

(6) → (7) Steam turbine

Turbine inlet steam temperature (T6) 650oC

Turbine outlet steam temperature 101.32oC
(T7)
Turbine outlet pressure (P7) 2 bar
Turbine number of stages 3 stages
Work done 21.56 mw

A threes stages of a steam turbine is used in the power plant with individual work done that is:

1. High Pressure Steam turbine : 2.098 MW

2. Intermediate Pressure Steam Turbine : 4.598 MW
3. Low Pressure Steam Turbine : 14.864 MW

In total 21.56 MW.

(7) → (8) Condenser

Condenser inlet temperature (T7) 101.32oC

Condenser inlet pressure (P7) 2 bar
Condenser outlet temperature (T8) 74.09oC
Cooling water in (T11) 25oC
Cooling water outlet (T10) 200oC

(8) → (9) Water Pump

Water inlet Temperature (T8) 74.09oC

Water outlet Temperature (T9) 77.4oC
Pressure inlet to pump (P8) 2 bar
Pressure outlet from pump (P9) 110 bar
Water pump power 368 kW