Reference no: EM132299085

Plant and Process Design Assignment -

In this assignment complete section A and prepare a P&ID diagram using British standards for the given Integrated Gasification Combined Cycle (IGCC). Prepare a table including the symbols used in diagram and reference it. Make sure you include level control for slurry tank and one temperature control location for cooling water.

Unit learning outcomes addressed:

• Apply thermodynamics to the understanding of various power cycles in industry.
• Have the ability to describe power cycles and industrial processes using standards.
• Apply knowledge of heat transfer to plant design.
• Apply knowledge of mechanical analysis to pressure vessel and piping design.

This is an individual exercise.

Presentation - Provide a report including list of headings, List of figures, List of tables, introduction, body of report, conclusions, and references. The report needs to be in Microsoft Word with a font size of 12. You can prepare equations/calculations/diagrams by hand, scan them, and insert into the word file.

Section A - Flow diagrams and standards

Prepare a P&ID for the attached integrated gasification combined cycle (IGCC) schematic, using the International standards given in the lecture notes for symbols/connections. Do the best you can, some symbols may be for approximately the correct equipment. Include a table of symbols. Reference the standards. You can use a software package such as autocad, or submit it neatly hand drawn (or a combination). This is an assignment to show that you understand how to access standards and put together a P&ID diagram, not on how to use software.

Please include: level control for slurry tank, one temperature control location for cooling water.

Section B - combined cycles

Overview: a combined gas - steam power cycle in Sweden provides electricity and hot water for heating duties for a small city. The gas turbine drives an electricity generator with an efficiency of 97%. A sub-critical coal fired boiler is used as a heat recovery steam generator, as well as providing additional steam from coal during the winter months. The steam turbine drives an electricity generator with an efficiency of 95%. The plant is located at sea level.

Detailed information:

a. The gas turbine has a pressure ratio of 8.0, compressor isentropic efficiency 88%, turbine isentropic efficiency 89%, gas temperature at compressor inlet 15^oC, gas temperature at turbine inlet 1070^oC. The air flow into the compressor is a constant 70 kg/s.

b. The boiler / heat exchanger drives a simple Rankine cycle with a heat exchanger pressure of 6.2 MPa absolute and a turbine outlet pressure of 10 kPa absolute. The steam is heated to 400 °C. The final gas exhaust temperature from the boiler/heat recovery steam generator is 150^oC. The feedwater temperature is 98^oC. The feedwater pump isentropic efficiency is 86% and the turbine isentropic efficiency is 83%. Assume there are no pressure losses in the piping. Assume the heat transfer efficiency of the boiler/heat exchanger does not change in both modes of operation. The boiler performance details are given in Table 1.

Table 1. Boiler performance details

Performance Parameter	Value
Boiler efficiency (%)	70
Gross calorific value of coal (kJ/kg)	25500
Coal use in a week (tonnes)	1600

Tasks -

1. Draw a schematic of the actual gas turbine cycle and temperature/specific entropy diagram. Determine the actual cycle efficiency, back work ratio and the power [in MW] produced by the gas turbine. Use air standard assumptions. Interpolate the values in the tables when required. Carry out the calculations by using the tables for ideal gas properties of air, such as Pr.

2. Work out the mass flow rate of steam produced by the gas turbine exhaust (use the turbine gas exhaust temperature determined using the relative pressure equation method), and the mass flow of steam produced by coal combustion.

3. Draw a schematic of the actual steam turbine cycle and temperature/specific entropy diagram. Then show the interaction between the Brayton and Rankine cycles.

4. Work out the net work, the cycle efficiency and the total power produced by the steam.

5. Determine the electrical power produced by the electricity generator driven by the gas turbine, by the electricity generator driven by the steam turbine, and the total electrical power.

Section C - shell and tube heat exchanger sizing

The vapour condenser for the combined gas-steam power cycle described in Section B heats river water from 15^oC to 18^oC. The condenser is a shell and tube heat exchanger with one shell pass and two tube passes. The cooling water is inside the tubes while the shell side has the condensing vapour.

More details:

a. The tube OD is 1¼" (inches), the tube wall thickness is 0.05 inches. There are 400 tubes in total.

b. The tube material is 316 Stainless Steel (SS). Assume that the effect of the steel's thermal conductivity is significant.

c. Steam condenses on the outer surface of the tubes with an associated convection coefficient of 10000 W/m².K. There is no fouling on the steam side of the tube surface.

Objectives:

1. Determine a fouling factor for the cooling river water and reference it.

2. Calculate the required mass flow rate of the cooling water.

3. Use the effectiveness-NTU method to determine the required tube length for the heat exchanger. (Detail your calculations).

Section D - Multiple effect evaporator analysis

For a desalination plant which has a multiple effect evaporator (two vessels in series and a non-contact condenser) as its main fresh water production system, determine:

- The temperature of the sea water in the two vessels.

- The temperature and enthalpy of the steam/vapour and the condensate at each step.

- The energy used in each evaporator vessel to evaporate water and the quantity of water evaporated per hour.

- The minimum quantity of cooling sea water required to fully condense the No. 2 vapour if the initial water temperature is 25 C and a temperature rise of 5 C is allowed for the cooling water.

- The quantity of total fresh water produced (do not count the LP steam condensate).

Draw a schematic of the setup with flows and conditions.

Information: use fresh water properties to calculate enthalpy. Include the effect on energy balance of the superheated water flowing from vessel 1 to vessel 2. Salt water inflow is 600 t/h at 80 C (a preheater has been used), LP saturated steam flow is 100 t/h. The salt water concentration in No.1 effect is 5%, and in No.2 effect it is 10%. Include the effect of boiling point rise (BPR).

Table 1.

Steam conditions	Pressure (kPa abs)
LP steam	220
No.1 vapour	140
No.2 vapour	80

Important: do not put together complicated equations. Detail energy and quantity of water evaporated step by step with a short explanation at each step.

Section E - Pipe and heat exchanger vessel structural design

E.1 For the high pressure steam and the feed water conditions given and calculated in Section B, a maximum allowable high pressure steam velocity of 15 m/s, and a maximum allowable feed water velocity of 1 m/s, determine the required pipe and flange size and pressure rating according to Australian standards.

E.2 Calculations with AS1210 - 'Pressure vessels', for a cylindrical vessel with the following parameters:

- Outside diameter 480 mm

- Length 2500 mm

- Wall thickness 5 mm

- Class 3 construction

- Steel grade PT490

- It has circumferential joints

- The joints are single-welded butt joint without the use of a backing strip

- Contains water at 95 C

Use the AS1210 pages provided as the main calculations, but you will may need to access other parts of AS1210, refer to lecture notes in Week 4.

Work out -

The allowable internal pressure.

The allowable external pressure.

Compare the values of allowable internal and external pressures and discuss the two modes of failure.

Section F -

Two site visits carried out with one page report for each site visit (to be submitted after the site visits).

Attachment:- Assignment File.rar