Комбинированные циклы тепловых двигателей: повышение эффективности и снижение затрат.

Assembly of heat engines that work in tandem from the same source of heat

A combined cycle power plant is an assembly of heat engines that work in tandem from the same source of heat, converting it into mechanical energy. On land, when used to make electricity the most common type is called a combined cycle gas turbine (CCGT) plant, which is a kind of gas fired power plant. The same principle is also used for marine propulsion, where it is called a combined gas and steam (COGAS) plant. Combining two or more thermodynamic cycles improves overall efficiency, which reduces fuel costs. The principle is that after completing its cycle in the first engine, the working fluid (the exhaust) is still hot enough that a second subsequent heat engine can extract energy from the heat in the exhaust. Usually the heat passes through a heat exchanger so that the two engines can use different working fluids. By generating power from multiple streams of work, the overall efficiency can be increased by 50–60%. That is, from an overall efficiency of the system of say 34% for a simple cycle, to as much as 64% net for the turbine alone in specified conditions for a combined cycle.

Historically successful combined cycles have used mercury vapour turbines, magnetohydrodynamic generators and molten carbonate fuel cells, with steam plants for the low temperature "bottoming" cycle. Very low temperature bottoming cycles have been too costly due to the very large sizes of equipment needed to handle the large mass flows and small temperature differences. However, in cold climates it is common to sell hot power plant water for hot water and space heating. Vacuum insulated piping can let this utility reach as far as 90 km. The approach is called "combined heat and power" (CHP). In stationary and marine power plants, a widely used combined cycle has a large gas turbine (operating by the Brayton cycle). The turbine's hot exhaust powers a steam power plant (operating by the Rankine cycle). This is a combined cycle gas turbine (CCGT) plant. These achieve a best of class real (see below) thermal efficiency of around 64% in base load operation. In contrast, a single cycle steam power plant is limited to efficiencies from 35 to 42%. Many new power plants utilize CCGTs. Stationary CCGTs burn natural gas or synthesis gas from coal. Ships burn fuel oil. Multiple stage turbine or steam cycles can also be used, but CCGT plants have advantages for both electricity generation and marine power. The gas turbine cycle can often start very quickly, which gives immediate power. This avoids the need for separate expensive peaker plants, or lets a ship maneuver. Over time the secondary steam cycle will warm up, improving fuel efficiency and providing further power. In November 2013, the Fraunhofer Institute for Solar Energy Systems ISE assessed the levelised cost of energy for newly built power plants in the German electricity sector. They gave costs of between 78 and 100 €/MWh for CCGT plants powered by natural gas. In addition the capital costs of combined cycle power is relatively low, at around $1000/kW, making it one of the cheapest types of generation to install.

The thermodynamic cycle of the basic combined cycle consists of two power plant cycles. One is the Joule or Brayton cycle which is a gas turbine cycle and the other is the Rankine cycle which is a steam turbine cycle. The cycle 1 2 3 4 1 which is the gas turbine power plant cycle is the topping cycle. It depicts the heat and work transfer process taking place in the high temperature region. The cycle a b c d e f a which is the Rankine steam cycle takes place at a lower temperature and is known as the bottoming cycle. Transfer of heat energy from high temperature exhaust gas to water and steam takes place in a waste heat recovery boiler in the bottoming cycle. During the constant pressure process 4 1 the exhaust gases from the gas turbine reject heat. The feed water, wet and super heated steam absorb some of this heat in the process a b, b c and c d.

The steam power plant takes its input heat from the high temperature exhaust gases from a gas turbine power plant.

The efficiency of a heat engine, the fraction of input heat energy that can be converted to useful work, is limited by the temperature difference between the heat entering the engine and the exhaust heat leaving the engine. In a thermal power station, water is the working medium. High pressure steam requires strong, bulky components. High temperatures require expensive alloys made from nickel or cobalt, rather than inexpensive steel. These alloys limit practical steam temperatures to 655 °C while the lower temperature of a steam plant is fixed by the temperature of the cooling water. With these limits, a steam plant has a fixed upper efficiency of 35–42%. An open circuit gas turbine cycle has a compressor, a combustor and a turbine. For gas turbines the amount of metal that must withstand the high temperatures and pressures is small, and lower quantities of expensive materials can be used. In this type of cycle, the input temperature to the turbine (the firing temperature), is relatively high (900 to 1,400 °C). The output temperature of the flue gas is also high (450 to 650 °C). This is therefore high enough to provide heat for a second cycle which uses steam as the working fluid (a Rankine cycle). In a combined cycle power plant, the heat of the gas turbine's exhaust is used to generate steam by passing it through a heat recovery steam generator (HRSG) with a live steam temperature between 420 and 580 °C. The condenser of the Rankine cycle is usually cooled by water from a lake, river, sea or cooling towers. This temperature can be as low as 15 °C.

Plant size is important in the cost of the plant. The larger plant sizes benefit from economies of scale (lower initial cost per kilowatt) and improved efficiency. For large scale power generation, a typical set would be a 270 MW primary gas turbine coupled to a 130 MW secondary steam turbine, giving a total output of 400 MW. A typical power station might consist of between 1 and 6 such sets. Gas turbines for large scale power generation are manufactured by at least four separate groups – General Electric, Siemens, Mitsubishi Hitachi, and Ansaldo Energia. These groups are also developing, testing and/or marketing gas turbine sizes in excess of 300 MW (for 60 Hz applications) and 400 MW (for 50 Hz applications). Combined cycle units are made up of one or more such gas turbines, each with a waste heat steam generator arranged to supply steam to a single or multiple steam turbines, thus forming a combined cycle block or unit. Combined cycle block sizes offered by three major manufacturers (Alstom, General Electric and Siemens) can range anywhere from 50 MW to well over 1300 MW with costs approaching $670/kW.

The heat recovery boiler is item 5 in the COGAS figure shown above. Hot gas turbine exhaust enters the super heater, then passes through the evaporator and finally through the economiser section as it flows out from the boiler. Feed water comes in through the economizer and then exits after having attained saturation temperature in the water or steam circuit. Finally it flows through the evaporator and super heater. If the temperature of the gases entering the heat recovery boiler is higher, then the temperature of the exiting gases is also high. for start up or for simple cycle operation of the gas turbine. Another less common set of options enable more heat or standalone operation of the steam turbine to increase reliability: Duct burning, perhaps with a fresh air blower in the duct and a clutch on the gas turbine side of the shaft. A multi shaft system usually has only one steam system for up to three gas turbines. Having only one large steam turbine and heat sink has economies of scale and can have lower cost operations and maintenance. A larger steam turbine can also use higher pressures, for a more efficient steam cycle. However, a multi shaft system is about 5% higher in initial cost. The overall plant size and the associated number of gas turbines required can also determine which type of plant is more economical. A collection of single shaft combined cycle power plants can be more costly to operate and maintain, because there are more pieces of equipment. However, it can save interest costs by letting a business add plant capacity as it is needed. Multiple pressure reheat steam cycles are applied to combined cycle systems with gas turbines with exhaust gas temperatures near 600 °C. Single and multiple pressure non reheat steam cycles are applied to combined cycle systems with gas turbines that have exhaust gas temperatures of 540 °C or less. Selection of the steam cycle for a specific application is determined by an economic evaluation that considers a plant's installed cost, fuel cost and quality, duty cycle, and the costs of interest, business risks, and operations and maintenance.

By combining both gas and steam cycles, high input temperatures and low output temperatures can be achieved. The efficiency of the cycles add, because they are powered by the same fuel source. So, a combined cycle plant has a thermodynamic cycle that operates between the gas turbine's high firing temperature and the waste heat temperature from the condensers of the steam cycle. This large range means that the Carnot efficiency of the cycle is high. The actual efficiency, while lower than the Carnot efficiency, is still higher than that of either plant on its own. The electric efficiency of a combined cycle power station, if calculated as electric energy produced as a percentage of the lower heating value of the fuel consumed, can be over 60% when operating new, i. e. unaged, and at continuous output which are ideal conditions. As with single cycle thermal units, combined cycle units may also deliver low temperature heat energy for industrial processes, district heating and other uses. This is called cogeneration and such power plants are often referred to as a combined heat and power (CHP) plant. In general, combined cycle efficiencies in service are over 50% on a lower heating value and Gross Output basis. Most combined cycle units, especially the larger units, have peak, steady state efficiencies on the LHV basis of 55 to 59%. A limitation of combined cycles is that efficiency is reduced when not running at continuous output. During start up, the second cycle can take time to start up. Thus efficiency is initially much lower until the second cycle is running, which can take an hour or more.

Heat engine efficiency can be based on the fuel Higher Heating Value (HHV), including latent heat of vaporisation that would be recuperated in condensing boilers, or the Lower Heating Value (LHV), excluding it. The HHV of methane is , compared to a LHV: a % increase.

Efficiency of the turbine is increased when combustion can run hotter, so the working fluid expands more. Therefore efficiency is limited by whether the first stage of turbine blades can survive higher temperatures. Cooling and materials research are continuing. A common technique, adopted from aircraft, is to pressurise hot stage turbine blades with coolant. This is also bled off in proprietary ways to improve the aerodynamic efficiencies of the turbine blades. Different vendors have experimented with different coolants. Air is common but steam is increasingly used. Some vendors might now utilize single crystal turbine blades in the hot section, a technique already common in military aircraft engines. The efficiency of CCGT and GT can also be boosted by pre cooling combustion air. This increases its density, also increasing the expansion ratio of the turbine. This is practised in hot climates and also has the effect of increasing power output. This is achieved by evaporative cooling of water using a moist matrix placed in the turbine's inlet, or by using Ice storage air conditioning. The latter has the advantage of greater improvements due to the lower temperatures available. Furthermore, ice storage can be used as a means of load control or load shifting since ice can be made during periods of low power demand and, potentially in the future the anticipated high availability of other resources such as renewables during certain periods. Combustion technology is a proprietary but very active area of research, because fuels, gasification and carburation all affect fuel efficiency. A typical focus is to combine aerodynamic and chemical computer simulations to find combustor designs that assure complete fuel burn up, yet minimize both pollution and dilution of the hot exhaust gases. Some combustors inject other materials, such air or steam, to reduce pollution by reducing the formation of nitrates and ozone. Another active area of research is the steam generator for the Rankine cycle. Typical plants already use a two stage steam turbine, reheating the steam between the two stages. When the heat exchangers' thermal conductivity can be improved, efficiency improves. As in nuclear reactors, tubes might be made thinner (e. g. from stronger or more corrosion resistant steel). Another approach might use silicon carbide sandwiches, which do not corrode. There is also some development of modified Rankine cycles. Two promising areas are ammonia/water mixtures, and turbines that utilize supercritical carbon dioxide. Modern CCGT plants also need software that is precisely tuned to every choice of fuel, equipment, temperature, humidity and pressure. When a plant is improved, the software becomes a moving target. CCGT software is also expensive to test, because actual time is limited on the multimillion dollar prototypes of new CCGT plants. Testing usually simulates unusual fuels and conditions, but validates the simulations with selected data points measured on actual equipment.

There is active competition to reach higher efficiencies. Research aimed at 1370 °C (2498 °F) turbine inlet temperature has led to even more efficient combined cycles. Nearly 60% LHV efficiency (54% HHV efficiency) was reached in the Baglan Bay power station, using a GE H technology gas turbine with a NEM 3 pressure reheat boiler, using steam from the heat recovery steam generator (HRSG) to cool the turbine blades. In May 2011 Siemens AG announced they had achieved a 60.75% efficiency with a 578 megawatt SGT5 8000H gas turbine at the Irsching Power Station. The Chubu Electric’s Nishi ku, Nagoya power plant 405 MW 7HA is expected to have 62% gross combined cycle efficiency. On April 28, 2016, the plant run by Électricité de France in Bouchain was certified by Guinness World Records as the worlds most efficient combined cycle power plant at 62.22%. It uses a General Electric 9HA, that claimed 41.5% simple cycle efficiency and 61.4% in combined cycle mode, with a gas turbine output of 397 MW to 470 MW and a combined output of 592 MW to 701 MW. Its firing temperature is between , its overall pressure ratio is 21.8 to 1. In December 2016, Mitsubishi claimed a LHV efficiency of greater than 63% for some members of its J Series turbines. In December 2017, GE claimed 64% in its latest 826 MW HA plant, up from 63.7%. They said this was due to advances in additive manufacturing and combustion. Their press release said that they planned to achieve 65% by the early 2020s. Thermodynamic benefits are that daily steam turbine startup losses are eliminated. Major factors limiting the load output of a combined cycle power plant are the allowed pressure and temperature transients of the steam turbine and the heat recovery steam generator waiting times to establish required steam chemistry conditions and warm up times for the balance of plant and the main piping system. Those limitations also influence the fast start up capability of the gas turbine by requiring waiting times. And waiting gas turbines consume gas. The solar component, if the plant is started after sunshine, or before, if there is heat storage, allows the preheat of the steam to the required conditions. That is, the plant is started faster and with less consumption of gas before achieving operating conditions. Economic benefits are that the solar components costs are 25% to 75% those of a Solar Energy Generating Systems plant of the same collector surface. The first such system to come online was the Archimede combined cycle power plant, Italy in 2010, followed by Martin Next Generation Solar Energy Center in Florida, and in 2011 by the Kuraymat ISCC Power Plant in Egypt, Yazd power plant in Iran, Hassi R'mel in Algeria, Ain Beni Mathar in Morocco. In Australia CS Energy’s Kogan Creek and Macquarie Generation’s Liddell Power Station started construction of a solar Fresnel boost section (44 MW and 9 MW), but the projects never became active.

In most successful combined cycles, the bottoming cycle for power is a conventional steam Rankine cycle. It is already common in cold climates (such as Finland) to drive community heating systems from a steam power plant's condenser heat. Such cogeneration systems can yield theoretical efficiencies above 95%. Bottoming cycles producing electricity from the steam condenser's heat exhaust are theoretically possible, but conventional turbines are uneconomically large. The small temperature differences between condensing steam and outside air or water require very large movements of mass to drive the turbines. Although not reduced to practice, a vortex of air can concentrate the mass flows for a bottoming cycle. Theoretical studies of the Vortex engine show that if built at scale it is an economical bottoming cycle for a large steam Rankine cycle power plant.