Project Title

Dehydration and Combined Cycle

Power Plant of 50 MMSCFD low
BTU Natural Gas

Presented By: Maaz Shoaib (B1233013)

Moiz Alvi (B1233015)
Sami-Ur-Rehman (B1233034)
Shahzad Meer (B1233036)
Shaikh Bilal (B1233037)

Supervisor: Assistant Professor

Adeel-Ur-Rehman
 PROJECT OUTLINE
 Planning and Scheduling
 Literature review
 Process Design
 Equipment Design
 Hazop Study
 Environmental Consideration
 Cost Estimation
 Why we designed in this process?
 We are design to convert Heat energy into mechanical energy which in
turns convert into electrical energy.
 Designing of a plant is very essential to convert it into a practical life.
 Designing of a process shows the feasibility of that process.
 Designing of a process helps to determine the cost of a plant.
 OBJECTIVE
• To utilize Low BTU gas to Conserve Energy.
1

• To overcome the shortfall of Energy Crises.

2

• To check the feasibility of Power Generation by Low BTU

3 gas.
 INTRODUCTION
 Our project deals with the generation of electricity by mean of low
BTU gas.
 We are using 50 MMSCFD of low BTU gas coming from well.
 Generating power using gas turbine as well as steam turbine
(i.e. combine cycle power plant).
 PROJECT OVERVIEW
BLOCK FLOW DIAGRAM

LOW BTU GAS STEAM STEAM

GAS FROM DEHYDRATION COMBUSTION TURBINE GENERATOR TURBINE
CONDENSER DEARRATOR
WELL UNIT UNIT

POWER
AIR GENERATOR
POWER
GENERATOR
 SCHEDULING OF PROJECT:

 WORK BREAKDOWN STRUCTURE (WBS):

Breaking whole project work into several number of small tasks.

 GANTT CHART:
Designating start and end time for each task.
 WBS:- Combined-Cycle
Power
Generating Plant

INITIALIZATION DESIGNING SAFETY STUDY DOCUMENTATION FINALIZATION

Process Selection Process

Feasibility Study Instrumentation HAZOP Study Report
Study Description
Submission

Feasibility Control Scheme FEED AND PRODUCT

Project Meeting Selection HAZOPed P&ID
analysis SUMMARY SHEET
Presentation

Data Process
P&ID EQUIPMENT AND
Collection Reliabilty DESIGN SUMMARY

Performing BASIS of DESIGN Instruments

Tasks Selection

Planning and
Feed, condition, Instruments
Scheduling
Composition Sizing

Standby
WBS/PERT/
philosophy
Gant Chart

Preliminary PROCESS
Estimated Cost SIMULATION

BFD

Material and
Energy Balance

PFD

Equipments
Design

Hydraulics of
Plant Piping
 Semes Semes
ter Cost ter Materi
break estim break al
Repor & Repor ation Piping Equip Proce & balan Block
t Exami t & HAZO Instru & ments ss flow Exami ces & flow DATA Literat
submi nation compi optimi P ment Hydra desig diagr nation Simula diagr COLLE ure
ssion s lation zation study ation ulics ning ams s tion 6-May-16 am CTION survey

9-Nov-16
7-Nov-16
3-Nov-16
18-Aug-16
9-Apr-16
26-Mar-16

5-Nov-16

2-Dec-16
11-Apr-16
20-Feb-16

30-Oct-16
9-Jul-16
1-Jul-16

3-Sep-15
23-Oct-15
12-Dec-15
31-Jan-16
21-Mar-16

(DAYS)
DURATION
10-May-16
29-Jun-16
18-Aug-16
7-Oct-16
GANTT CHART

26-Nov-16
15-Jan-17
 ROUTE TO SOLUTION

 So far our route to accomplish our project tasks.

1. Meeting with personnel for guidance.

2. Books and research papers followed yet.

 MEETING WITH PERSONNEL FOR
GUIDANCE.
Meeting with our project external (SIR HANI).

1ST Meeting:
 Discuss about low BTU gas.
 Why they are not converting low BTU gas into sales gas.
 What is the ultimate solution.
 Shearing there well gas composition.
2nd MEETING:
 Discuss about the operating condition for combustion of gas.
 % excess air, Reactor type, % conversion.

3rd MEETING:
 Showed our flue gas composition.
 Discussed about combined cycle power plant (i.e. Our major area of
concern)
 MEETING WITH OUR INTERNAL (SIR ADEEL):
 Almost 9 to 10 get-togeather with sir adeel.
 Help us to make our project scheme.
 Guiding us to design a reactor by some other way as we have not found
any proper refernce to design it yet.
 Gave us suggestion to minimize the deviation of result calculated
manually and from hysys.
 Corrected us in case of any blender in our scheme.
 MEETING WITH OTHERS:
Sir Ahsan:
 Recommend many books and research paper related to our topic.
 Help us in converging hysys calculation.
 Suggest many rule of thumb in our calculation.
 BOOKS FOLLOWED YET:
POWER-PLANT TECHNOLOGY BY M.M EL-WAKIL:-
 For literature survey.
 For overview of power plant, comparison of different technologies and
different cycles.

STEPHEN R.TURNS:-
 For material balance calculation.

J.M. SMITH:-
 For Calculation Of Combine Cycle.

GPSA:-
 For rated power of pump and compressor.
 WHERE TO GO FROM HERE?
Up to now most of the task has been accomplished. Following are the
tasks to be achieved for the completion of our project.
 Energy balance on reactor at high pressure.
 Designing of Gibbs reactor.
 P&ID
 HAZOP STUDY
 COST ESTIMATION
 GTCC TECHNOLOGY DEMONSTRATION
 Main Equipment
 Air Compressor
 Combustion Reactor
 Steam & Gas Turbines
 HRSG
 Condenser
 Deaerator
 Pumps
 Gas to
6 Atm.

13 Deaerator

HRSG Pump 2

Feed-Water 11
12

Combustor
Fuel Gas
8

Condensate
3
Superheated
2 2 2 Steam
B D F Pre- 4
2 2 2 cooler
A C E
2
7
IC-3 G
IC1 IC-2 Steam
Turbine G
Stage 1 Stage 2 Stage 3 Stage 4 Gas Turbine G
Wet Steam
9
5
2 Condenser

Gas Turbine
Pump 1
Exhaust
10

Process Flow Diagram of Gas Turbine Combine Cycle (GTCC) Power Plant
 STREAMS CONDITIONS
Line No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Deaerator
Compressor Compressor Combuster Gas Turbine Gas to SuperHeate Condenser Pump1 Deaerator Pump2 HRSG Feed
Stream Gas Feed
Inlet Outlet Outlet Exhaust Atm. d Steam
Feed
Feed Feed Feed Water Feed Water
Steam

Temp. °F 130.9 86 130.9 2838 1463 375.4 925 374 85 85 85 270 272

Pressure, Psia 1010 14.7 1010 1010 42 22 725.2 42.06 0.59 0.59 42.06 42.06 736.2

Flow rate, lb/s 42.68 260.3 260.3 303 303 375.3 77.16 12.23 64.52 64.52 64.52 77.16 77.16
J. H. Horlock, ADVANCED GAS TURBINE CYCLES, Elsevier Science 2003, fig: 7.9, page 124
LIVE STEAM PRESSURE AND TEMPERATURE

Kehlofer, Rolf, Hannmenn, Frank, Rukes, Ben. Combined cycle gas & steam turbine power plants, 3rd ed. PennWell
Corporation, 2009, Fig 3.17 and 3.20, page 46 and 49
 CONDENSER

 Pressure 0.59 psia (0.04 bar)

 St. Quality 0.9094
 Duty 6.176E4 Btu/sec

Kehlofer, Rolf, Hannmenn, Frank, Rukes, Ben. Combined cycle gas & steam turbine power plants, 3rd ed. PennWell
Corporation, 2009, Fig 3.19, page 48
 FEED WATER

 Temp. 133 C (271.5 F)

 Flow rate 77.16 lb/s (35 kg/s)

Kehlofer, Rolf, Hannmenn, Frank, Rukes, Ben. Combined cycle gas & steam turbine power plants, 3rd ed. PennWell
Corporation, 2009, Fig 3.21, page 50
 POSSIBLE WAYS OF GENERATING ELECTRICITY
FROM LOW BTU GAS

 Steam turbine
 Gas turbine
 Combined cycle power plant
THERMODYNAMIC COMPARISON OF ST, GT AND
CC

Kehlofer, Rolf, Hannmenn, Frank, Rukes, Ben. Combined cycle gas &steam turbine power plants, 3rd ed. PennWell
Corporation, 2009
 WHY COMBINED CYCLE POWER PLANT?

 Compatibility to grid
 Combine cycle can reach over 60% efficiency
 Fewer moving parts and less vibration
 Very low toxic emissions
 High power to weight ratio

http://www.slideshare.net/cleopettra/group5-44030866
COMBINED CYCLE POWER PLANTS IN SINDH
Station Location Capacity (MW) Notes

Bin Qasim power Karachi, sindh 560 Natural gas fired

plant-II Combined cycle
power plant

Foundation power Daharki, sindh 181 Combined cycle

company Daharki power plant
limited

Engro powergen Ghotki, sindh 227 Combined cycle

Qadirpur limited power plant

https://en.wikipedia.org/wiki/List_of_power_stations_in_Pakistan
 COMPARISON
Foundation Power Company Our Project

 Fuel Low Btu Gas  Fuel Low Btu Gas

 Heating Value 590 Btu/Scf  Heating Value 450 Btu/Scf
 Gas Flow 65 MMSCFD  Gas Flow 50 MMSCFD
 Capacity 181 MW  Capacity 172 MW
 Efficiency 48%  Efficiency 51.16%

http://www.fpcdl.com.pk/Technical-Data.html
 MAJOR PARAMETERS WHICH INFLUENCE THE
COMBINED CYCLE POWER PLANT

 Compression ratio
 Turbine inlet temperature

Islam, Mohd, Hasan M. M., Tiwari A. K.; effect of operating parameters on their performance of combined cycle power plant 1; no 7
(2012):1-2
 EFFECT OF COMPRESSION RATIO ON OVERALL
EFFICIENCY

Islam, Mohd, Hasan M. M., Tiwari A. K.; effect of operating parameters on their performance of combined cycle power plant 1; no 7
(2012):1-2
 EFFECT OF INLET TURBINE TEMPERATURE ON
OVERALL EFFICIENCY

Islam, Mohd, Hasan M. M., Tiwari A. K.; effect of operating parameters on their performance of combined cycle power plant 1; no 7
(2012):1-2
 MATERIAL BALANCE OF COMBUSTION
REACTION

 General Reaction:
 General Reaction of Hydrocarbon CxHy stoichiometric combustion:

CxHy + a O2 x CO2 + (y/2) H2O

 Where a = x + y/4
 %age Conversion = %C = 100 %
 %age Excess air = 30%
Components Reaction:

C1 ; CH4 + 2 O2 1 CO2 + 2 H2O

C2 ; C2H6 + 3.5 O2 2 CO2 + 3 H2O
C3 ; C3H8 + 5 O2 3 CO2 + 4 H2O
i-C4 ; C4H10 + 6.5 O2 4 CO2 + 5 H2O
n-C4 ; C4H10 + 6.5 O2 4 CO2 + 5 H2O
i-C5 ; C5H12 + 8 O2 5 CO2 + 6 H2O
n-C5 ; C5H12 + 8 O2 5 CO2 + 6 H2O
C6 ; C6H14 + 9.5 O2 6 CO2 + 7 H2O
 RESULTS:
 Total O2 Req. = 5246.25 lbmol
 Total Air Req. = 24982.14 lbmol
 Excess Air = 32476.8 lbmol
 Total H2O produced = 2711.13 lbmol
 Total CO2 produced = 5070.24 lbmol
 Total CO2 out = 6538 lbmol
 Total N2 out = 21386.51 lbmol
 CALCULATION OF ADIABATICE FLAME
TEMPARATURE : -

LHV + A ∝∗ HHV ∗ Cpa ∗ ta − 80 /106

tc =
%ash
1− + A ∝∗ HHV/106 ∗ Cpg
100

 LHV = LOWER HEATING VALUE = 5911 BTU/LB

 HHV = HIGHER HEATING VALUE = 6493 BTU/LB
 A = THEORITICAL AIR REQUIRED = 730 LB
 ∝ = EXCESS AIR FACTOR = 1 + E/100
 E = EXCESS AIR = 30%
 ta = TEMP OF AIR = 313 0F
 Cpa = SPECIFIC HEAT OF AIR = 0.266 BTU/lb.0F
 Cpg = SPECIFIC HEAT OF PRODUCT = 0.3412 BTU/lb.0F

Put all values in above formula to get :

 tc = 2607.2 0F
AIR COMPRESSOR CALCULATION
 Duty Comparison
Equipment Manual, MW Hysys, MW
HRSG 102 103.5
Turbine Sec-1 21.4 21.22
Turbine Sec-2 15.64 15.88
Condenser 66.6 66.67
Pump 1 0.063 0.011
Feed water Heater 0.01 0.04
 Stream Comparison
Line No. 4 5 6 7 8 9 10 11

Combuster Gas Turbine SuperHeated Deaerator Condenser Deaerator

Stream Outlet Exhaust
Gas to Atm.
Steam Feed Steam Feed
Pump1 Feed
Feed Water

Temp. °F 2838 1463 375.4 1000 374 85 85 85

Hysys Pressure, Psia 1010 42 22 725.2 42.06 0.59 0.59 42.06

Flow rate, lb/s 303 303 375.3 77.16 12.23 64.52 64.52 64.52

Temp. °F 2607 1467 375.4 1000 374 85 85 85

Manual Pressure, Psia 1010 42 22 725.2 42.06 0.59 0.59 42.06

Flow rate, lb/s 303 303 303 77.16 11.96 65.2 65.2 65.2
 ACKNOWLEDGMENT

 Imran Bukhari
 Athar Shaukat
 Hani Muhammad
 References
 Weston, Kenneth. Energy conversion. 2nd ed. Nebraska: PWS press, 1992. E-book.
 El-Wakil, M., M.. Power Plant Technology. 3rd ed. Singapore: McGraw-Hill, 1985.
 Islam, Mohd, Hasan M. M., Tiwari A. K.; effect of operating parameters on their performance of
combined cycle power plant 1; no 7 (2012):1-2.
 Power Generation Technologies by Paul Breeze , Chapter 4 ,page no 81-92 , Second Edition,
 Combined Cycle Gas and Steam Turbine Power Plant by Rolf kellofar ,Chapter 2-3,page no 6-35.
 Advanced Gas Turbine Cycle by J.H Horlock ,Chapter 7.
 Thermodynamic by JM. Smith , Chapter 8, 7th Edition.
 http://www.ub.umu.se/en/write/references/writing-references-oxford (Accessed 2016-10-15)
 Kehlofer, Rolf, Hannmenn, Frank, Rukes, Ben. Combined cycle gas &steam turbine power plants. 3rd
ed. United States: PennWell Corporation, 2009.
 Power Generation: Combined Cycle Power Plant-How It Works.
 https://powergen.gepower.com/resources/knowledge-base/combined-cycle-power-plant-how-it-
works.html (Accessed 2016-8-23)
Thank You