Thermodynamic analysis provides a way to search for opportunities to improve technological processes and design solutions of machines and equipment. However, in a market economy the economic criterion and the desire to gain a profit and its maximization ultimately determines the feasibility of using specific technical solutions, and economic effectiveness analysis forms the basis for taking decisions regarding investments. The economic criterion is superior to the technical criterion. However, it should be strongly emphasized that economic analysis is only possible after previous thermodynamic analysis. Its results offer the input values for the subsequent economic analysis.
2.1. Analysis of Exergy of the Hierarchy System of Gas-Gas Engine Driving the Compressor Chiller
The balance of exergy of the hierarchy system of gas-gas engine driving the compressor chiller has been presented below –
Figure 5.
Exergy balance of the system (engine + chiller) for its preset operation can be reflected by the following relationship:
where:
—increase of exergy of an external source of heat delivered to the system,
—power of the hierarchic gas-gas engine; the engine power is the sum of gas turbine and turboexpander power, ,
—chiller driving power.
The increase of exergy of external sources of heat delivered to the system can be reflected by the following relationship:
As follows from Equation (2), exergy of heat source with a temperature of , from which a stream of powering heat is collected, decreases, where the exergy drop is lower than the amount of heat . In case of the chiller, exergy of cooling chamber with temperature of , from which a stream of heat is collected , increases, while directions of heat streams and exergy are opposite in this case.
Loss of exergy in the system can be reflected by the following relationship:
where the heat stream
is identical to the stream of chemical energy of fuel burned in the combustion chamber of the gas turbine,
. The fuel combustion temperature is
.
The power derived from the system can, for instance, be determined by use of exergy balance formula (1), by substituting Equations (2) and (3):
Equation (4), its final form, can be also calculated directly from the system energy balance. It is demonstrated by the left and right side of the equation.
Heat streams transmitted to the environment from the hierarchic two-cycle engine
and the most efficient one-cycle chiller with best thermodynamic features
are reflected by the following equations, respectively:
where efficiency of the chiller is reflected by the following equation:
A detailed analysis of thermodynamics and efficiency of trigeneration system with hierarchic gas-gas engine for cogeneration of electricity, heat and cold has been presented below.
2.2. Analysis of System Comprising Compressor Chiller
The economic analysis of trigeneration system—
Figure 1,
Figure 2 and
Figure 3—accounts for the input quantities: gas turbine power
, turboexpander power
, thermal power
of the heat exchanger, cooling power
of either the compressor or absorption chiller, as well as the stream of the chemical energy of the gas
burned in the gas turbine. We can emphasize at this point that the power of the gas turbine
determines the remaining quantities:
,
,
and obviously decides on
. Hence, the power of the gas turbine
and the temperatures of the flue gas
fed into it determine the capacity of the examined trigeneration system. Another important matter is associated with the development of a mathematical model that can provide the account of the economic profitability of the trigeneration system in such a way that it can be employed to generalize the results of the study, so that the resulting calculations can be applied with regard to any power of the gas turbine, and thus apply to any alternative of the power of the trigeneration system. For this purpose, only dimensionless quantities were applied in the model:
,
,
,
.This is due to the fact that only dimensionless approach can be applied to generalize the considerations, i.e., it offers the assessment of the economic effectiveness of the performance of the trigeneration system with any electrical, heat and cooling power.
As a consequence, the comprehensive figures are employed in this study, in other words they can be applied to any power of the investigated system. These powers, as we already noted and we can emphasize once again, are determined only by the power of the gas turbine and the temperature of the gases extracted from the combustion chamber K of the gas turbine. This temperature forms the basic characteristic of a turbine and is always given as part of the manufacturer’s data. As a last resort, to know the specific cost of cold generation in the trigeneration systems discussed in this paper, it is sufficient to know the temperature of the gas extracted to feed to the gas turbine as well as the current prices of gas, electricity and heat— Figures 7–12, Figures 15–20.
The fundamental quantities that determine the economic feasibility of gas-gas trigeneration systems include the energy efficiency of a gas turbine and turbo-expander operating according to Joule’s cycles. They are determined using energy balances.
On the basis of the
Joule’s circulation of the gas turbine, we obtain (Equations (8)–(18) [
20]):
The efficiency is the greater along with the bigger temperature . This temperature is limited only by the heat resistance ability of the blading system in a turbine.
The final form of Equation (1) can be derived after we substitute the irreversible adiabates amb-1 and 2-3 into it—
Figure 6:
where:
From the formula (8), we can derived the optimum ratio of the pressure
, for which the circulation assumes its maximum efficiency
, hence, when its maximum power is achieved (an identical procedure is followed when we need to establish the maximum efficiency
of the turboexpander). The ratio
forms the function of the temperatures
,
and the mechanical efficiency
of the compressor and turbine (in the analysis we assumed that the mechanical efficiency of the compressor and turbine are the same) and the internal efficiency of the compressor
and turbine
:
where:
- isentropic exponent of the circulating medium (in the calculations it was assumed that = 1.4),
, pamb—pressure of the circulating medium accompanying the heat absorption and emission (in the calculations we assumed that = 0.1 MPa).
The thermodynamic calculations assumed an ambient temperature of = 288 K and the mechanical efficiency of the compressor and gas turbine are the same and equal to = = = 0.97, and the internal efficiencies are equal to = 0.87, = 0.85.
The optimum value of
results from the condition that:
Following the differentiation of Equation (8) and application of the condition (13), we obtain:
Hence
where:
The square root of Equation (14) is unfeasible, since the temperature would then be greater than temperature .
The maximum value of is derived from Equation (8) after the value is applied to replace . As a consequence, for and a given value of we can derive the maximum power of the gas turbine that is applied in the economic analysis. In the manufactured gas turbines, assumes the value of .
The temperatures of the circulating medium behind the compressor
and behind the turbine
are derived on the basis of irreversible adiabatic processes:
As noted already, an identical procedure is applied to obtain and with a note that in the place of the temperatures , and in Formulae (8), (12), (16), (17) and (18), we need to substitute temperatures: , and , and the pressure is applied to replace the value of in Formula (12). The maximum capacities expressed by , that are derived on the basis of values , form the input quantities for the economic calculations (Formula (19)). The results of thermodynamic calculations for the gas turbine set and turboexpander are presented in Figures 24–26.
As indicated above, the capacities
,
derived from thermodynamic analysis form the input for the further economic analysis. Its purpose involves the determination of the specific cost of the production of cold. It is calculated using the formula for the discounted value of
NPV that is obtained throughout
T years of operation of the trigeneration gas and gas system applied for combined production of electricity, heat and cold [
21,
22,
23]:
[
24].
Where the annual production of heat and cold is expressed by the respective formulae (Equations (20)–(22) [
20]):
and the driving power of the compressor chiller is given the relation:
where:
, , , , , , , , , —terms of the exponents representing the changes in time of electricity, heat, cold, fuel prices, tariff charges on the environmental emissions, CO2 allowances; , , , , , , etc.− initial prices of electricity, fuel, heat, cold, CO2 emission allowances, etc., —stream of the chemical energy of fuel combustion in the gas turbine (), —investment in the gas-gas system and chiller, , , , , pdust—specific charges on CO2, CO, NOx, SO2, particulate matter emissions, r— interest rate of capital investment, xsal,t,ins—factor applied to account for the cost of remuneration, taxes, insurance, etc. (usually the value xsal,t,ins is equal to around 0.25), z—discount coefficient (freezing coefficient) on investment J at the instant when the investment is completed, δserv—annual rate of fixed cost relative to the investment (cost of maintenance and overhaul of equipment), —thermal efficiency of chiller (in this analysis we adopted the use of a steam compressor chiller operating according to the Linde circulation; the ammonia forms the circulating medium in the system; in the calculations we adopted = 3.2), —internal electric load of the system, —efficiency of the electric generator, , , , , —CO2, CO, NOx, SO2, particulate matter emissions per specific value of the chemical energy of fuel, —ratio of annual electricity production to annual heat production, —annual duration of the operation of the trigeneration system (in the calculations, we assumed a value of 8424 h; this accounts for the two-week downtime period projected within an annual operating schedule), —annual operating time of a chiller expressed in hours.
From the conditions
NPV = 0 and
= 0, we can derive the formula to represent the specific cost of cold production over the period of
T years:
[
24],
where:
—specific investment in the gas-gas engine (calculated per unit of electric capacity, , —specific investment in the chiller (calculated per unit of electric capacity), (the calculations account for two alternatives of this investment; , ).
The revenues from the sales of electricity and heat (Formulae (19) and (23)) form the avoided cost of cold production.
In addition to capital expenditure, the energy efficiency of the gas turbine, chiller power and its operating times, prices of electricity, fuel and heat, one of the factors that has a significant impact on the unit cost of production of cold is associated with the price of carbon dioxide emission allowances . It fluctuates to a considerable degree, even on a week to week basis, as it is often a speculative price. In the calculations, for its comparative purposes, its dual alternative value was adopted. In one of the alternatives, it was assumed to be equal to the so-called reference settlement price = 20.38 €/MgCO2 (~90 PLN/MgCO2), which are derived on the basis of the Directive 2003/87/EC and later 2009/29/EC imposes the EU ETS (European Union Emission Trading Scheme) emissions trading system, and in the other = 20 PLN/MgCO2.
The formula in (23) also determines the specific costs of the production of cold in all three alternatives of the systems operating with heat regeneration, i.e., for systems with an applied regenerative heat exchanger: (1) only in a gas turbine, (2) only in a turboexpander and (3) in a system in which regenerative heat exchangers are employed simultaneously in the gas turbine and in the turboexpander. As a result, in Formula (23), higher values of the specific values of investment are obtained for the various power ratios in the particular alternatives of the system design derived from thermodynamic analysis.
where:
ec—prices of heat in PLN (Polish Zloty) per GJ, efuel—prices of fuel in PLN (Polish Zloty) per GJ, —specific investment in the chiller (calculated per unit of electric capacity) in PLN (Polish Zloty) per MW, —annual operating time of a chiller expressed in hours per year.
As we can see from
Figure 7,
Figure 8,
Figure 9,
Figure 10,
Figure 11 and
Figure 12, the specific cost of cold production
gets higher as a consequence of the decrease in the price of electricity and the higher prices of fuel and CO
2 emission allowances, and along with the greater cost of investment. As a result of increasing the value of
x, and thus increasing the production of cold in the system (Formulae (21), (22)), this cost increases as well. As a consequence, the electricity production decreases, and thus the revenues from its sale decreases as well, which forms the avoided cost associated with the production of cold.
On the basis of the analysis of the performance of the system, it is also feasible to establish an answer to the question: to what extent does the use of heat regeneration in the turboexpander in
Figure 4, leading to an increase in the electricity production, affect the value of specific cost of production of cold? Under the assumption of the fact that the investment associated with a system comprising regeneration is the same as the cost for a system excluding a regenerative heat exchanger, it appears that the decrease of this cost is negligible, as it does not exceed 0.5 PLN/GJ in the whole range of variations in temperature
. Therefore, the curves representing the specific cost presented in
Figure 7,
Figure 8,
Figure 9,
Figure 10,
Figure 11 and
Figure 12 for a system without regeneration overlap with the curves representing a system with regenerative heat exchanger. Therefore, we can conclude that the design of a gas-gas system including a turboexpander including a regenerative heat exchanger leads to a zero value of the increase in the specific cost of cold production in the best case, for the case when we take into account the increase in expenditures in the economic calculation associated with the capital costs (depreciation and financial cost) as well as cost of the normal operation (repairs and maintenance). Therefore, the construction of a system with heat regeneration is completely economically unfeasible.
The analysis of the specific cost of cold production presented in
Figure 7,
Figure 8,
Figure 9,
Figure 10,
Figure 11 and
Figure 12 also demonstrates, as already noted above, that it is more profitable to produce only electricity and heat in the system [
1] than combine this production with additional production of cold. Therefore, it is important to answer the question: what should be the price of cold so that it would be profitable to produce it.
Condition of Economic Profitability of Application of Compressor Chiller in the Trigeneration System comprising Gas-Gas Engine
A necessary condition for the economic feasibility of using a compressor chiller in the trigeneration system is related to the fact that the value of
NPV derived from its operation (Formula (19)) is greater than the profit gained from the operation of the system in which only electricity and heat is produced (in Formulae (19) and (22) zero need to then substitute
and
). This condition is therefore expressed by the relation:
By application of Equation (15), we can derive the final form of the condition from (24) to represent the mean price (
) of the sales of cold over a period of
T years:
where the mean price
of the sales of electricity over the period of
T years is expressed by the formula:
However, it should be very strongly emphasized that the condition of the economic feasibility of the application of the trigeneration system is not related to fulfilling of the relationship (25), but to the fact that the following relation is fulfilled:
which means that the sales price of the production of cold should be at least not lower from the specific cost associated with its production. This is due to the possible condition in which the price
(Formula (25)) is lower than the cost
(Formula(26)). This can occur when the electricity price assumes a relatively low price, generally associated with the large cost
—
Figure 13. The price
is, in contrast to the cost
, derived on the basis of excluding the cost of fuel and environmental charges, which are removed in the process of subtracting profit expressed by
NPV, i.e., when the profit
NPV derived from the operation of the trigeneration system we subtract the value of
NPV gained from the cogeneration system (Formula (25)).
The courses of the exemplary curves
and
are presented in
Figure 13.
Table 2 contains a summary of the data taken for its calculations.
2.3. Analysis of System Comprising an Absorption Chiller
The basic advantage of the absorption chiller is associated with the fact that such a system does not include a compressor, and therefore electric power is not applied for the purposes of driving it, while its operating principle is based on the use of the waste enthalpy of the flue gas from a gas-gas engine,
Figure 1c. As a result of this, in comparison to the system comprising a compressor chiller, a greater volume of electricity is produced, i.e., the noblest, and thus the most valuable, and the most expensive form of energy, and the revenue from its sale is related to the cost of avoided cold production. The disadvantage of the system comprising an absorption chiller is its low refrigerating power. The temperature of the flue gas which constitutes the source of heat in the desorber of the absorption chiller needs to be higher than the temperature of the ammonia solution that is fed into it. This temperature is equal to around
, whereas the temperature
of the flue gas fed into the desorber is in the range from around 458 to 524 K (this temperature increases along with the temperature of the combustion of gas
in the combustion chamber K of the gas turbine; value
= 458 K corresponds to the temperature
= 1100 K, whereas the temperature
= 524 K corresponds to
= 1800 K [
1]). The disposable span of the temperatures, i.e., the range that is feasible for application to drive the chiller exhaust, is therefore relatively small and is found from about 63 to about 130 K, which involves a relatively small value of the heat flux
extracted from the cooling elements in the system in comparison to the case when the compressor chiller is applied. The refrigerating power
of the absorption chiller is therefore expressed by the equation:
and the annual production of cold is expressed by the relation:
where the energy balances of the circulations of the gas turbine and turboexpander can be applied to the fluxes of thermal capacities
of the circulating medium flow in the Joule circulation through the gas turbine
GT and turboexpander
TE:
where:
—powers of the gas turbine
GT and turboexpander
TE,
Figure 3,
—temperature of circulating medium behind the compressor
,
Figure 3,
—temperature of circulating medium fed at the inlet to
GT,
Figure 3,
—temperature of circulating medium extracted from
GT,
Figure 3,
—temperature of circulating medium behind the compressor
,
Figure 3,
—temperature of circulating medium fed at the inlet to
TE,
Figure 3,
—temperature of circulating medium extracted from turboexpander
TE,
Figure 3,
—temperature of heating medium fed at the inlet to the chiller,
Figure 3,
—thermal efficiency of cooling process of the absorption chiller; it was assumed to be equal to
,
—annual operating time of the chiller expressed in hours.
Figure 14 contains the results of thermodynamic calculations concerned with the value of the ratio of annual heat production to annual production of electricity
and the value of the ratio of annual cold production to annual production of electricity
in the system with a thermal chiller. We can note here that the ratio
in the system with the compressor chiller is about three times higher, as the enthalpy of flue gas extracted from the engine is applied only for heat production,
Figure 1 and
Figure 2. This ratio, just as for the system with an thermal chiller, it also depends on the temperature
and decreases from 1/2.16 to 1/3.77 in the range
.In addition, the cooling power of the system comprising the compressor chiller, which is relative to the value of
x (Formula (22)), is significantly higher as a result of the driving of the chiller by electricity (formula (21)). In addition, its thermal efficiency is equal to
= 3.2 whereas for the absorption chiller, this is
. For x ≈ 0.1, the cooling power of the compressor chiller is already equal to the capacity of the absorption chiller. As a consequence, the revenues gained from the sales of heat in the system with the compressor chiller—
Figure 1 and
Figure 2—is about three times larger than the revenues resulting from the application of the system comprising an absorption chiller. However, in a system comprising a compressor chiller, the revenues from the sales of electricity are decreased to the same extent that the value of
x increases to meet the demand of the power to drive the chiller.
The total discounted
NPV gained from the operation of the trigeneration system comprising an thermal absorption chiller is expressed by the relation [
23,
24]:
whereas the specific cost of production of cold based on the conditions that
NPV = 0 and
= 0 is given by the formula:
where:
As we can see from the results of calculations presented in
Figure 15,
Figure 16,
Figure 17,
Figure 18,
Figure 19 and
Figure 20, the specific cost of production of cold depends to the greatest extent on the price of electricity. We should note that when the specific cost associated with production of cold is compared in the system with the compressor chiller for the value
x = 0.1, i.e., for the same production of cold in both systems, the specific cost is lower in the compressor chiller.
When we calculate the cost in the system including a regenerative heat exchanger in the turboexpander in
Figure 4, and under the assumption that the investment in the system comprising regeneration is the same as for the system without regeneration, it can be concluded that this cost decreases to a negligible extent and does not exceed 1 PLN/GJ in the entire range of variations in the temperature
, which is apparent in the system comprising a compressor chiller.
In order to achieve an increases cooling power of the absorption chiller (Formula (28)), the range of the temperatures of the flue gas
applied to drive this chiller should be increased. The temperature span in this range, as already noted above, is relatively small and depends on the temperature of the gas fed into the gas turbine, as it ranges from around 63 to around 130 K. To increase this range, it would be necessary to supplementary firing gas in the turboexpander in the channel which routes air from the preheater N to the turboexpander TE (this is known from the literature on gas-steam systems as the concept of so-called supplementary firing [
2]),
Figure 3.
As a result, the temperature
and, consequently, the temperature
will be increased. We should note, however, that combustion of fuel using burners located in the firing chamber located in the turboexpander channel N-TE leads to the conversion of a hierarchical engine—
Figure 1,
Figure 2,
Figure 3 and
Figure 4—into a quasi-hierarchical engine, i.e., a dual-fuel engine. In general, the energy efficiencies of quasi-hierarchical systems are lower compared to those in hierarchical systems.
As a result of increasing the value
by
= 100 K as a result of the combustion of gas in the channel N-TE, the temperature
increases to
. Depending on the temperature
, the temperature
increases from the value
to the value of
. As a consequence of increasing
by
= 200 K, this temperature assumes the value of
. The ratio of the cooling power to the electrical capacity of the system in this case increases without gas combustion from the value
,
Figure 11, to
, accompanied by the increase of the temperature
by the value of
= 100 K and to the value
and is accompanied by the increase of the temperature
by the value
= 200 K.
As a result of the increase of temperature by the value equal to , we have to do with an increase of the efficiency to . The values of these efficiencies are derived from the formula (50) after the value of zero substitutes and temperatures and are used in the place of the temperature . The values of ( is derived for the value of ) and are presented in Figure 22.
The combustion of extra fuel in the turboexpander changes the efficiency of the generation of electricity in it. It is derived from the energy balance –
Figure 21:
where:
—enthalpy of flue gas fed into the chiller following supplementary firing of the fuel,
—level of supplementary firing in the engine,
, on the basis of which we can derive the formula that represents the efficiency of electricity generation in a gas-gas engine in a system with supplementary firing:
and if we assume that
= 0, the equation in (30) represents the efficiency of the gas-gas engine without supplementary firing:
The values of the efficiencies
and
in the function of the temperatures of the flue gas fed into the gas turbine
and value of
are presented in
Figure 22.
As a result of dividing the relations (37) by (38), we derive the following:
The stream of the chemical energy associated with extra fuel combustion is derived from the equation:
where:
—mass stream of supplementary fired gas,
—gross calorific value of gas, where the stream corresponding to the heat capacity of flue gas
routed into turboexpander is equal to approximately to heat capacity of air prior to supplementary firing, which in turn results from the energy balance in the air preheater N [
1] and it equal to the stream of heat capacity of flue gas
extracted from the gas turbine. The stream of heat capacity of flue gas
results from the energy balance of the turbine,
Figure 21:
where:
—flux of enthalpy of the flue gas at the exhaust of the gas turbine.
By application of Equations (40) and (41) and on the basis of the relation that
, we can derive the level of supplementary firing:
Despite the increase of the value
to the value equal to
—
Figure 21—this supplementary firing leads to the decrease of the efficiency of electricity generation in the engine. This is due to the fact that the ratio
is only slightly lower from one, since
is marginally smaller than
—
Figure 22. We can note at this point that the revenue from the sale of electricity has a decisive effect on the economic profitability of the trigeneration system. Therefore, the additional gas combustion in the N-TE channel is not only unfeasible from the thermodynamic perspective, but in addition, due to the small increase in the cooling power of the system and the increase in investment associated with the supplementary firing and supplementary firing chamber in the N-TE channel, this option is economically unprofitable. The condition of profitability could then be a relatively high cold price and a low gas price. In such a case, only for the relatively large values of the temperature
, i.e., for the high values of
, accompanied by the conditions when the temperatures
assume values in the range of 1100 ÷ 1400 K that are equal to the values of the temperatures
of the flue gas fed into several year-old designs of gas turbines characterized by low efficiencies
, the ratio
is only higher than one. The low efficiency of old designs of gas turbines results from the low heat resistance of the turbine blades, which leads to low values of permissible temperatures. Current designs include temperatures in the range of even above 1800 K. However, the considerable role taken on by afterburning in the turboexpander means that the hierarchical turboexpander engine does not make any sense in terms of its technical aspects. In such a case, the turboexpander then takes on the function of a gas turbine.
The same characteristics of the courses as the ones that are contained in
Figure 22 are assumed by the curves
,
for the engine including heat regeneration in the turboexpander—
Figure 4—for the alternative when gas afterburning is applied in the N-TE channel in it.