Improved efficiency combined cycle power plant

Abstract: The efficiency of a combined cycle power plant is improved by preheating fuel (100) supplied to a combustion turbine (10) wherein an increased feedwater flow through an economizer section (26) of a heat recovery steam generator (24) is provided, and the excess flow (102), over that required to sustain saturated steam production in an evaporator section (28), is conducted through a heat exchanger (100) in which the fuel (58) is preheated, thereby extracting additional heat from the heat recovery system.

Description: The present invention relates generally to combined cycle power plants. More particularly, the present invention relates to a method for improving the efficiency of a combined cycle power plant by preheating fuel supplied to a combustion turbine of the power plant. Typically, a combined cycle power plant comprises a combustion turbine driving an electrical generator, a heat recovery steam generator (hereinafter "HRSG") receiving exhaust gas from the combustion turbine, and a steam turbine coupled to another electrical generator. Also, typically, the HRSG comprises three heat exchanger sections, a superheater section, an evaporator section, and an economizer section. The exhaust gas from the combustion turbine flows first over the superheater section, then over the evaporator section, and finally over the economizer section. Condensed water from the steam turbine is supplied as feedwater to an inlet of the economizer section. The feedwater is heated by the exhaust gas and heated feedwater is supplied to the evaporator section which produces saturated steam. The saturated steam is thereafter provided to the superheater section which produces superheated steam, which is supplied to the steam turbine. Thus, the steam turbine is interposed in a closed loop connecting the inlet and outlet of the HRSG, i.e., the inlet of the economizer section and the outlet of the superheater section. The heat recovered from the exhaust gas-in the HRSG is limited by the temperature difference between the exhaust gas and the steam evaporation temperature (i.e., the evaporator "pinch" temperature). Although the economizer section helps to improve plant efficiency, the additional heat which can be recovered by the economizer section is limited by the water flow rate necessary to match the steam production in the evaporator section. Thus, part of the thermal energy of the system is wasted and there still remains a potential for increasing the efficiency of the power plant. U.S. Patent 4,099,374 discloses a fuel preheating method, where part of the feedwater is diverted from the evaporator section to a fuel preheater, where it preheats the fuel gas, which is then in turn sent to the combustion turbine. Preheating the fuel gas with energy that otherwise would have been wasted increases the efficiency of the power plant. It is the principal object of the present invention to provide another method of preheating the fuel gas in order to improve plant efficiency. With this object in view, the present invention resides in a method of increasing efficiency of a combined cycle power plant wherein exhaust gas from a combustion turbine is conducted through a heat recovery steam generator (HRSG), feedwater is conducted through an economizer section of the HRSG at a flow rate to provide heated feedwater, and then through an evaporator section of the HRSG to produce saturated steam at a production rate, the feedwater is conducted through the economizer section at a flow rate greater than is required to sustain the production rate of steam in the evaporator section; and a portion of the heated feedwater is diverted from the economizer section (before the evaporator section) to a heat exchanger and then returned to an inlet of the economizer section, and fuel for the turbine is conducted through the heat exchanger so as to be heated by said feedwater. The said portion of the heated feedwater is diverted from the feedwater conducted to the evaporator section. Preferably, the size of the economizer section is such that increasing the flow rate of feedwater therethrough does not substantially reduce the temperature of heated feedwater that would otherwise be supplied by the economizer section. For a 25% increase in flow rate through the economizer section,approximately a 20% increase in the heat transfer surface area of the economizer section (over that required without any preheating of the fuel gas), has been found to maintain the steam production rate at the same value as experienced prior to the increase in flow rate while heating the fuel to 150°C (300°F). This amount of preheating increases plant efficiency 0.5% to 1%. The invention will become more readily apparent from the following detailed description of the exemplary embodiment thereof shown, by way of example only, in the accompanying drawing in which: Figure 1 is a diagrammatical illustration of a combined cycle power plant according to a preferred embodiment of the present invention. A combined cycle power plant as shown in the figure comprises a combustion turbine 10, a heat recovery steam generator ("HRSG") 24 and a steam turbine 40. The combustion turbine 10 comprises a compressor section 12 having an air inlet 16 and operatively coupled to drive an electrical generator 18. The compressor section 12 is coupled to a turbine section 14 by means of a rotor 20. A combustion section 22 heats compressed gas from the compressor section 12 and supplies it to the turbine section 14 in well-known fashion. Fuel is supplied to an inlet of the combustion section 22 as shown at 60. The HRSG 24 receives hot exhaust gas from the combustion turbine 10 as shown at 32. The HRSG comprises three heat exchanger sections, a superheater section 30, an evaporator section 28 and an economizer section 26, each having an inlet and an outlet. As is well known, the exhaust gas flows first over the superheater section 30, then over the evaporator section 28, and finally over the economizer section 26. Additional heat exchanger sections may be provided and the invention is not limited in scope to the use of an HRSG having only three sections. A closed loop around the HRSG 24 is defined by piping sections connecting the outlet of the superheater section 30, steam turbine 40, condenser 42, condensate pump 44, feedwater line 48, deaerator 56, boiler feed pump 54, and the inlet to the economizer section, as shown. As is well known, feedwater 52 is flowed through the economizer section 26 to provide heated, pressurized feedwater at its outlet. The heated, pressurized feedwater 38 is provided to a steam drum 34 operatively coupled to the evaporator section 28 to produce saturated steam in well-known fashion. A valve 64 is adjusted to maintain the correct ratio of steam to water in the drum 34. Saturated steam 36 is provided to the superheater section 30. Superheated steam 50 is thereafter directed through the steam turbine 40 which drives electrical generator 46. Makeup water is added, if needed, as shown at 62. The system thus far described is well known in the art. In standard power plants without fuel preheating the size (i.e., surface area exposed to exhaust gas) of the economizer section 26 and the flow rate of the feedwater 52 are selected so as to match the desired rate of saturated steam production in the evaporator section 28. However, according to the invention, the size (i.e., surface area exposed to the exhaust gas) of the economizer section 26 and the flow rate of feedwater therethrough are both increased so that (1) the rate of flow of feedwater through the economizer section 26 exceeds that required to match the rate of steam production in the evaporator section 28, and (2) the temperature of the pressurized, heated feedwater 38 is not substantially reduced below that which would otherwise be provided by the economizer section 26. It has been found that, for a 25% increase in flow rate through the economizer section, approximately a 20% in the heat transfer surface area of the economizer section, or about a 5% increase in the overall surface area of the HRSG (over that normally required without the invention), is required to maintain the steam production rate in the evaporator section at the same value as experienced prior to the increase in flow rate while heating the fuel to 150°C (300°F). The amount of preheating increases plant efficiency 0.5% to 1%. The additional hardware required by the practice of the present invention has been labeled 100, 102, and 104. As shown, a piping section 102 connects the junction of the outlet of the economizer section 26 and drum 34 to the inlet of a heat exchanger 100. A piping section 104 connects the outlet of the heat exchanger 100 to a loop that is connected to the inlet of the economizer section 26. Fuel is flowed to an inlet of the heat exchanger, as shown at 58, then to the fuel inlet of combustion section 22, as shown at 60. The excess amount of heated, pressurized feedwater 38 resulting from the increased flow rate of feedwater through the economizer section 26 is diverted from the inlet of the steam drum 34, and hence from the evaporator section 28, flowed through the heat exchanger 100, and thereafter returned to the inlet of the economizer section 26. As shown, the heated feedwater 104 from the heat exchanger 100 is flowed to deaerator 56 before it is flowed to the inlet of the economizer section 26. Condensed steam from the steam turbine is also flowed to the deaerator 56, then to the economizer inlet. The excess heated, pressurized feedwater 38 is diverted at a temperature approaching the evaporator temperature, i.e., the economizer "approach" temperature. Fuel 58 for the combustion turbine 10 is preheated by virtue of the heat exchanger 100. Since heating of the fuel 58 is accomplished using heated water obtained from a heat source located after the evaporator section (relative to the direction of flow of the exhaust gas), and further, since the temperature of the heated feedwater 38 delivered to the evaporator section 28 is not substantially reduced, the recovery of the heat utilized to preheat the fuel 58 does not reduce the quantity of superheated steam otherwise available for use in the steam turbine 40. The fuel 58 is thus heated with energy which would otherwise be lost or unavailable for use. It has been found that implementation of the invention increases the system's overall efficiency by 0.5% to 1%. Sizing of the economizer section 26 and selection of the flow rate of the feedwater therethrough may be chosen using well-known design equations, tables, etc. A conventional shell and tube heat exchange may be used for the heat exchanger 100. The cooled water discharged from the heat exchanger 100 may be either immediately returned to the inlet of the economizer section 26 or first used for other heating purposes. In the illustrated embodiment, the cooled water from the heat exchanger 100 is used for deaeration and is mixed with the condensed water from the steam turbine 40.

Claims: A method of operating a combined cycle power plant wherein exhaust gas (32) from a combustion turbine (10) is conducted through a heat recovery steam generator (HRSG) (24), feedwater (52) is conducted through an economizer section (26) of the HRSG (24) at a flow rate to provide heated feedwater (38), and then through an evaporator section (28) of the HRSG (24) to produce saturated steam at a production rate, the feedwater (52) being conducted through the economizer section (26) at a flow rate greater than is required to sustain the production rate of steam in the evaporator section (28); and a portion of the heated feedwater (38) is diverted to a heat exchanger (100) and then returned to an inlet of the economizer section (26), and fuel (58) for the turbine (10) is conducted through the heat exchanger (100) so as to be heated by said feedwater; characterized in that said portion of the heated feedwater (38) is diverted from the feedwater (52) conducted to the evaporator section (28) . A method according to claim 1, characterized in that the economizer section (26) is provided with a greater surface area exposed to the exhaust gas (32) than would be required to provide heated feedwater (38) when the flow rate matches the production rate, such that the temperature of the heated feedwater (38) remains substantially unchanged by the greater feedwater (52) flow through the economizer (26).

Inventors: BALDWIN THEODORE SUTLER, MYERS GERALD ARTHUR, PAVEL JAMES, BALDWIN, THEODORE SUTLER, MYERS, GERALD ARTHUR, PAVEL, JAMES
Applicants: WESTINGHOUSE ELECTRIC CORP, WESTINGHOUSE ELECTRIC CORPORATION
Application year: 1990
Main classification: F01K23
IPC codes: F01K23, F02C7