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Analysis of Efficiency of the Ship Propulsion System with Thermochemical Recuperation of Waste Heat

更新时间:2016-07-05

1 Introduction

According to the BP Energy Outlook data(2016),the world population will increase up to 8700 million people by 2035.In addition,1600 million people will be in great necessity of energy.Production of energy will be growing worldwide by 1.5%per year over the period from 2012 to 2035.This will require development of new energy technologies.Despite mainstreaming of renewable energy technologies,the share of natural gas as an energy source will continue to grow(Fig.1).

江冬英(1977-),女,福建省福州人,硕士,福建生物工程职业技术学院,讲师,研究方向:药物政策法规。

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Gas consumption will increase from 31%in 2012 to 34%in 2035.Pipelines will remain the major means of gas transportation(Fig.2),but the share of liquefied natural gas(LNG)transportation will increase from 32%in 2012 to 46%in 2035(BP 2016).

Global demand for LNG has doubled over the last 10 years and is over 200 million tons per year.In 2014,the volume of LNG transportation was about 243 million tons(according to BG Group).According to the World LNG Market Forecast 2016-2020,capital investments in the LNG market will reach the mark of$241 billion over the period from 2016 to 2020.

As seen from the obtained dependencies(Fig.11),when the exhaust gas temperature corresponds to the nominal operation mode of the UGT 2500,it is possible to perform efficient conversion of ethanol and butane(reduction in specific fuel consumption is equal to 20%and 18%,respectively).The thermochemical recuperation of the GT exhaust gas heat when converting propane and butane is less efficient(16%and 12%,respectively).

The dimensions of such ships are determined by the volumetric cargo capacity of liquefied natural gas measured in cubic meter.The standard volume of an LNG carrier is equal to 155,000 m3,but 31 Q-flex gas carriers and 14 Q-max gas carriers built during 2007-2010 have the cargo capacities of 216,000 and 266,000 m3,respectively.

According to the requirements o f Chapter 4 of MARPOL Annex V I,the Energy Efficiency Design Index(EEDI)is a mandatory mechanism of the energy efficiency standard for ships.The attained EEDI is a measure of a ship’s energy efficiency determined as follows(IMO 2014,2016):

The attained EEDI must be calculated for each new ship.

Fig.1 Shares of primary energy sources(BP 2016)

One of basic ways to influence the EEDI is application of innovative devices for power(electric)generation on board,such as Electricity from waste heat recovery.

The thermochemical recuperation(TCR)is the promising way of waste heat recovery of heat engine(Fig.3).

A substantial part of fuel energy introduced to heat engine is recovered with the engine exhaust gases.The energy of the exhaust gases can be used to provide endothermic reactions of hydrocarbon fuel transformation.The exhaust gases are directed into the chemical reformer and then into the vaporizer.The reformed fuel gas is used in the heat engine.

It should be noted that the innovative plasma technology(Gatsenko and Serbin 1995;Matveev et al.2013,2014;Matveev and Serbin 2012;Serbin et al.2014,2015)can be used for thermochemical transformations,to convert different types of hydrocarbons into hydrogen-rich gas and other fuels,as well as electricity and other forms of energy.

Hydrocarbon fuel can be converted into hydrogen containing gas through steam reforming.A heat engine is supplied with the gaseous products of fuel reforming,mainly the mixture of hydrogen and carbon monoxide(synthesisgas).For example,if using methane,after absorbing heat in the reformer,the methane reacts with the steam according to the following reactions:

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Fig.2 Distribution of the methods of natural gas transportation(BP 2016)

Fig.3 Heat engine with thermochemical recuperation(Tartakovsky et al.2011)

Comparing the synthesis gas to the base hydrocarbon fuel,the fuel calorific value is increased.

The paper is organized as follows:Section 2 considers the analysis of key factors affecting the efficiency of thermochemical recuperation of secondary energy resources,Section 3 deals with the study of the efficiency of a combined gas turbine and diesel plant with TCR,and Section 4 deals with the study of a combined propulsion plant with thermochemical recuperation of secondary energy resources for LNG carriers.

2 Analysis o f Key Factors Affecting the Efficiency of a Power Plant with TCR

The main factors that affect the efficiency of a power plant with TCR are as follows:

- Temperature potential of the flows of the waste heat energy sources in engines

- Dependence of change in the rate of increase of the base fuel calorific value HU on the reaction temperature

- Heat input of the exhaust gas necessary for fuel conversion

Efficiency of the thermochemical conversion of hydrocarbon fuels can be calculated as follows:

由表4说明,土样2土壤中没有添加化学修复剂时,其中锌含量最高的是阔小麦天,最高值为500.3mg/L,最低的是马铃薯,最低值为411.7mg/L。铅含量最高的是油菜,最高值为100.3mg/L,最低的是狼尾草,最低值为70.2mg/L。铬含量最高的是马铃薯,最高值为30.2mg/L,最低的是刺儿菜,最低值为25.2mg/L。铜含量最高的是狼尾草,最高值为29.7mg/L,最低的是刺儿菜,最低值为24.3mg/L。砷含量最高的是油菜,最高值为7.7mg/L,最低的是狼尾草,最低值为5.7mg/L。镉含量最高的是油菜,最高值为2.2mg/L,最低的是狼尾草,最低值为1.5mg/L。

where TR is the reaction temperature is the difference between the low calorific values(LCV)of the conversion products and the base hydrocarbon fuel

As base equations,steam conversion reactions for ethanol,butane,ethane,and propane were used.

Based on the fundamental properties of substances(Dean 1999),the rate of conversion was calculated using the equilibrium constants of the main reactions at a pressure of 0.1 MPa.

The calculation results were processed with the use of the regression analysis method proposed by the authors:for ethanol

The diagram of a three-section thermochemical reactor is shown in Fig.9.After mixing,ethanol and water are preheated by the exhaust gases in the heat exchanger T1.Then,the resultant steam is superheated in the heat exchanger T2.The thermochemical reactor is modeled as an equilibrium reactor defined by the condition of minimization of the Gibbs free energy and taking into account the chemical and phase equilibrium.

where T4 is the gas temperature downstream of the GT.

for propane

for ethane

for methane

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The rate of increase of the calorific value of the base hydrocarbon fuel is determined as follows:

The results of determination of the increase in calorific capacity of the conversion products in correlation to the base fuel characteristics are shown in Fig.4.The calculation is carried out with the use of the equilibrium constants of the basic reactions under the pressure of 0.1 MPa.

Fig.4 Rate of increase of the calorific value of the base hydrocarbon fuel as a function of the reaction temperature

Of special interest is the analysis of the temperature potentials of waste heat in such basic energy-converting machinery as a medium speed four-stroke diesel engine(4SDE)and a gas turbine engine(GT).

Figure 5 shows the waste heat potentials of the GT and 4SDE of a comparable power.

Comparison of the calculation results and analysis of the GT and 4SDE waste heat potentials allow concluding the following.For the available temperature range of exhaust gases of the modern series-production gas turbine engine(up to 450°C),conversion of ethanol,butane,propane,and ethane is efficient.The thermal potential of secondary energy sources of the 4SDE allow s for a moderate ethanol conversion,but does not allow converting other hydrocarbons efficiently.

3 Study o f the Efficiency o f Combined Gas Turbine and Diesel Power Plant with TCR

Gas turbine technologies hold a special place in the energy sector.Gas turbine engines of a simple cycle are moderately efficient.High temperature of the exhaust gases of a gas turbine engine can be used in complex and combined cycles to increase its efficiency.Korobitsyn(1998)points out that development of these technologies often follows an S-shaped path(Fig.6).

A gas turbine engine with thermochemical recuperation(CRGT)is based on steam conversion of a hydrocarbon fuel by means of recuperation of the exhaust gas heat.During that process,the advantages of TCR are manifested by enhancement of the energy and environmental characteristics of the fuel properties.

Fig.5 Comparison of waste heat potentials of secondary energy sources of the gas turbine and four-stroke diesel engine

There are various techniques of thermochemical and plasma conversion of a base carbohydrate fuel(Korobitsyn 1998;Nosach 1989;Kesser et al.1994;Alves and Nebra 2003;Tartakovsky et al.2014;Serbin et al.2011,2016).Thermochemical recuperation with steam conversion is the most widespread one.

The criterion of the plant efficiency is taken to be its specific fuel consumption SFC,kg/(kW h).

Analysis of the results of calculation of the GT and 4SDE waste heat potentials shows the prospects of using a combined gas turbine-electric and diesel engine plant with thermochemical recuperation of waste heat.

Fig.6 Technology development paths

The diagram of the combined gas turbine and diesel power plant with thermochemical recuperation of the exhaust gas heat by means of steam conversion of a hydrocarbon fuel,in this case—bioethanol(shown in Fig.7),was developed at the Admiral Makarov National University of Shipbuilding(Cherednichenko 2015).

The pumps(12,15)deliver water and ethanol in appropriate proportions from the tanks(13,14)to the evaporators(11,16).There,the heat of exhaust gases from the GT(1)causes sequential heating,evaporation,and super heating up to the start temperature of steam conversion.The resulting vapors of ethanol and water are mixed in the mixer(10)and fed to the reactor(9).Induced by the heat of the GT exhaust gases flowing in the tubular annulus of the TCR reactor,the conversion reaction takes p lace with output in the form of a hydrogen-containing gas.Afterwards,the synthesis gas enters the heat exchanger(8),where it is cooled to the desired temperature.After the cooler,the hydrogen containing gas enters the CO2 neutralizer(7),from which pure hydrogen is injected through the solenoid valve(6)onto the inlet of the turbocharger assembly compressor(2)and is fed further with air directly to the cylinders of the 4SDE(4).

The main aim of the study is the high-level analysis of interrelations between thermodynamic parameters of the gas turbine plant with thermochemical heat recuperation and characteristics of the internal combustion engine that runs on the products of the hydrocarbon fuel conversion.

The key assumptions used to simplify the analysis are as follows:

1)The input of the exhaust gas heat required for fuel conversion is determined by the heat balance of the thermochemical reactor

where G gasis the flow rate of the GT exhaust gases,сP is the mean mass heat capacity of the exhaust gases at a constant pressure in the relevant temperature range,and ΔT=fis the reduction in the exhaust gas temperature required for fuel conversion.

2)The maximum allowable temperature of the endothermic reaction of fuel conversion T R is determined respectively as:

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Fig.7 Combined gas turbine and diesel power plant with the thermochemical heat recovery

1. gas turbine; 2. compressor of turbocharger; 3. turbine of turbocharger; 4. diesel engine; 5. charge air cooler;6.solenoid-operated valve; 7. neutralization tank; 8. synthesis gas cooler; 9. thermo-chem ical reactor; 10. mixer; 11. water vaporizer; 12. water pump; 13.water tank; 14.ethanol tank;15.ethanol pump; 16. ethanol vaporizer

The developed ASPEN Plus turbine blade-cooling model shown in Fig.8 was incorporated into the simulation model.

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for butane

The presented internal combustion engine model in the ASPEN Plus shown in Fig.10 and includes the following:substance flows of fuel,air and gas,flow mixers,turbochargers,intermediate charge air coolers,expansion unit,compression unit,and reactor.A turbine(or expansion block)is used to simulate expansion processes in cylinders;a compressor is used for compression process modeling,and combustion processes are modeled in the reactor.

Fig.8 ASPEN Plus turbine blade-cooling model

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We analyzed the change in the specific fuel consumption of the internal combustion engine operating as a part of the gas turbine and diesel plant with thermochemical recuperation of the heat of the GT exhaust gases(Fig.7).The modeling concerned the power plants on the basis of the gas turbine engine UGT 2500 of the power=2.8 MW(Table 1)and the medium speed 4SDE engine Wärtsilä 18V32,5L64,18V46.

The examples of the calculation results are shown in Fig.11.

The fleet of LNG carriers,which are also called“floating pipelines,”consists of 455 ships,and 111 more ships comprise the “book of orders” (Lloyd’s List Intelligence 2017).

Fig.9 ASPEN Plus three-section thermochemical reactor model

Fig.10 ASPEN Plus internal combustion engine model

Increase in the calorific value of the LNG conversion products from the reaction temperature ΔH U=f(T R)can be presented as follows:

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4 Characteristics of a Propulsion Plant with Thermochemical Recuperation o f Heat of the Secondary Energy Resources of LNG Carriers

The gas evaporating during the LNG transportation is commonly referred to as boil-off gas(BOG).According to the data presented by Głomski and Michalski(2011),about 0.1%-0.2%of the volume of the transported cargo evaporates daily.The BOG can be used as a fuel for the power plant.

Classification of the propulsion plants of LNG carriers includes two major groups of plants depending on the BOGapplication:those re-liquefying the cargo vaporized during transportation and those using it as a fuel.

Table 1 Parameters of the GT UGT 2500

Parameters Value Number of compressors 1 Number of turbines 1 Turbine inlet temperature,T3/°С 951 Compressor pressure ratio,πк 12 Exhaust gas flow,G gas/(kg s-1) 14.7 Exhaust temperature,T4/°С 450 Power,Ne/MW 2.8 Efficiency/% 28.5

Presently,there is a large number of configurations of the propulsion plants for LNG carriers(Oka et al.2004;MAN Diesel A/S 2007;Chang et al.2008;MAN Diesel&Turbo 2013;Fernández et al.2017).The plants based on dual-fuel engines using BOG as a fuel currently have the most widespread use.The DFDE(dual-fuel medium speed diesel with electric propulsion)plants are most popular,as they involve implementation of dual-fuel four-stroke diesel generators and electric propulsion motors.

GE Marine,Dalian Shipbuilding Industry Company(DSIC),and Lloyd’s Register have collaborated on the project of the COGES(combined gas turbine and steam with electric propulsion)plant for 174,000 m3 of the LNG carrier.The plant includes one 30-MW gas turbine engine,one heat utilization turbine generator,and two dual-fuel diesel generators for operation on the low power consumption modes,and as a power reserve.The main advantage of the plant is reduction of polluting emissions,improvement of the mass-dimensional parameters,and reliability.Fuel consumption for the DFDE and COGES plants is approximately the same(GE Marine 2013;GE Marine 2014).

The publication of Dzida and Olszewski(2011)considers the GOGES power plants with the power of 40-50 MW for a LNG carrier with the cargo capacity of 266,000 m3.According to the studies presented in the paper,the GOGES plant based on four GTEs Cyclone SGT 400(Siemens)and a steam turbine waste-heat loop with two-pressure boilers has the efficiency of 50.7%.The generated power of the steam turbine waste-heat loop is 49%of the total plant power,which raises some doubts about feasibility of such a configuration in the ship’s conditions.

Fig.11 Specific fuel consumption of the diesel engine as a function of the gas turbine exhaust gas temperature.a Primary hydrocarbon fuel ethanol,b butane,c propane,and d ethane.Diesel engine:1.Wärtsilä 18V32;2.Wärtsilä 5L64;3.Wärtsilä 18V46

The publication of Pan et al.(2015)indicates that the CRGT is a promising option for the ship power plant due to its efficiency and low level of emissions.

The diagram of the combined gas turbine-electric and diesel-electric power plant with thermochemical recuperation of the exhaust gas heat by means of steam conversion of natural gas or the cargo evaporation products(COGED+TCR)is shown in Fig.12.

The COGED+TCR 45-MW propulsion plant was considered to comprise the gas turbine engine Siemens SGT 400(Table 2)and three medium speed engines Wärtsilä 5L64.

The LNG composition varies substantially,which affects the conversion efficiency.The works(Benito 2009 and Dobrota et al.2013)suggest using the LNG classification according to its density(Table 3).

The calculations show that the heat potential of the exhaust gases of the UGT 2500 is sufficient to produce the quantity of synthesis gas required for operation of the 4SDE Wärtsilä 18V46 engine.At that,the ratio of powers of the diesel and gas turbine enginesis about 6.

where a,b,c,d,e,f,g,and h are the coefficients obtained by processing the calculation results by means of regression analysis(Eqs.11-14).

The method of mathematical modeling was applied to analyze the change in the specific consumption of LNG in the COGED+TCR during its operation on the convertible synthesis gas of various compositions.

The following two variants were considered:

Variant 1.The GT operates on natural gas,while the 4SDE runs on the convertible synthesis gas.

Variant 2.Simultaneous operation of the GT and 4SDE on the convertible synthesis gas.

The results of the calculation are presented in Table 4.

More efficient plant operation on the Heavy LNG is caused by high content of ethane in gas of this type.In this conversion temperature range(500-550°C),the increase in calorific value of the ethane conversion products is three times higher than that of methane(Fig.3).Hence,it is of interest for further studies to assess efficiency of the suggested power plant configuration with regard to gas carriers specializing in transportation of liquid ethane.

Fig.12 Combined diesel-gas turbine power plant with the thermochemical heat recovery

1. LNG tank; 2. LNG pumps; 3. LNG vaporizer; 4. LP compressor;5. preheater; 6. HP compressor; 7. heat recovery preheater; 8.thermo-chemical reactor; 9. synthesis gas cooler; 10. neutralization tank; 11. gas turbine; 12. diesel engine; 13. turbocharger; 14. heat recovery steam generator; 15. water pump; 16. water tank

Table 2 Parameters of the gas turbine Siemens SGT 400 used in the COGED+TCR propulsion plant

Parameters Value Number of compressors 1 Number of turbines 2 Turbine inlet temperature,T3/°С 1251 Compressor pressure ratio,πк 16.8 Exhaust gas flow,G gas/(kg s-1) 39.4 Exhaust temperature,T4/°С 555 Power generation,N e/MW 12.9 Efficiency/% 34.8

Table 3 LNG classification based on density

Parameter Letter identification LNG Light Medium Heavy Density/(kg m-3) ρ 427.7 445.7 464.8 Composition(%)Methane(CH4) Y M 98.0 92.0 87.0 Ethane(C2H6) Y E 1.4 6.0 9.5 Propane(C3H8) Y P 0.4 1.0 2.5 Butane(C4H10) Y But 0.1 0.0 0.5 Nitrogen(N2) Y N 0.1 1.0 0.5

According to the data on Q-max LNG carriers given in Cw ilew icz and Górski(2011),up to 180 tons of cargo evaporate daily at the cargo passage with full loading.The calculations show that this is sufficient for operation of a combined diesel and gas turbine plant with TCR of the total power of 45 MW.

5 Conclusions

The results of mathematical modeling of the characteristics of diesel and gas turbine power plants with thermochemical heat recovery of the gas turbine exhaust gas heat by means of hydrocarbon fuel converting show possibilities for reducing fuel consumption in the diesel engine up to 20%.

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Table 4 Analysis of the effectiveness of the COGED+TCR ship power system

Type of power plant Type of LNG Light Medium Heavy Plant efficiency/%COGED without TCR 44.0 COGED+TCR,var.1 46.5 46.7 46.7 COGED+TCR,var.2 48.2 48.5 48.9

The gas turbine waste heatcan provide efficient conversion of hydrocarbon fuels at the ratio of the powers a diesel engine and a gas turbine engine being up to 6.

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The obtained theoretical results concerning the working processes in the combined diesel and gas turbine plants with TCR show that simultaneous operation of the diesel and gas turbine engines on the LNG vapor conversion products increases the efficiency coefficient of the plant by 4%-5%.

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OleksandrCherednichenko,SerhiySerbin
《Journal of Marine Science and Application》2018年第1期文献

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