Mastodon Power plant and calculations: Topping cycle & calculations

### Topping cycle & calculations

Topping cycle & calculations

A Co-generation system can be classified as either a topping cycle or a bottoming cycle on the basis of sequence of energy generated & use.

In a topping cycle, the fuel supplied is used to first produce power and then thermal energy, which is the by-product of the cycle and is used to satisfy process heat requirements.

In a topping cycle, a primary heat source, such as a gas turbine or an internal combustion engine, is used to drive a generator and produce electricity. The primary cycle typically operates at higher temperatures and generates high-pressure and high-temperature exhaust gases.

The exhaust gases from the topping cycle are then directed to a waste heat recovery boiler or a heat exchanger, where their residual heat is captured. This waste heat is then used to produce steam, which drives a steam turbine or an organic Rankine cycle (ORC) turbine in the bottoming cycle.

Topping cycles are commonly used in combined cycle power plants, where they offer improved efficiency and performance compared to standalone gas turbines or internal combustion engines. The integration of a bottoming cycle allows for the utilization of waste heat, maximizing the overall energy output of the system.

In a bottoming cycle, the primary fuel used produces high temperature thermal energy and the heat rejected from the process is used to generate power through a heat recovery Boiler & Turbo generator.

Bottoming cycles are suitable for manufacturing processes that require heat at high temperature in furnaces & kiln and reject heat at significantly high temperatures.

The bottoming cycle operates at lower temperatures and utilizes the waste heat energy to generate additional power. By extracting energy from the waste heat, the topping cycle achieves higher overall efficiency compared to a single-cycle power generation system.

Topping cycle calculation:

A Co-generation facility is defined as one, which simultaneously produces two or more forms of useful energy such as electrical power and steam, electric power and shaft (mechanical) power, etc.” The project may qualify to be termed as a co-generation project, if it is in accordance with the definition and also meets the qualifying requirement outlined below:

Topping cycle mode of co-generation – Any facility that uses non-fossil fuel input for the power generation and also utilizes the thermal energy generated for useful heat applications in other industrial activities simultaneously.

For the co-generation facility to qualify under topping cycle mode, the sum of useful power output and one half the useful thermal output be greater than 45% of the facility’s energy consumption, during season.”

Following inputs required for calculation of topping cycle:

• Fuel consumption
• Fuel GCV
• Steam given to processes & their heat content
• Power generation

Topping cycle is calculated by using following formula

TC Eff = (Sum of total heat supplied to process in kcal X 50% + Total electricity generated in kcal) X 100 / Fuel energy

Example

A 44 MW Co-generation plant is operating at 41 MW load and utilizing bleed & extraction steam for process heating. Calculate the topping cycle efficiency

The inputs required are as below

 Sl No Particular/Parameters UOM Value 1 Boiler fuel consumption TPH 85 2 Fuel GCV Kcal/kg 2250 3 Process-1 steam flow TPH 12 4 Process steam-1 enthalpy Kcal/kg 740 5 Process-2 steam flow TPH 170 6 Process steam-2 enthalpy Kcal/kg 653 7 Power generation MWH 41

Calculation:

Total heat content in input fuel = 85 X 1000 X 2250 =191250000 kcal

Heat content in process-1 steam = 12 X 1000 X 740 =8880000 kcal

Heat content in process-2 steam = 170 X 1000 X 653 =111010000 kcal

Power generation in kcal = 41 X 1000 X 860 = 35260000 kcal

TC Eff = (Sum of total heat supplied to process in kcal X 50% + Total electricity generated in kcal) X 100 / Fuel energy

TC Eff = ((8880000+111010000) X 50% + 35260000) X 100 / 191250000

TC eff = 49.78%