Showing posts with label Efficiency & performance. Show all posts
Showing posts with label Efficiency & performance. Show all posts

What is Entropy??

 













In heat engine theory, the term ENTROY plays a very vital role and leads to important results which by other methods can be obtained much more laboriously.

It may be noted that, all the heat is equally not available for converting into work. Heat that is supplied to a substance at higher temperature has greater possibility of conversion into work rather than heat supplied to a substance at lower temperature.

Meta Description: Confused by entropy? This guide breaks down the law of entropy in simple terms. Learn how this fundamental concept of thermodynamics affects everything from the cosmos to your daily life.

We’ve all experienced it. An ice cube melts in your drink. Your once-organized desk slowly descends into chaos. A hot cup of coffee gets colder, never hotter, on its own. These everyday events seem unrelated, but they are all governed by a single, powerful, and often misunderstood scientific law: the Second Law of Thermodynamics, often called the Law of Entropy.

In simple terms:

·         Entropy is a measure of how energy is distributed in a system.

·         It tells us how much of the system’s energy is unavailable to do useful work.

·         It also represents the degree of disorder or randomness of particles within the system.

 

Entropy is a function of quantity of heat which shows the possibility of conversion of that heat into work. The increase in entropy is small when heat is added at higher temperature and is greater when heat addition is made at a lower temperature.

Thus, the for maximum ENTROPY there is minimum availability for conversion into work and for minimum entropy there is maximum availability for conversion into work.

As per the Third law of Thermodynamics: When a system is at zero absolute temperature, the entropy of a system is zero. That is The Entropy of all perfect crystalline solids is zero at absolute zero temperature.

Entropy may also be defined as the thermal property of a substance which remains constant when substance is expanded or compressed adiabatically in a cylinder.

In the simplest sense, entropy is a measure of disorder or randomness in a system. In thermodynamics, however, it is more precisely defined:

Entropy is a measure of the amount of energy in a system that is unavailable to do useful work.

This makes entropy a central concept in the Second Law of Thermodynamics, which states that in any natural process, the total entropy of an isolated system always increases or remains constant.

In an isolated system, entropy never decreases. Processes naturally move toward states of higher entropy.

 

Characteristics of Entropy:

1-It increases when the heat is supplied irrespective of the fact whether temperature changes or not.

2-Entropy decreases when heat is removed whether temperature changes or not

3-It remains unchanged in all adiabatic frictionless processes

4-Entropy increases if temperature of heat is lowered without work being done as in a throttling processes.

 

Entropy and Irreversibility:

One of the most practical consequences of entropy is that it explains why certain processes are irreversible.

A cup of hot coffee placed on a table will cool down, but the table will never spontaneously heat the coffee back up.

An inflated balloon can burst, but the air inside will not naturally return into the balloon.

Entropy is more than an abstract thermodynamic term — it is a guiding principle of nature. It tells us why processes have direction, why machines have limits, and why time seems to move forward. From a melting ice cube to the vast fate of the universe, entropy governs the flow of energy and the evolution of systems.

Understanding entropy is not only essential for physicists and engineers but also provides us with a deeper appreciation of the hidden order behind everyday phenomena.

Two Sides of the Same Coin: Thermodynamic vs. Informational Entropy

The concept of entropy has also revolutionized the field of information theory, thanks to Claude Shannon.

·         Thermodynamic Entropy: Deals with the physical dispersal of energy.

·         Informational Entropy: Measures uncertainty or the surprise factor in a message. A string of random letters has high informational entropy (it's very surprising/unpredictable). A meaningful sentence in English has low informational entropy (it's predictable and ordered).

 Read more>>>>>>powerplant and calculations

40-Thumb rules for sugar Cogeneration plant design

 











Objective: Design of Cogeneration plant for 5000 TCD Sugar and 60 KLPD Molasses based Distillery plant

Thumb rules for power plant design

Sl.No.

Particular

Capacity as per Thumb rule

1

Capacity of the Sugar plant

5000 TCD

2

Distillery plant capacity

60 KLPD

3

Steam required to Sugar process

Cane crushing capacity X 40% = 5000X 40% =2000 MT/day =85 TPH

4

Steam required for distillery process

Steam required for distillery process plant =Distillery plant capacity X 3.5

                                                                                            = 60 KLPD X 3.5 = 210 TPD = 8.75 TPH

 

5

Total steam demand for sugar and distillery process

85 + 8.75 = 93.75 TPH

6

Sugar plant auxiliary Power consumption

The auxiliary power consumed per hour by any sugar plant as a Thumb rule = Cane crushing capacity X 80% X 110% =5000X80%110%=4.4 MWH

 

7

Employee & labour Colony power consumption

Sugar plant power consumption X 4 to 5%  =   4400 X 4 to 5% = 170-220 KWH = 0.17 to 0.22 MW

 

8

Power consumption of distillery plant

Sugar plant power consumption X 20-25% = 4400 X 20-25% = 0.88 to 1.1 MW

 

9

Total power consumption of Sugar process and related auxiliaries

Total power consumption= 4.4 + 0.22 +1.1=5.72 MWH

 

10

Turbine extraction steam flow

Extraction steam flow = Process steam flow + Deaerator steam flow

Deaerator steam flow=Process steam flow X 10%

11

Boiler capacity

Boiler capacity = Turbine extraction steam/0.7 = = 85 + 85 X 10% = 93.5 TPH/0.7 =133.5 =135 TPH

12

Boiler fuel (Bagasse) consumption

At the average SFR (steam to fuel ratio) 2.4 Boiler bagasse consumption = 135 / 2.4 =56.25 TPH

 

13

Bagasse saving per day

= (Sugar mill bagasse generation-Boiler fuel consumption) X 24

 = (60.42-56.25) X 24 = Appx. 100 MT/day

14

% of Bagasse saving

% of bagasse saving = 100 X 100/(60.42 X 24) =6.9%

 

15

Turbine capacity

Power generation in Turbine = (Bleed-1 steam flow X (Main steam Enthalpy-Bleed-1 enthalpy) + Bleed-2 steam flow X (Main steam Enthalpy-Bleed-2 enthalpy) + Extraction steam flow X (Main steam Enthalpy-Extraction enthalpy) + Exhaust steam flow X (Main steam Enthalpy-Exhaust enthalpy)) / 860

 

Power generation in Turbine = (8 X (828-738) + 20 X (828-703) + 93.45 X (828-645) + 14 X (828-611)) / 860

Power generation in Turbine = 720+2500+17110.5+3038 =27.17 MW

Net Power generation = 27.17 X 98% X 95% = 25.29 MW = 25 MW

Therefore, Turbine power generation capacity = 25 MW

16

Specific steam consumption (SSC)

SSC=Steam consumption / Power generation = 135 / 25 = 5.4

17

Specific fuel consumption (SFC)

SFC= SSC / SFR = 5.4 / 2.4 = 2.25 Kg/Kw

 

18

Alternator capacity/size

Alternator capacity = Turbine Power generation capacity/Power factor

= 25/0.8 = 31.25 MVA

19

Lube oil system capacity calculation

 

19a

Lube oil pump capacity

Lube oil pump capacity in M3/Hr = Turbine capacity in MW X 2.0

That is AOP/MOP capacity = 25 MW X 2.0 = 50 M3/hr each

 

19b

Capacity of EOP pump

Capacity of EOP pump = Lube oil pump (AOP or MOP) capacity X 25% = 50 X 25% = 12.5 M3/hr

 

19c

Capacity of COP pump

Capacity of COP pump = Lube oil pump capacity (AOP or MOP) X 10% = 50 X 10% = 5 M3/hr

 

19d

MOT storage capacity

As a thumb rule, MOT storage capacity = Quantity of oil flow (Lube & control oil) X 225

                 = (50+5) X 225 =12375 litre, can be rounded up to 12500 Litres

 

19e

OHOT storage capacity

As a thumb rule, Storage capacity of Overhead oil tank (OHOT) is = Main Oil tank (MOT) tank capacity X 35% = 12500 X 35% = 4375 liters, can be taken up to 4500 liters

 

19f

Oil cooler capacity

Oil cooler heat load = 50 M3/hr X 10 = 500 KW = 500 X 860 = 430000 kcal/hr.

 

Quantity of Cooling Water circulation = Heat load / Cooling water temperature difference

                                                                    = 500 X 860 kcal/hr / 4 deg C X 1000 = 107.5 M3/Hr.

 

 

19g

Oil Vapour extraction fans capacity calculation

As a Thumb rule Oil vapour extraction fan capacity in m3/sec = Total oil flow (Lube & Control oil) X 9

OVEF capacity = (50+5) X 9 = 495 M3/sec and static pressure will be 250-300 mmwc

20

Capacity of export Transformer

 Capacity = (Total maximum power generated-Cogen Auxiliary power consumption)

 = 25 MW-(25 X 8%) = 23 MW

Therefore, export transformer capacity will be 23 MW/Power factor =23/0.8 =28.75 or 30 MVA

 

21

Auxiliary Transformer capacity

Auxiliary Transformer capacity = Cogeneration Maximum Home Load X 120% / Power factor

                                                   =25 X 12% X 120% / 0.8 = 4.5 =4.5 MVA X 2 Nos

Note: Maximum APC considered is 12% and total transformers considered -2 Nos (2 X 100%)

Capacity of Transformers= 4.5 MVA

Out of two transformers one transformer can be used as converter (For VFD) and one as distribution transformer for other auxiliaries.

22

Boiler feed pumps capacity

Capacity of Operating Boiler feed pump = Boiler MCR X 135%

So, total capacity of the feed pumps = 135 X 135% = 182.25 M3/hr

 

Capacity of each pump = 182.25/2 = 91.12 or 92 M3/hr

Head of the pump = Boiler operating pressure X 140% = 110 X 140% = 154 Kg/cm2 or 1540 meter (Appx).

 

23

ID fans capacity

Capacity of the ID fan in m3/sec = Boiler capacity X / 2 = 135 / 2 = 67.5 m3/sec & Static pressure: 250-300 mmwc

 

24

Total combustion air required

Capacity of FD & SA fans = ID fan capacity X 80%

Therefore, capacity of FD & SA fans = 67.5 m3/sec X 80% = 54 m3/sec

 

25

Capacity of FD fan

Capacity of FD fan = 55% of ID fan flow

Capacity of FD fan = 55% X 67.5 m3/sec = 37.12 m3/sec & Static pressure: 250-280 mmwc

 

 

26

Capacity of SA fan

Capacity of SA fan = 25% of ID fan flow

Capacity of SA fan = 25% X 67.5 m3/sec = 16.87 =17 m3/sec & Static pressure: 600-650 mmwc

27

DM plant capacity

Capacity = Total losses in Power plant = 2 X 22 M3/Hr.

 

28

RO plant capacity

RO plant capacity = 22 X 110% = 24.2 or 25 M3/hr

2 X 25 M3/Hr

29

Main circulating cooling water

MCW water = Maximum exhaust from condensate X 70

Maximum exhaust from Turbine= Turbine inlet steam in season operation X 75% X 70%

Maximum exhaust = 135 X 75% X 70% = 70.87 = 71 TPH

Main circulating water (MCW) = 71 X 70 = 4970 M3/hr

 

30

Auxiliary Cooling water

Auxiliary cooling water required = 4970 X 8% =397.6 = 400 M3/hr.

31

Total circulating water

Total circulating water = MCW + ACW water = 4970 + 400 = 5370 M3/hr

32

Cooling tower storage capacity

Cooling tower storage capacity = Total circulating water X 25% = 5370 X 25% =1342.5 = 1345 M3.

 

33

Capacity of MCWP pumps

Capacity of each (3 Nos-2W+1S) main cooling water pumps (MCWP) : 4970 X 50% = 2485, can take 2500 M3/each pump

 

34

Capacity of ACWP pumps

Capacity of ACWP pumps = 400 M3/hr -2 Nos (1-working + 1-standby)

35

Capacity of instrumentation air compressor

As a Thumb rule: Capacity of instrumentation air compressor in m3/min = Power plant capacity in MW/4

So, Compressor capacity = 25/4 =6.25 M3/min X 2 Nos (1-Working + 1-Stand by)

36

Capacity of Service air compressor

Service air Compressor capacity = 25/4.2 =5.8 M3/min X 2 Nos (1-Working + 1-Stand by)

37

Capacity of fuel handling plant.

Capacity of the fuel handling plant would be = Bagasse generated from mill X 120%

Therefore, capacity of the fuel handling plant = 60.42 TPH X 120% =72.50, can be rounded up to 75 TPH.

Or Bagasse handling capacity = Boiler fuel consumption at SFR 2.4 X 130%

 = (135/2.4) X 130% = 73.125, can be rounded up to 75 TPH

38

Stack or Chimney size

Stack height = 75

ID : 3.3 M

OD: 3.9 M

 

39

ESP sizing

AS a thumb rule, ESP collection area = Flue gas flow in M3/hr / 67

ESP collection area = 345960 M3/hr /67 = 5164 M2

Specific collection area = 5164 / 96.1 =53.73, can be rounded up to 54 m2/m3/sec

Flue gas velocity in ESP = 0.9 to 1 m/sec

Migration velocity =8 to 9 cm/sec

 


Read more>>>>Sugar based Cogeneration plant complete design

Read more>>>>>Powerplant and calculations

15-Emergencies in power plant operation

Most visited posts