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1 Introduction 1.1 General overview ACE Power Embilipitiya (Pvt) Ltd (APE) is an independent power producer in Sri Lanka with a capacity of 100 MW net electrical power output, supplying electricity to the national grid with a minimum guaranteed energy amount of 697.7 GWh per year, which is equivalent to nearly 7000 hours per year of full-load operation. The power plant was commissioned in 2005 and operates on a 10-year power purchasing agreement with Ceylon Electricity Board (CEB). The plant is equipped with 14 Caterpillar 16CM32C engine-generator units running on heavy fuel oil, each with a rated power capacity of 7.5 MW; and the generated electricity is supplied to the Embilipitiya grid station of CEB via a 132 kV transmission line. The entire operations and maintenance work of the power plant is carried out with local expertise under ISO 9001:2008, ISO 14001:2004, OHSAS 18001 management systems and 5S industrial housekeeping standard. The overall efficiency of the energy conversion typically falls below 40% with much of the energy lost as waste heat taken away by the exhaust gas and sunk by the other waste heat flow streams of the turbocharged Caterpillar 16CM32C engines. In an attempt to recover waste heat, APE has installed eight numbers of thermal oil boilers operated with waste heat recovery (WHR) from the exhaust gas of eight engine units and the recovered heat is used for process heating of heavy fuel oil. The exhaust heat of the remaining six APE engine units are left unattended and this study was focused on the feasibility and design procedures for Heat Recovery Steam Generation (HRSG) units for the remaining six engines to recover maximum possible heat from the exhaust gas with the purpose of additional electricity generation by a steam cycle; and selecting a suitable standard steam turbine according to heat estimated recovery capacity of the above HRSG. Exhaust gas from six engines (Engine no 9 to 14) as shown in Figure 1.2 is expected to be used for HRSG, since other eight engines have WHR boilers. Figures 1.1 and 1.2 show the present layout and exhaust gas pipe arrangement of the plant. 1.2 Statementoftheproblem With the climate patterns becoming more unpredictable due to global warming Sri Lanka has to rely on thermal electricity generation for the reliability of the national electricity grid especially during drought or less rainy seasons. The country is 100% dependent on expensive imported coal and oil for thermal power generation as alternative to the locally available hydro power. Therefore, it is of vital importance that the thermal power plants of Sri Lanka make the most out of the imported energy sources of fuel. At the same time, protecting the environment as much as possible, by reducing the GHG emissions is very much a timely necessity. 1PDF Image | waste heat recovery steam power system for ACE Embilipitiya
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