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3 Methodology The waste heat recovery potential from exhaust gas of Caterpillar 16CM32C engine was investigated as the first step of the study. At the initial stage the quantity of recoverable waste heat was calculated by comparison between an installed waste heat thermal oil boiler at APE and an engine without a waste heat recovery method at fully loaded condition. A calculation was performed taking into account the calorific value of fuel used and the operating conditions in order to find the maximum theoretical waste heat recovery potential of the six available engines of APE. The approach for WHR from Caterpillar 16CM32C engines at the APE site was selected as a HRSG citing the possibility of selecting a suitable steam turbine from the market and producing additional electrical power thus converting the plant into a combined cycle. A preliminary design modelling of the HRSG was done considering the approach point and the pinch point variables, which affect the steam temperature profile and steam production rate. The pinch point temperature difference was selected as 8oC and special care was taken to avoid temperature cross situations. The optimization of the modelled HRSG was performed using the Engineering Equation Solver software package (EES). Initially, trial runs were carried out in EES to arrive at the maximum possible power output without compromising on size and cost by varying the pinch point and other parameters. A second set of EES trial runs were carried out to find out the optimum steam pressure for the HRSG keeping the pinch point temperature constant at 80C. The steam pressure was varied from 5 bar to 17 bar for the trials and the limiting factor for setting the maximum possible power output was taken as the sulfur dew point temperature of the outgoing exhaust gas after heat recovery. A commercially available steam turbine was selected and evaluated with maximum possible power output according to availability to suit the context of APE. 18PDF Image | waste heat recovery steam power system for ACE Embilipitiya
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