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6 Discussion and Conclusions This work considered the conceptual modeling of a HRSG for the APE diesel engine plant in Sri Lanka, to improve the energy performance and overall efficiency of the power plant. The waste heat recovery potential from only the exhaust gas of the Caterpillar 16CM32C engines was investigated as a first step. 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. It was found that the energy potential by recoverable process heat from one engine unit per hour is (Qg) 9807.87MJ. In the APE site, six engine units are available for energy recovery. According to technical and practical limitations such as pinch point temperature difference, approach point temperature difference, terminal temperature difference and sulfur dew point of stack, modeling process of HRSG was done using the Engineering Equation Solver software. The approach point temperature was selected as 8oC and avoiding temperature cross situations. The Optimization of the modelled HRSG was performed using again the Engineering Equation Solver software. Trial runs were carried out to arrive at the maximum possible power output without compromising on size and cost. A second set of EES trial runs were carried out to find out the optimum steam pressure for 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. In the modelling process, the results indicate that lowest possible steam pressure and highest steam temperature gives maximum power output from steam turbine. However, the commercially available small scale steam turbines in the market do not exactly match with our requirement. Then a steam turbine was selected with a maximum possible power output according to availability. Rated power output of selected turbine is 3.579 MW. From the chosen steam turbine, 12884.4 MJ of energy was recovered per hour and this amount is 21.89% of recoverable total energy of flue gas per hour basis. In conclusion, Energy potential by recoverable process from one Caterpillar 16CM32C engine is (Qg) 9807.87 MJ per hour. The approach point temperature was selected as 8oC in order to avoid temperature cross situations. The optimization of the modeled HRSG was performed using the Engineering Equation Solver software. 33PDF Image | waste heat recovery steam power system for ACE Embilipitiya
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