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In this paper, an improved system to efficiently utilize the low-temperature waste heat (WHUS) from the flue gas of coal-fired power plants is proposed based on heat cascade. The essence of the proposed system is that the waste heat of exhausted flue gas is not only used to preheat air for assisting coal combustion as usual but also to heat up feedwater and the low-pressure steam extraction. Preheated by both the exhaust flue gas in the boiler island and the low-pressure steam extraction in the turbine island, thereby part of the flue gas heat in the air preheater can be saved and introduced to heat the feedwater and the high-temperature condensed water. Consequently, part of the high-pressure steam is saved for further expansion in the steam turbine, which obtains additional net power output. Based on the design data of a typical 1000 MW ultra-supercritical coal-fired power plant in China, in-depth analysis of the energy-saving characteristics of the optimized WHUS and the conventional WHUS is conducted. When the optimized WHUS is adopted in a typical 1000 MW unit, net power output increases by 19.51 MW, exergy efficiency improves to 45.46%, and net annual revenue reaches 4.741 million USD. In terms of the conventional WHUS, these aforementioned performance parameters are only 5.83 MW, 44.80% and 1.244 million USD, respectively. The research of this paper can provide a feasible energy-saving option for coal-fired power plants.

To maximize the system-level heat integration, three retrofit concepts of waste heat recovery via organic Rankine cycle (ORC), in-depth boiler-turbine integration, and coupling of both are proposed, analyzed and comprehensively compared in terms of thermodynamic and economic performances. For thermodynamic analysis, exergy analysis is employed with grand composite curves illustrated to identify how the systems are fundamentally and quantitatively improved, and to highlight key processes for system improvement. For economic analysis, annual revenue and investment payback period are calculated based on the estimation of capital investment of each component to identify the economic feasibility and competitiveness of each retrofit concept proposed. The results show that the in-depth boiler-turbine integration achieves a better temperature match of heat flows involved for different fluids and multi-stage air preheating, thus a significant improvement of power output (23.99 MW), which is much larger than that of the system with only ORC (6.49 MW). This is mainly due to the limitation of the ultra-low temperature (from 135 to 75 • C) heat available from the flue gas for ORC. The thermodynamic improvement is mostly contributed by the reduction of exergy destruction within the boiler subsystem, which is eventually converted to mechanical power; while the exergy destruction within the turbine system is almost not changed for the three concepts. The selection of ORC working fluids is performed to maximize the power output. Due to the low-grade heat source, the cycle with R11 offers the largest additional net power generation but is not significantly better than the other preselected working fluids. Economically, the in-depth boiler-turbine integration is the most economic completive solution with a payback period of only 0.78 year. The ORC concept is less attractive for a sole application due to a long payback time (2.26 years). However, by coupling both concepts, a net power output of 26.51 MW and a payback time of almost one year are achieved, which may promote the large-scale production and deployment of ORC with a cost reduction and competitiveness enhancement.

Abstract:In this paper, an improved system to efficiently utilize the low-temperature waste heat from the flue gas of coal-fired power plants is proposed based on heat cascade theory. The essence of the proposed system is that the waste heat of exhausted flue gas is not only used to preheat air for assisting coal combustion as usual but also to heat up feedwater and for low-pressure steam extraction. Air preheating is performed by both the exhaust flue gas in the boiler island and the low-pressure steam extraction in the turbine island; thereby part of the flue gas heat originally exchanged in the air preheater can be saved and introduced to heat the feedwater and the high-temperature condensed water. Consequently, part of the high-pressure steam is saved for further expansion in the steam turbine, which results in additional net power output. Based on the design data of a typical 1000 MW ultra-supercritical coal-fired power plant in China, an in-depth analysis of the energy-saving characteristics of the improved waste heat utilization system (WHUS) and the conventional WHUS is conducted. When the improved WHUS is adopted in a typical 1000 MW unit, net power output increases by 19.51 MW, exergy efficiency improves to 45.46%, and net annual revenue reaches USD 4.741 million while for the conventional WHUS, these performance parameters are 5.83 MW, 44.80% and USD 1.244 million, respectively. The research described in this paper provides a feasible energy-saving option for coal-fired power plants.

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