Journal of Mechanical Engineering Vol 18(1), 21-38, 2021

Performance Optimization of
Combined Cycle Power Plant
Considering Various Operating
Parameters

Sachin Kumar*
Department of Mechanical Engineering, Jagannath University,
124103 Jhajjar, Haryana, India
*skmtech11@gmail.com

ABSTRACT
Combined cycle power plants are popular in thermal engineering field for
their higher efficiency as compared to normal cycles such as Rankine and
Brayton Cycle. But main disadvantages of the cycle are waste heat rejection
and low work output. To overcome these difficulties a heat recovery system is
used in present work to recover waste heat of Brayton cycle as a steam
generator for Rankine cycle in a combined Gas-Vapor cycle. In present
work, effect of factors such as “compression ratio”, “inlet air temperature”
and “turbine inlet temperature” on cycle efficiency was calculated. It was
found that cycle efficiency increases with increase in these factors. It was
found that optimum value of compression ratio is 12-18 for maximum output
of combined cycle. Whereas inlet air temperature has adverse effect on cycle
efficiency so it should be kept lower while increase in turbine inlet
temperature increases the cycle’s work output and hence efficiency. Optimum
values of turbine inlet temperature were found in range of 1600-1700 K

Keywords: Combined cycle efficiency, Work Output, Compression Ratio

(12-18), Inlet Air Temperature (IAT), Turbine Inlet Temperature (TIT).

Nomenclature:-

AP = Approach Point
PP = Pitch Point
T = Temperature
___________________
ISSN 1823-5514, eISSN 2550-164X Received for review: 2020-03-18
© 2021 Faculty of MechanicalEngineering, Accepted for publication: 2020-11-10
Universiti Teknologi MARA (UiTM), Malaysia. Published: 2021-01-15
Sachin Kumar

WHRB = Waste Heat Recovery Boiler

Q̇ = Heat Transfer Rate
wC, wT = specific work output of compressor and turbine
h = Enthalpy
CP = Specific heat at constant pressure.
EO = Economizer Outlet.
FW = Water Flow Rate.
ST = Steam
G = Gas
W = Water
TIT = Turbine Inlet Temperature
TGEX = Exit Gas Temperature
r = Compression Ratio
η = Efficiency
ηCC = Combined Cycle Efficiency.

Introduction

In electric power generation, a combined cycle is an assembly of heat engines

that work in tandem off the same source of heat, converting it into
mechanical energy, which in turn usually drives electrical generators. The
principle is that the exhaust of one heat engine is used as the heat source for
another, thus extracting more useful energy from the heat, increasing the
system's overall efficiency. This works because heat engines are only able to
use a portion of the energy their fuel generates (usually less than 50%). The
remaining heat (e.g., hot exhaust fumes) from combustion is generally
wasted. Combining two or more thermodynamic cycle results in improved
overall efficiency and reduces fuel costs. In stationary power plants, a
successful, common combination is the Brayton cycle (in the form of a
turbine burning natural gas or synthesis gas from coal) and the Rankine
cycle.
In combined cycle, a gas turbine generator generates electricity and
heat in the exhaust is used to make steam, which in turn drives a steam
turbine to generate additional electricity. This last step enhances the
efficiency of electricity generation. Many new gas power plants in North
America and Europe are of this type. Such an arrangement used for marine
propulsion is called combined gas (turbine) and steam (turbine) (COGAS).
Conversion of an existing steam power plant in a combined cycle power
plant is cost effective as well as more efficient as compared to former [1].
Based on recent technology and future demand the main focus in study of
CCGT is to focus on exergy optimization by reducing heat loss [2]. Moreover
the power production of combined cycle can be increased by evaporator and
absorption cooling up to 5-10% whereas as precooling of cycle reduce the

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 Performance Optimization of Combined Cycle Power Plant

temperature range of combustion chamber [3, 4].

Various comparative studies on various kind of combined cycles and
methods of improving efficiency of combined cycle and has been done by
developing a genetic algorithm to study complex design of combined cycle
for utilizing waste heat [5-8]. In 2004, exergy analysis of reheat combined
cycle was done to design and optimization of cycle which in turns conclude
that the efficiency and power output of the cycle can be increased by
replacing reheat in expansion process [9, 10]. Cyclic efficiency of power
plant can be increased by using air precooler connected to the evaporator of
power plant [11]. Kakaras et al. [12-13] developed three method for air
cooling viz; a) evaporative cooling b) refrigeration cooling c) evaporative
cooling of pre-compressed air. It was concluded that the highest incremental
electricity generation is realized by absorption intake air cooling. In terms of
the economic performance of the investment, the evaporation cooler has the
lowest cost of incremental electricity generation and lowest payback period.
Concerning to the cooling method of pre-compressed air, the results shows a
significant gain in capacity, but the total cost of incremental electricity
generation in this case is the highest.
The cyclic performance of power plant can be increased by
maximizing turbine rotor inlet temperature in the gas turbine; optimizing the
gas turbine pressure ratio for gas turbine performance; optimizing steam
turbine and boiler pressure; and maximizing steam injection in the gas
turbine [14, 15]. Whereas pre-cooling of inlet air by absorption chiller can
increase the cycle efficiency [16]. Butcher & Reddy [17] studied
performance of a waste heat recovery power generation system based on
second law analysis is investigated for various operating conditions. The
temperature profiles across the heat recovery steam generator (HRSG),
network output, second law efficiency and entropy generation number are
simulated for various operating conditions.
Hawaj & Mutairi [18] investigated the effect of different parameters,
such as steam to gas mass flow rate ratio, inlet steam turbine temperature,
compressor pressure ratio, and gas turbine (GT) combustion efficiency on the
performance of the combined cycle. In another aspect of the study, the
relative advantage of using CCPP with absorption cooling over thermally
equivalent mechanical vapor compression (MVC) cooling was also
demonstrated. Whereas reheated cycle is best cycle as compared of single
stage cycle and intercooled cycle [19]. Locopo et al. [20] did second law
analysis of three different cycles viz., a cycle uses exhaust gases produced by
the engine, another with the addition of cooling water with engine exhaust,
and third, a regenerated cycle. The overall efficiency of the cycle was
increased by 12% for the cycle without bottoming.
Godoya et al. [21] characterized combined cycle gas turbine power
plants by minimum specific annual cost values and determined wide ranges
of market conditions as given by the relative weights of capital investment

23
Sachin Kumar

and operative costs, employing a non-linear mathematical programming

model. Sipheng Zhu et al. [22] did a theoretical study of bottoming the
Rankine cycle to recover engine waste heat by comparing five different
working fluid on MATLAB software. Engine performance was mainly
affected by working fluid properties and superheating temperature which
causes slight changes in the overall efficiency of the cycle. Martinez et al.
[23] reviewed micro heat and power system with renewable energy
resources. Khan et al. [24] use bypass valves to optimize the performance
and a 45% increase in network output was obtained with an increase in
turbine inlet temperature from 1000K to 1400K simultaneously increasing
the efficiency of the cycle from 15% to 31%. More ever the plant efficiency
can be increased by providing sequential combustion and steam cooling [25].
Ahmadi et al. [26] reviewed solar power technologies used for electric power
generation. Their work points out two ways of generating electricity by solar
energy viz; converting solar irradiations into electricity using PV model, and,
secondly, harnessing thermal energy by implementation of concentrated solar
power (CRS) plants like Linear Fresnel collectors and parabolic trough
collectors showing that PV modeled power plants are the better ones as
compared to CRS.
A simulation model was proposed by Kumar et al. [27] for
determining steam flow rate and overall efficiency of 250 MW coal based
power plant. Effect of varying load on thermal efficiency of the plant was
discussed and results shows that overall efficiency of the plant was slightly
affected with increase in load. In 2019, Kumar et al. [28] proposed two ways
of waste heat recovery system of a gas engine to generate electricity. In first
approach a single heat recovery boiler was used in which all mixed gases are
allowed to pass through before entering to pre-heater and grid cooler.
Whereas, in second method, vapor mixture was allowed to pass through
steam turbine. Comparing the both methods resulted that the first approach
recovered 23931 KJ/s of waste heat with 23.5% power generating efficiency
whereas in second approach 21253 KJ/s waste heat was recovered with
22.2% efficiency.
Since last few years various case studies and energy analysis as well
as economical aspects of combined cycle power plant has been done [29-31].
In the present study effect of some design parameters such as gas turbine
compression ratio, ambient air temperature, turbine inlet temperature, on
factors such as fuel consumed (kg) per 100 kg of air, gas turbine outlet
temperature, work obtained from the combined cycle, combined cycle
efficiency will be calculated.

Design principle
An open circuit gas turbine cycle has a compressor, a combustor, and a
turbine. In this type of cycle, the inlet turbine temperature and flue gas
temperature are kept in ranges of 900-1400 °C, and, 450 to 650 °C

24
 Performance Optimization of Combined Cycle Power Plant

respectively. This range of temperature provides a lot of heat to be used in

the Rankine cycle for the generation of steam. In the present work, the
turbine's exhaust heat passed through a heat recovery steam generator
(HRSG) with a live steam temperature between 420 and 580 °C to convert
water into steam. The cooling process in the Rankine cycle is done by
circulating water from outside sources like rivers of the cooling tower at low
temperature, say, 15 °C.

Working Principle
A combined cycle power plant consists of a Brayton cycle at the first stage
and a Rankine Cycle on a later stage is shown in Figure 1. In the first stage
air as a fuel is compressed isentropically in an air compressor and then sent
to the combustion chamber where compressed air is heated by fuel. The hot
gas is then made to flow over turbine blades which in turn generate electricity
and the exhaust is passed to the heat recovery steam generator. The output as
steam from the steam generator is now used as working fluid for the second
stage i.e. in the Rankine cycle, to generate electricity. At the second stage,
the steam output from the steam generator is now passed to the steam turbine
which in turns generates electricity and the exhaust of the steam turbine is
passed to the condenser where it condensed in the form water and again fed
to the steam generator with the help of water pump as shown in Figure 1.

Figure 1: Working principle of single pressure CCPP.

25
Sachin Kumar

The waste heat recovery process in a single pressure WHRB is

illustrated on a temperature profile diagram in Figure 2. Water enters the
boiler in the form of compressed liquid at condensate temperature (T FW). As
the water receives heat from the hot exhaust gases, it becomes saturated,
starts boiling, and is superheated. On the hot side, the exhaust gases leaving
the gas turbine enter the steam generator and get cooled finally to the stack
temperature (TSTACK).
For maximum heat recovery, the stack temperature should approach
the acid saturation point of the exhaust gases, while keeping the pressure
drop as well as the size of the boiler within the desirable limits. The factors
which affect the cost and effectiveness of any WHRB are the pinch point,
approach point, allowable backpressure, stack temperature, steam pressure,
and steam temperature. The minimum temperature difference for heat
transfer, which is known as pinch point plays an important role in identifying
the optimum heat recovery and size of heat exchangers. The approach point
is the difference between the saturation temperature and the temperature of
water leaving the economizer. Lowering the approach point will increase the
probability of steaming in economizer which may cause hammering and
blanketing.

Figure 2: Temperature/Heat energy diagram for a single pressure WHRB.

The gas side pinch point temperature (T P) and economizer exit

temperature (TEO) are calculated by assuming the drum saturation pressure
(PDrum).

TP = TDRUM + PP (1)
TEO = TDRUM - AP (2)

26
 Performance Optimization of Combined Cycle Power Plant

The steam generated for each kg/sec of exhaust gases can be determined by
applying mass and energy conservation principles across the super-heater and
evaporator.

(3)
The WHRB, being considered is a non-firing boiler. Therefore the heat
transfer is predominantly by convection. It is customary to neglect the
radiative heat transfer, particularly because the reduction in heat transfer due
to soot deposition/ fouling etc. is also ignored and it is assumed that these
two approximately compensate each other. The heat across each section of
the boiler can be estimated as follow:

(4)

(5)
(6)

The flue gas temperature in the stack can also be estimated based on the heat
balance across economizer.

(7)

Low stack temperature is always desirable from the point of waste

recovery. However, to avoid the corrosion from moisture formation in the
economizer, the minimum temperature should always be kept higher than the
acid dew point temperature. Also, the size of the economizer depends on the
stack temperature which has, therefore, to be justified on the economic
consideration.

Mathematical Modeling

The following Parameters are taken for the present study:

Compression ratio: 8-20
Inlet Air Temperature: 275-325 K
Turbine Inlet Temperature 1250-1700 K

The effect of all these parameters was studied to establish the combined cycle
work output and efficiency. For a given compressor isentropic efficiency

27
Sachin Kumar

 c and pressure ratio rc , other state variables for the incoming and outgoing
streams can be calculated. The inlet and outlet humidity ratios will be the
same. The energy balance yields the compressor work wc and compressor
outlet temperature.

wai  wao (8)

 c 1
Tao
  rc   cc
Tai (9)

The polytropic efficiency of the compressor and turbine can be calculated

according to:

c= 1 - [0.04 + (rc - 1)/150] (10)

t = l - [0.03 + (rt - 1)/180] (11)
(12)
Specific heat ratio for the humidified air is being given by the following
relation:

C pc
c 
Cvc (13)

where Cpc and Cvc can be determined from the following relations:

C pc  C pa  wai C pw
(14)
Cvc  Cva  wai Cvw
(15)

Specific heat of air at constant pressure is given by the following relation:

C pa  C0  C1T  C2T 2  C3T 3  C4T 4

(16)
Cva  C pa  R
(17)
f
C p  C pa   cp
f 1 (18)
where,

28
 Performance Optimization of Combined Cycle Power Plant

 cp  CP0  CPT
1  CP2T  CPT
2
3
3
 CP4T 4  CPT
5
5
(19)

Enthalpy of air is being given by the following formula:

T
ha   C pa dt
0 (20)
C C C C
ha  C0T  1 T 2  2 T 3  3 T 4  4 T 5  CH
2 3 4 5 (21)

For the expansion ratio of the gas turbine, “re” temperature at the exit of the
turbine isentropic process can be calculated by:

(  g 1)
g
Tgos  Tgi (re )
(22)

The actual temperature Tgo at the exit of the turbine can be calculated by:

Tgi  Tgo
T  (23)
Tgi  Tgos

The energy balance yields the turbine work wT given by the following
relation:

(24)

Change in enthalpy of air after adding fuel in the combustion chamber is:

cc m f CV  hgo  hgi  h3  h2

(25)

where hgo may be calculated as:

f
hgo  ha  h
1 f (26)
 h  H 0  H1T  H 2T 2  H 3T 3  H 4T 4  H 5T 5 (27)

Heat transfer and efficiency can be calculated by the following equations:

29
Sachin Kumar

Pump work:

(28)

If the efficiency of the pump is taken into consideration then:

hFW  h f
hFW  h f  (29)
p

Work done by the steam turbine is:

(W .D) ST  hMST  hEX (30)

Net work done will be:

(W .D) net  (W .D) ST  W p

(31)

(32)

Hence the associated bottoming cycle and plant efficiencies are:

W .D net
 SC 
QSC
(33)
PGT  PSC PCC
CC  
Qin M f LHV

Result Analysis and Discussion

For the present study, the pressure ratio of gas turbines varied from 8 to 20
bar. With an increase in compression ratio, compressor exit temperature
increases which result in the decrement of fuel consumption keeping the inlet
temperature of the turbine constant (Figure 3). In the present work capacity
of the blade material of the turbine for bearing thermal stress was kept on
mind for deciding values of the inlet gas temperature of the turbine. The main
purpose of the study is to focus on the recovery of waste heat of gas turbine

30
 Performance Optimization of Combined Cycle Power Plant

exit which can be utilized to generate steam in steam turbines and further
generate electric power by implementing heat recovery steam generator.

Fuel consumed (Kg) per 100 Kg of air

4.1
4
3.9
3.8
3.7
3.6
3.5
3.4
3.3
3.2
3.1
8 10 12 14 16 18 20
Gas turbine com pression ratio

Figure 3: Effect of gas turbine compression ratio on fuel consumption

The cycle compression ratio has a direct effect on gas turbine outlet
temperature. As the compression ratio increases, gas turbine outlet
temperature decreases which makes lesser heat available for pressurized
water in HRSG (Figure 4).

1200
Gas turbine outlet temperature (K)

1000

800

600

400

200

0
8 10 12 14 16 18 20
Gas turbine com pression ratio

Figure 4: Effect of the compression ratio of the gas turbine on gas turbine
outlet temperature.

31
Sachin Kumar

For the lower cycle pressure ratio, sufficient heat is available to

convert the pressurized water into steam. But after a pressure ratio of 18, flue
gas temperatures becomes low enough to lower the heat supplied to
pressurized water. Due to this steam turbine work output is decreased and
after the pressure ratio of 18, a decreased work output from the cycle is
obtained (Figure 5).

570

560
Work obtained in cycle(KJ)

550

540

530

520

510

500
8 10 12 14 16 18 20
Gas turbine com pression ratio

Figure 5: Change in work obtained from a combined cycle with a change in

gas turbine compression ratio.

As it may be observed that there is not much gain in work output by

changing the compression ratio but efficiency gain is reasonable (Figure 6).
To calculate the cycle efficiency a ratio of work output and energy supplied
is taken. As the increase in pressure ratio lower the fuel consumption so the
energy supplied to the cycle decreases and efficiency increases.

32
 Performance Optimization of Combined Cycle Power Plant

45

Combined cycle efficiency (%)

40
35
30
25
20
15
10
5
0
8 10 12 14 16 18 20
Gas turbine com pression ratio

Figure 6: Change in combined cycle efficiency with a change in gas turbine

compression ratio.

Ambient air temperature never remains constant. Now from the

analysis, it is being found that as the IAT will increase fuel requirement will
decrease. This is because TIT is fixed for this case and if the IAT increases
then the combustion chamber inlet temperature will also increase. But the
combustion chamber outlet temperature is fixed. So the fuel requirement
decreases (Figure 7).

3.6
Fuel injected in Kg per 100 Kg of air

3.5

3.4

3.3

3.2

3.1

3
275 280 285 290 295 300 305 310 315 320 325
Am bient air tem perature (K)

Figure 7: Change in fuel injected in the combustion chamber with a change in

ambient air temperature.

33
Sachin Kumar

For the design conditions if the TIT is fixed then, as the gas turbine
inlet temperature will keep on increasing then the fuel requirement will
decrease. But due to the increase in the ambient temperature the mass flow
rate of the air to the compressor also decreases which leads to lesser work
output and lesser efficiency (Figure 8). Inlet air cooling may bring the
ambient air to the designed condition.

580
Work obtained from combined cycle

560

540

520
(KJ)

500

480

460

440
275 280 285 290 295 300 305 310 315 320 325
Inlet air tem perature(K)

Figure 8: Change in work obtained from a combined cycle with a change in

inlet air temperature.

An increase in ambient temperature reduced fuel consumption and

simultaneously work output also decreased to a level that has a considerable
impact on the performance of the combined cycle causing lower efficiency as
shown in Figure 9. With the increase in the inlet or ambient air temperature,
the fuel requirement of the combined cycle decreases by 11%, and similarly
work output of the cycle also decreases by 14% which has more impact on
cycle efficiency, thus, causing a reduction in combined cycle efficiency
(Figure 9).

34
 Performance Optimization of Combined Cycle Power Plant

38.4

Combined cycle efficiency (%)

38.2
38
37.8
37.6
37.4
37.2
37
36.8
36.6
36.4
275 280 285 290 295 300 305 310 315 320 325
Am bient air tem perature

Figure 9: Change in combined cycle efficiency with a change in ambient air

temperature.

Highest TIT is decided by the metallurgical stress-bearing capacity of

turbine blade material. With the higher TIT larger is the fuel consumption
and work obtained in the cycle and combined cycle efficiency also increases.
For designing the gas turbine the compression ratio is kept between the
maximum work and maximum efficiency. Increasing the TIT increases
combined cycle efficiency. Benefit of increasing a lower temperature is more
and it decreases with TIT. It is so due to increase in the consumption of fuel
to attain higher TIT. After a turbine inlet temperature of 1700 K not much
increase in efficiency is observed.
A significant increase in combined cyclic efficiency was noted with a
varying inlet temperature of flue gases in the turbine. Higher flue gas
temperature at turbine inlet results in larger work output and hence the
performance increases as well. But as the inlet temperature of flue gases
reaches a value 1700K no further significant change in combined cycle
performance was achieved.
The energy analysis is not sufficient for accurate prediction of
combined cycle power plant performance. Energy analysis gives only an idea
about the efficiency and work obtained from the cycle. It does not tell us
about the major sites of energy losses. For the complete analysis exergy
analysis is also required. The present work makes a base for the exergy
analysis.

35
Sachin Kumar

Conclusion
In present work, waste heat of gas turbine was used to generate electricity by
implementing heat recovery steam generator. Fuel consumption of power
plant can be reduced by increasing compression ratio keeping inlet
temperature of gas turbine constant, which in turn, decreases the gas turbine
outlet temperature resulting less available heat for steam generator. With
increase in compressor ratio, the cycle’s work output and efficiency increases
significantly and reaches to a maximum value at compression ratio 18 bar. It
was observed that an increase in pressure ratio lower the fuel consumption
and thus less energy consumption was occurred thus increased cyclic
efficiency was obtained. Inlet ambient air temperature has adverse effect on
cycle’s efficiency and should be kept below 270 K. Turbine inlet temperature
has remarkable effect on cycle’s efficiency. It was observed that when
turbine inlet temperature reaches to 1500 K then cycle’s efficiency and work
output increases effectively and from results it is clear that cycle reaches to
maximum efficiency at 1700 K.

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