Numerical Analysis of Power Flow and Greenhouse Gas Reduction of Power Generation Plant in Factory

Ng, Chon Khoon (2025) Numerical Analysis of Power Flow and Greenhouse Gas Reduction of Power Generation Plant in Factory. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This project focuses of analysis of power flow and greenhouse gas (GHGs) emission reduction in a power generation plant utilizing CCGT with HRSG. The plant, operated by Jingxing Holdings (M) Sdn. Bhd., operates HRSG with a duct burner to have flexibility operation and input power to increase steam generation when needed. A steady-state and dynamic HRSG model was developed using Aspen Hysys to simulate the operation of the system under various scenarios. Actual operational data were used to validate the model to ensure its reliability. The project is divided into 2 areas. Firstly, it involves the development and comparison of HRSG models with manual control and PID control on the fuel valve which feed the fuel into duct burner. The controller purpose is to regulate the steam drum pressure, which can improve responsiveness to steam demand variations or other disturbances. The second part involving evaluation between performance of the power plant with and without the implementation of a condensate and heat recovery process. A techno-economic analysis (TEA) was utilised to determine the benefits in terms of recovered heat, fuel savings, energy and chemical cost reductions, and GHGs emission mitigation. Results show that the PID-control implemented to fuel valve offers better pressure regulation with faster response time, adaptive to the dynamic changes compared to manual control. Secondly, the recovery systems contribute to substantial daily savings of RM 34,279.23 in energy costs, natural gas savings of 2,594.52 kg/day, biomass savings of 32,390.15 kg/day, and 22,903.08 kgCO2e/day in GHGs emission reduction. The findings confirm that control system optimization and recovery process implementation significantly enhance plant efficiency, sustainability, and economic performance.