Co-Generation

Introduction

Introduction Whats a Cogeneration/CHP System?

Generation of multiple forms of energy in one system: heat and power Defined by its prime movers
Reciprocating engines Combustion or gas turbines, Steam turbines Microturbines Fuel cells

COGENERATION PLANT LAYOUT

TO POWER SUPPLY
Feed water

Fuel

BOILER

TURBINE
PRDS

ALTERNATOR

Air

TO PROCESS
CONDENSER TO COOLING TOWER

TO PROCESS

How Cogeneration Saves Energy

Introduction Efficiency Advantage of CHP

Conventional Generation (58% Overall Efficiency)

36 Units (Losses)

Combined Heat & Power (85% Overall Efficiency)

60 100

= 40%

24 Uni ts

68
34 Uni ts

40

= 85%

6 Units (Losses)

10 Units (Losses)

Introduction
Benefits of Cogeneration / CHP)
Increased efficiency of energy conversion and use
Lower emissions, especially CO2

Ability to use waste materials

Large cost savings Opportunity to decentralize the electricity generation Promoting liberalization in energy markets

Types of cogeneration systems

Type of Cogeneration Systems

Steam turbine Gas turbine Reciprocating engine Other classifications:
- Topping cycle - Bottoming cycle

Type of Cogeneration Systems Steam Turbine Cogeneration System

Widely used in CHP applications
Oldest prime mover technology Capacities: 50 kW to hundreds of MWs

Thermodynamic cycle is the Rankin cycle that uses a boiler

Most common types Back pressure steam turbine Extraction condensing steam turbine

Type of Cogeneration Systems

Back Pressure Steam Turbine
Steam exits the turbine at a higher pressure than the atmospheric
HP Steam

Boiler

Turbine

Advantages: -Simple configuration -Low capital cost -Low need of cooling water -High total efficiency Disadvantages: -Larger steam turbine -Electrical load and output can not be matched

Fuel

Condensate Process

LP Steam

Figure: Back pressure steam turbine

Type of Cogeneration Systems

Extraction Condensing Steam Turbine
HP Steam

Steam obtained by extraction from an intermediate stage Remaining steam is exhausted

Boiler Fuel

Turbine

LP Steam Condensate Process

Relatively high capital cost, lower total efficiency

Control of electrical power independent of thermal load

Condenser

Figure: Extraction condensing steam turbine

Type of Cogeneration Systems Gas Turbine Cogeneration System

Operate on thermodynamic Brayton cycle atmospheric air compressed, heated, expanded excess power used to produce power Natural gas is most common fuel
1MW to 100 MW range Rapid developments in recent years Two types: open and closed cycle

Type of Cogeneration Systems

Open Cycle Gas Turbine
Open Brayton cycle: atmospheric air at increased pressure to combustor
Exhaust Gases Condensate from Process HRSG Steam to Process Combustor Fuel

Old/small units: 15:1 New/large units: 30:1

Exhaust gas at 450600 oC

G Generator Compressor Air Turbine

High pressure steam produced: can drive steam turbine

Figure: Open cycle gas turbine cogeneration

Type of Cogeneration Systems

Closed Cycle Gas Turbine
Heat Source

Working fluid circulates in a closed circuit and does not cause corrosion or erosion Any fuel, nuclear or solar energy can be used

Heat Exchanger

G Generator Compressor Turbine

Condensate from Process

Steam to Process

Figure: Closed Cycle Gas Turbine Cogeneration System

Type of Cogeneration Systems

Reciprocating Engine Cogeneration Systems
Used as direct mechanical drives
Many advantages: operation, efficiency, fuel costs Used as direct mechanical drives Four sources of usable waste heat
Figure: Reciprocating engine cogeneration system (UNESCAP, 2000)

Type of Cogeneration Systems Topping Cycle

Supplied fuel first produces power followed by thermal energy Thermal energy is a by product used for process heat or other Most popular method of cogeneration

Type of Cogeneration Systems Bottoming Cycle

Primary fuel produces high temperature thermal energy
Rejected heat is used to generate power Suitable for manufacturing processes

Assessment of cogeneration systems

UNEP 2006

Assessment of Cogeneration Systems Performance Terms & Definitions

Overall Plant Heat Rate (kCal/kWh):
Ms x (hs hw) Power Output (kW )
Ms = Mass Flow Rate of Steam (kg/hr) hs = Enthalpy of Steam (kCal/kg) hw = Enthalpy of Feed Water (kCal/kg)

Overall Plant Fuel Rate (kg/kWh)

Fuel Consumption * ( kg / hr ) Power Output (kW )

Assessment of Cogeneration Systems

Steam Turbine Performance
Steam turbine efficiency (%):
Actual Enthalpy Drop across the Turbine (kCal / kg) x 100 Isentropic Enthalpy drop across the Turbine (kCal / kg)

Gas Turbine Performance

Overall gas turbine efficiency (%) (turbine compressor):
Power Output (kW ) x 860 x 100 Fuel Input for Gas Turbine (kg / hr ) x GCV of Fuel (kCal / kg)

Assessment of Cogeneration Systems

Heat Recovery Steam Generator (HRSG) Performance
Heat recovery steam generator efficiency (%):
M s x ( hs hw ) [ M f x Cp (t in t out )] [ M aux x GCV of Fuel (kCal / kg)]
Ms = Steam Generated (kg/hr) hs = Enthalpy of Steam (kCal/kg) hw = Enthalpy of Feed Water (kCal/kg) Mf = Mass flow of Flue Gas (kg/hr) t-in = Inlet Temperature of Flue Gas (0C) t-out = Outlet Temperature of Flue Gas (0C) Maux = Auxiliary Fuel Consumption (kg/hr)

x 100

Energy efficiency opportunities

Steam Turbine Cogeneration System Steam turbine:

Keep condenser vacuum at optimum value Keep steam temperature and pressure at optimum value Avoid part load operation and starting & stopping

Energy Efficiency Opportunities

Gas Turbine Cogeneration System
Gas turbine manage the following parameters:
Gas temperature and pressure

Part load operation and starting & stopping

Temperature of hot gas and exhaust gas Mass flow through gas turbine Air pressure

Trigeneration

Tri generation or combined cooling, heat and power (CCHP) is a more complex implementation of cogeneration. The recycled heat is used to activate chiller engine which operates by utilizing thermal as source of energy (regeneration system). This combination triggers tri generation which in turn simultaneously produces electricity, heating, and cooling.

This system enhances efficiency of fuel consumption and cooling system at the same time.

Thanks