Training programme on Energy Efficient technologies for climate

change mitigation in Southeast Asia

Cogeneration

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Session Agenda: Cogeneration

Introduction
Types of steam turbine cogeneration
system
Types of gas turbine cogeneration
system
Cogeneration classification
Performance evaluation
Energy efficiency opportunities
Case Studies
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 Introduction

What’s a Cogeneration/CHP System?

• The sequel generation of multiple
forms of useful energy in one
integrated system
• Defined by its “prime movers” that is
the equipment driving the system
• Prime movers include reciprocating
engines, combustion or gas turbines,
steam turbines, microturbines, and fuel
cells
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 Introduction

Efficiency Advantage of CHP

36 Units
Conventional Generation (58% (Losses)
Overall Efficiency)

Combined Heat & Power (85%

Overall Efficiency)

24
60  = 40% Uni
ts

100 68

34
40 Uni
 = 85% ts

6 Units 10 Units
(Losses) (Losses)

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 Introduction

Benefits of Cogeneration (CHP):

•Increased efficiency of energy conversion and use
•Lower emissions, especially CO2
•Some waste materials such as refinery gases,
process or agricultural waste can be used
•Large cost savings
•Opportunity to decentralize the electricity
generation, particularly for natural gas systems
•One of the most important vehicles for promoting
liberalization in energy markets

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 Type of Cogeneration System

Steam Turbine Cogeneration System

• Widely used in CHP applications
• This is the oldest prime mover technology with
capacities from 50 kW to hundreds of MWs for
large plants
• The thermodynamic cycle is the “Rankin cycle”
that uses a boiler
• Most common are backpressure and extraction
condensing types, choice depends on quantities
of power and heat, quality of heat and economic
factors

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 Type of Cogeneration System

Back Pressure Steam Turbine

• Steam exits the turbine at a higher pressure
that the atmospheric
HP Steam
Advantages:
-Simple configuration
-Low capital cost
Boiler Turbine -Low need of cooling water
-High total efficiency
Fuel
Condensate
Disadvantages:
LP
Process Steam -Larger steam turbine
-Electrical load and output
can not be matched

Figure: Back pressure steam turbine

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 Type of Cogeneration System

Extraction Condensing Steam Turbine

HP Steam

• Steam obtained by
extraction from a
intermediate stage Boiler Turbine
Fuel

• Remaining steam is
LP Steam
exhausted Condensate
Process

• Relatively high
capital cost, lower
total efficiency Condenser

• Control of electrical
power independent
of thermal load
Figure: Extraction condensing steam turbine

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Type of Cogeneration System

Gas Turbine Cogeneration System

• Operates on the thermodynamic “Brayton
cycle” by using the excess power produced
that is not consumed by the compressor
• Natural gas is the most common fuel and the
typical range varies from a fraction of 1MW to
100 MW
• Thanks to rapid developments it has gained
technology progress, cost reductions and
greater environmental performance

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 Gas Turbine Cogeneration Systems
Open Cycle Gas Turbine Cogeneration Systems

Exhaust
Gases
• Open Brayton (Joule) cycle: Condensate
compressor derives atmospheric air at from Process

increased pressure to the combustor HRSG

Steam to

• Old/small units: 15:1 Process

Combustor
New/large units: 30:1 Fuel

• Exhaust gas at 450-

600 °C
G

• High pressure steam Generator

Turbine
produced that can Compressor

also drive a steam Air

turbine Figure: Open cycle gas turbine cogeneration

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 Cogeneration Classification

Topping Cycle
• The supplied fuel first produces power
followed by thermal energy
• Thermal energy is a byproduct used for
process heat or other
• This is the most popular method of
cogeneration

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 Cogeneration Classification

Bottoming Cycle
• Primary fuel produces high temperature
thermal energy
• The rejected heat is used to generate
power through a recovery boiler and
turbine generator
• Suitable for manufacturing processes and
used in cement, steel, ceramic, gas and
petrochemical industries

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 Performance evaluation

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 )

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Energy Efficiency Opportunities

Steam Turbine Cogeneration System

a) Condenser vacuum
• Most important factor as small deviations can result in
significant efficiency changes
• Reasons for changes include differences in cooling
water inlet temperature and flow, fouled condenser
tubes or air leaks

b) Steam temperature and pressure

• Variations can be due to errors in plant design

c) Part load operation and starting & stopping

• Operations of certain loads for certain periods have
major influences on thermal efficiency
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 Energy Efficiency Opportunities

Gas Turbine Cogeneration System

a) Gas temperature and pressure
• Gas temperature and conditions at the gas turbine
inlet may inhibit efficiency

b) Part load operation and starting & stopping

• Operations of certain loads for certain periods have
major influences on thermal efficiency
• When the plant comes on and off line affect thermal
efficiency due to energy losses

c) Other
• Other factors include changes in temperatures, high
mass flows and pressure changes
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 • CASE STUDY 1

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 EXISTING CONDITION
Steam Generation - 60 Tons/hr at 10kg/cm²
Fuel Oil Fired Boilers Evaporation Ratio - 1:14
Fuel Oil Cost - US $ 500/Ton
G. C. V. of Fuel Oil - 10,200 KCal/kg
Enthalpy of Steam - 660 KCal/kg
Electricity Consumption - 12,000 KWh/hr
Electricity Cost - US $ 0.10/KWh
Plant Operating hrs per year - 350x24 = 8400 hrs

Work out cost economies of Co-generation scheme as per following

details:-
Installation of Fluidized bed Rice Husk Fired Boiler
Steam Generation - 60 Tons/hr. at 40 Bar, 380˚C, Super heat
Enthalpy of steam - 755 kcal/kg
G. C. V. of Rice Husk - 3200 kcal/kg
Cost of Rice Husk - US $ 30/Ton
Evaporation Ratio - 3.65

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 COST OF ENERGY CONSUMED
Cost of Thermal Energy Fuel Oil Consumption
= 60/14 = 4.28 Tons/hr
• Annual Fuel Oil Consumption
= 4.28x8400 = 35952 Tons/hr
• Cost of Fuel Oil
= 35952x500 = 17.97 or 18 US Million $
Cost of Electrical Energy
Electricity Consumption = 12,000 kWh/hr
Annual Electricity consumption = 12,000 x 8400
= 100.8 Million kWh
Cost of Electricity = 100.8 x 0.1
= 10.08 Million US $

Total Cost of Energy = 18 + 10.08 = 28.08 Million US $

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 COST ECONOMICS OF CO-GENERATION SCHEME

60T/hr 40Bar, 380˚C, H=755 kcal/kg

60T/hr 10Bar, H=660 kcal/kg

Calculate Power Generation if turbine & alternator Losses are around 10%
Heat Balance across extraction Turbine= 60,000(755-660) = 5,700 x 10³ kCal/hr
Net Heat available for power Generation = 5,700 x 10³ x 0.9 kCal/hr
= 5130 x 10³kCal/hr
(We know 860kcal = 1kWh ) = 5130 x 10³/860
= 5965kWh/hr or
= 5965 x 8400 = 50.1Million kWh/yr

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 COST ECONOMICS
COST OF RICE HUSK USED IN FLUIDIZED BED BOILER
Steam Generation - 60T/hr at ; 380˚C at 40 Bar
Evaporation Ratio - 3.65
Cost of Rice Husk - US $ 30/Ton
Rice Husk Consumption - 60/3.65 = 16.44 tons/hr
Annual Rice Husk Consumption - 6.44 x 8,400 = 1,38,096Tons/yr
Cost of Rice Husk - 138096 x 30 = US $ 4.143 Million

COST OF ELECTRICITY PURCHASED FROM GRID

Total Power Consumption – Power Generated through Co-generation
=100.8-50.1 = 50.7 Million kWh
Cost of Electricity = 50.7 x 0.1 = 5.07 Million US $

Total Monetary Savings = 28.08-(4.143+5.07)

= 18.86 Million US $

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 • CASE STUDY 2

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Case Study : Utilization of Solar Energy (steam, heat)
for HVAC requirements

• An auto ancillary company in north India has an

abundance of sun-light throughout the year
• The total building air-conditioning load of 110
TR
• The roof top area available for the utilization of
solar energy was 700 sq m. which could lead to
cooling of about 30 TR
• Achieved through 20 solar concentrators with a
30 TR Vapor Absorption Machine, VAM with a
COP of 1.1

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 Product specifications

•The main component of the system is the 16 m2 Scheffler solar parabolic

concentrator.
•It concentrates the sun light in to approx. 30 cm. where the high optical
temperature around 500 Deg C is generated.
• This temperature is carried in by a circular receiver by means of heat
exchange in between the water, which is circulating inside the receiver and
the optical temperature to generate hot water of 140 degree centigrade.
•The solar parabolic concentrators are tracked automatically, but the focus is
fixed at the point of receiver.
•PRODUCT FEATURES –
Dish Area - 16 sq.m Dish Rating - 5 kW/h.
Fixed Focus design with PLC based control system for daily tracking.
Dual Axis tracking system.

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Schematic Diagram

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 Technical details

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 Cost Economics
Sr. No Description Cost in USD
1 Price for 20 Nos Solar Concentrators 45000
2 Central Tracking system 12000
Storage tank and heat exchanger with valves and
3 instrumentation 12000
4 Structure and supports for Solar Frame 12000
Double Effect VAM of 30 TR with first charge of Lithium
5 Bromide 60000
Balance of Plant – hot water pumps and piping, cooling
6 tower, cooling water pumps and piping. 67000

7 Solar Dish Erection and Commissioning 2300

Erection and commissioning of VAM and Balance of
8 Plant 18000
9 Total 228300

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 For further inquiries Contact
asthanaak@yahoo.co.in

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