Combined Heat and Power (CHP)

• Pharmaceutical industries, Chemical industries, Food and agricultural

product processing industries, Paper industries, Textile industries,
Seawater desalination plants, District heating / cooling plants etc. have
significant demand for electricity and a year around demand for process
heat
• Electricity can be purchased from national power grid and boiler can be
operated to generate steam
• Combined Heat and Power (CHP) plants may simultaneously produce
both electrical power and useful thermal energy from one fuel source at
low cost
Typical Energy Distribution for
Individual Power and Boiler Plant 2

Efficiency of remote
power plant =
75/200 = 37.5%
Ultimate efficiency of
remote power plant
= 70/200 = 35%
Efficiency of local
boiler = 80/100 ➢ 300 units fossil fuel is consumed to generate 70
= 80% units eclectic power and 80 units heat energy
Typical Energy Distribution for
Individual Power and Boiler Plant 3

Efficiency of CHP plant to

generate electric power and
heat energy = (70+80) / 200
= 75%

➢ 200 units fossil fuel is consumed to generate 70

units eclectic power and 80 units heat energy
Fossil Fuel Driven Electric Energy Generation
Technologies 4

Conventional Power Plants:

▪ Gas Engine
▪ Gas Turbine
▪ Steam Turbine
▪ Combined Cycle Power Plant

Picture Source: https://insights.globalspec.com/article/2895/combined-cycle-power-plants-is-

their-reign-assured

Components of Combined Cycle Power Plant

➢ Opportunities and limitations for enhancing electricity generation efficiency

➢ Opportunities for utilizing the recoverable waste heat
Fossil Fuel Driven Electric Power Plant
5

Gas Turbine

Steam Turbine

Source: https://www.shutterstock.com/search/gas+turbine

Gas Engine

Source: https://instrumentationtools.com/classification-
of-steam-turbines/

Source: https://www.clarke-energy.com/gas-engines/genset/
 Options for CHP Plants:
Gas Turbine Topping Cycle 6

• Fuel energy is utilized first in gas turbine to generate electricity and then
exhaust heat is extracted for thermal applications
Heat input Qin = Q23 = h3-h2
Compressor work Wcomp = h2 – h1
Turbine work Wturbine = h3 – h4
Net work Wnet = Wturbine - Wcomp

Cycle efficiency for electric

power generation:
th = Wnet/Qin
th = (h3 – h4 – h2 +
h1 )/(h3 – h2)
Turbine exhaust gas
temperature T4 is
about 500oC to 600oC
Extracted heat Net output energy CHP plant efficiency:
Qextract = Q45 = h4-h5 Qnet output = Wnet + Qextract CHP = Qnet output / Qin
 Options for CHP Plants:
Gas Turbine Bottoming Cycle 7

• Fuel energy is utilized first in furnace. Heat is recovered from flue gas of
furnace and used in gas turbine gas turbine to generate electricity
• Combustion chamber in gas-turbine cycle is optional; depends on furnace
exhaust gas temperature

Extracted heat by cycle

Qextract = Q32 = h3-h2

Cycle efficiency for

electric power Heat input Qin = Q24 = h4-h2 Process heat
generation: Compressor work Wcomp = h2 – h1 Qprocess = Q56
th = Wnet/Qin Turbine work Wturbine = h4 – h5 = h5-h6
Net work Wnet = Wturbine - Wcomp
 Options for CHP Plants:
Steam Turbine Topping Cycle 8

• Heat is being
utilized first for
generating electricity
in steam turbine and
then low pressure
and low temperature
steam is used for
process heating
(thermal application)

Heat input Qin = Q12 = h2-h1 Cycle efficiency for electric

Turbine work Wturbine = h2 – h3 power generation:
Process heating Qprocess = h3 – h4 th = Wnet/Qin
Condenser heat rejection Qcond = h4 – h5
Pump work Wpump = h1 – h5 CHP plant efficiency:
Net work done Wnet = Wturbine – Wpump CHP = (Wnet +Qprocess)/Qin
Increasing Pressure of Liquid and Vapor
9

Problem: Determine the work input required to a pump and an isentropic

compressor to increase the pressure of saturated water and saturated vapor
respectively from 100 kPa to 1 MPa.

Solution:
Required input work to pump:
2
W pump ,in =  vdP
1

v1 = specific volume of saturated water at

100 kPa = 0.001043 m3/kg
As liquid water is incompressible,
v2 = v1 = v = 0.001043 m3/kg
2
W pump ,in =  vdP = v( P2 − P1 ) = 0.001043 x(1000 − 100) = 0.94kJ / kg
1
Increasing Pressure of Liquid and Vapor
10

Required input work to isentropic compressor:

4 4
Wcomp,in =  vdP =  dh = h4 − h3
3 3
h3 = hg @ 100 kPa = 2675.5 kJ/kg
s3 = sg @ 100 kPa = 7.3594 kJ/(kg K)
s4 = s3 = 7.3594 kJ/(kg K)

For s4 = 7.3594 kJ/(kg K) and P4 = 1 MPa,

from superheated steam table
h4 = 3195.5 kJ/kg

Wcomp,in = h4 − h3 = 3195.5 − 2675.5 = 520kJ / kg

➢ Increasing pressure of steam (or gas) using compressor would require

over 500 times more work than increasing pressure of liquid using a pump
 Options for CHP Plants:
Steam Turbine Bottoming Cycle 11

• Temperature of flue gases from industrial furnaces (used in metallurgy,

cement industry etc.) is quite high
• Heat is utilized first in industrial furnace and then heat of exhaust gas is
extracted in boiler for generating electricity in steam turbine

➢ Analysis is same as steam turbine topping cycle

Options for CHP Plants: Reciprocating Engine
12

• Recovered steam or hot

water can be used in
industrial processes or in
absorption chiller
Extracted heat
Qextract = Q12 = h2-h1

Extracted heat
Qextract = Q34 = h4-h3
Combined Cycle Cogeneration
13

• Combined cycle is current trend of power generation technology

• When the outlet steam

of steam turbine is
condensed in a
condenser and feed
back to the boiler, the
combined cycle will
produce electricity only
with an efficiency of
about 50%.
Back Work Ratio
14

Back work ratio = (Compressor work

Wnet
or Pump work) / Turbine work Wturbine

• Back work ratio for gas-turbine is

large as gas is compressed Wpump /
• Back work ratio for steam-turbine is Wcompressor
only a few percent as liquid pressure
is increased in pump
Calculation of Enthalpy During Isentropic
Compression Process 15

• Process: Isentropic
• Given P1, T1 and P2
• Find: T2 and h2

Steps: Read from table

T1 Relative pressure Pr1

Read from table Calculate relative pressure

T2 and h2 Pr2 = (P2/P1) Pr1
Problem on Gas Turbine Power Plant
16

Problem: Pressure ratio of a gas-turbine is 8. Gas temperature at compressor

inlet is 27oC and turbine inlet is 1027oC. The efficiency of compressor is 85%
and turbine is 95%. Using ideal gas properties of air and accounting for the
variation of specific heats with temperature, determine:
(a) Gas temperature at the exit of the compressor and the turbine
(b) Back work ratio
(c) Thermal efficiency
Problem on Gas Turbine Power Plant
17

T1 = 27oC = 27 + 273 = 300 K

From table: h1 = 300.19 kJ/kg and Pr1 = 1.386
Pr2 = (P2/P1) Pr1 = 8 x 1.386 = 11.09
From table: h2 = 544.35 kJ/kg, T2 = 540 K
T3 = 1027oC = 273 + 1027 = 1300 K

From table: h3 = 1395.97 kJ/kg and Pr3 = 330.9

Pr4 = (P4/P3)Pr3 = (1/8) x 330.9 = 41.36

From table: h4 = 789.11 kJ/kg , T4 = 770 K

Problem on Gas Turbine Power Plant
18

Compressor isentropic work Wcomp,i = h2 – h1

= 544.35 - 300.19 = 244.16 kJ/kg
Compressor actual work Wcomp,a = Wcomp,i/c (a) Compressor:
= 244.16/0.85 = 287.2 kJ/kg Wcomp,a = h2a – h1
Turbine isentropic work Wturbine,i = h3 – h4 287.2 = h2a – 300.19
h2a = 587.4 kJ/kg
= 1395.97 - 789.11 = 606.86 kJ/kg
Turbine actual work Wturbine,a = Wturbine,i x t From Table:
for h2a = 587.4 kJ/kg
= 606.86 x 0.95 = 576.5 kJ/kg
T2a = 581.3 K
Problem on Gas Turbine Power Plant
19

Turbine: Wturbine,a = h3 – h4a

576.5 = 1395.97 – h4a
h4a = 819.5 kJ/kg (c) Thermal efficiency:
From Table: th = Wnet/Qin = (Wturbine,a – Wcomp,a)/Qin
for h4a = 819.5 kJ/kg = (Wturbine,a – Wcomp,a) /(h3 – h2a)
T4a = 797.7 K = 524.7oC (High!)
=(576.5 - 287.2)/(1395.97 – 587.4)
(b) Back work ratio = Wcomp,a/Wturbine,a = 0.358 = 35.8 % (About 1/3 !)
= 287.2 / 576.5 = 49.8% (High!)
Performance Enhancement Opportunities of
Gas Turbine 20

➢ Intercooling, Reheating and Regeneration systems are incorporated in gas

turbine power plant to improve the thermal efficiency

• Net work of gas-turbine cycle = Turbine work – Compressor work

• Net work of gas-turbine cycle can be increased by either reducing compressor work or
increasing of turbine work or both
• Compressor work can be decreased by using multistage compression with intercooling
• Turbine work can be increased by using multistage expansion with reheating
• Complicated control system; High maintenance cost
Carnot Vapor Power Cycle
21

Carnot Vapor Cycle T-s diagram of Carnot Vapor Cycle

Heat input in boiler Q12 = h2 – h1 • For fixed upper and lower
Turbine work output W23 = h2 – h3 temperature limits, Carnot
cycle has highest efficiency
Heat rejected in condenser Q34 = h3 – h4
T3
Work input in compressor W41 = h1 – h4 c = 1 − Unit of T: K
T1
Net work Wnet = W23 – W41 = Q12 – Q34
➢ Thermal efficiency increases with the increase of av. temp. at which heat is added to
system or with the decrease of av. temp. at which heat is rejected from the system.
Carnot Vapor Power Cycle
22

Carnot Vapor Cycle T-s diagram of Carnot Vapor Cycle

• Carnot cycle is not practical.

• Impracticalities:
(i) Compression of wet vapor is difficult (not practical to design a
compressor that will handle two phases)
(ii) Impingement of liquid droplets on the turbine blades causes erosion
Carnot Vapor Power Cycle
23

Carnot Vapor Cycle (Not Practical) T-s diagram of Carnot Vapor Cycle

Practical Vapor Power Cycle T-s diagram of Vapor Power Cycle

Problem on Vapor Power Cycle
24

Problem: The operation of a steam power plant is presented in below T-S

diagram. The steam enters the turbine at 30 bar and 600oC and is condensed
in the condenser at pressure of 0.1 bar. Determine the thermal efficiency of
the power plant. (1 bar = 100 kPa)

Vapor Power Cycle T-s diagram of Vapor Power Cycle

Problem on Vapor Power Cycle
25
From saturated table, for P5 = 0.1 bar
 Sf@0.1bar = 0.649 kJ/kg.K and
Sfg@0.1bar = 7.5 kJ/kg.K
S5 = Sf@0.1bar + X5Sfg@0.1bar
X5 = 0.914 (better)
h5 = hf@0.1bar + X5hfg@0.1bar
h5 = 2378.3 kJ/kg
h6 = hf@0.1bar = 192 kJ/kg
Qin at boiler = h4 – h1 = 3486.98 kJ/kg
6@0.1 bar = 990 kg/m3 Qout at condenser = h5 – h6 = 2186.3 kJ/kg
Pump work, Wpump = (P1-P6)/6 = Thermal efficiency
3.02 kJ/kg th = (Qin at boiler – Qout at condenser)/Qin at boiler
= 37.3%
h1 = h6 + Wpump = 195.02 kJ/kg
Turbine power output
From superheated table, for P4 = 30 Qturbine = h4 – h5 = 1303.7 kJ/kg
bar and T4 = 600oC  h4 = 3682 kJ/kg
and S4 = 7.507 kJ/kg.K = S5 % heat loss in condenser
= 2186.3/ 3486.98 = 62.7%
Performance Enhancement Opportunities of
Steam Turbine 26

➢ Thermal efficiency increases with the increase of av. temp. at which heat is
added to system or with the decrease of av. temp. at which heat is rejected
from the system.

• Increasing of boiler pressure will increase temperature of heat addition:

High construction cost of boiler
• Decreasing of condenser temperature: Cooling water of low temperature
is required
Performance Enhancement Opportunities of
Steam Turbine 27

Regenerative Ranking Cycle: Steps for increasing temperature of heat

addition by extracting or “bleeding” steam from turbine at various points and
mixing with the feed water

• Feed water may reach to saturation temperature

• Control system is more complicated. Economically feasible for large plants
• Output work will decrease. Cycle efficiency will increase (  40 to 45%)
Cogeneration Process
28

• Chemical, oil production and refining, food processing, textile industries,

pulp and paper, steel industries etc. heavily rely on process heat and
electricity
• Process heat in these industries is usually supplied by steam at 5 to 7 atm
and 150 to 200oC
• Cogeneration systems can generate both electric power and steam from
single fuel source economically.

Ideal Cogeneration Process: • Plant demand constant 50 kW

electric energy & 100 kW heat
at 150oC
• Steam leaves turbine as
saturated vapor at about 5 bar
(temp 150oC)
• Steam leaves process as
saturated water at 150oC
• No heat rejection in condenser.
100% thermal efficiency.
Practical Cogeneration Process
30

Boiler heat input:

Qboiler = m3(h4 – h3)
Condenser heat rejection:
Qcondenser = m7(h7 – h1)
Process heat:
Qprocess = m5h5 + m6h6 - m8h8
Turbine work:
Wturbine = (m4-m5)h4 - m6h6 - m7h7

• Optimum CHP condition: All steam expands in turbine to extraction pressure

and continues to process heating unit. m5 and m7 are zero and thus no
waste heat
• Plant should be designed so that the optimum operating conditions are
achieved for most of the time
• CHP plant could be integrated to process heating for nearby plants, hot
water system for commercial building, district heating (space heating) etc.
Combined Gas-Vapor Cogeneration System
31
• Gas temperature
at inlet of gas-
turbine is about
1150oC and at
outlet about 500oC
• High temperature
exhaust gas of
gas-turbine use as
heat source for the
bottoming steam
power cycle
• Generally, more
than one gas-
turbine is needed
to supply sufficient
heat to steam
turbine
• Electricity
Net work output + Process heat delivered generation
Utilization factor =
Total heat input efficiency  53%
Trigeneration System
32

Four different outputs

from same fuel source:
1) Electric power
2) Chilled water for air-
conditioning
application
3) High temperature
steam for process
heating
4) Low temperature for
process heating
Absorption Chiller 33
Plant’s Efficiency vs. Steam/Electric Power
Ratio 34

➢ Cogeneration
plant should be
selected based on
steam and electric
power demand of
the industry
CHP Characteristics
35

• Fuel input = Electricity generated + Heat recovered + Losses

F = E + H + Losses

• Heat / Electricity Ratio =

Heat Energy Recovered
Electrical Energy Generated

Heat Energy Recovered

• Waste Heat Output Fraction =
Fuel Energy Input

Electrical Energy Generated

• Electric Efficiency = Fuel Energy Input

• Plant Thermal Efficiency or Total Efficiency,  =

Electrical Energy Generated + Heat Energy Recovered
=
Fuel Energy Input
Feasibility of CHP
36

• Determine relative quantities of heat (temperature of hot water or steam) and

electricity required in facility
- Hotels, Office buildings: Absorption chillers or domestic purpose
- Hospitals: Sterilization, drying of laundry etc
• Variation of heat and electricity demand over time
• Determine optimum configuration and size for CHP system to match
electricity and heat output from cogeneration to the demands of the site
• Assess the cost-effectiveness of CHP
CHP Plant Sizing Options
37

• Option-1: CHP to match heat energy demand

– Minimize supplementary boiler to meet any shortfall of heat energy
– Electricity generator is operated as high “Capacity Factor” (ratio of
average monthly electricity output to maximum rating) as possible.
– Excess electricity could be sold to grid or shortfall of electricity could be
purchased from grid
– Most attractive sizing option

• Option – 2: CHP to match electrical energy demand

– Use supplementary boiler to meet any shortfall from CHP plant
– Excess heat energy will be discharged to atmosphere

• Option – 3: CHP to recover more heat energy than demand of site

– This option is viable only when nearby sites agree to purchase the
extra heat and electricity outputs
CHP Operation Options
38

• Option – 1: Electricity Matching

– Plant operate to match the electrical energy demand of the site
– If co-generated heat is insufficient, standby boiler are operated
– If there is excess heat, it is damped via cooling towers or radiators
– Electricity matching is generally not tend to energy efficient operation
• Option – 2: Heat Matching
– Plant operate to match the heat demand of the site
– Electricity is imported or exported back to the grid, if necessary

• Option – 3: Switching Off

– It could be more economical to switch off the CHP plant and purchase
electricity from the grid if tariff of electricity is less than the cost of co-
generating
– Heat is supplied by standby boilers
Financial Feasibility of CHP
39

Financial feasibility of CHP depends on:

• Fuel price and availability
– Possibility of future increases in fuel prices need to be considered
– If rate of increase in fuel price is greater than rise in utility electricity
prices then the financial viability of co-generating diminishes
• Electricity tariffs
• Capital costs
(Cost of Prime mover, Control instrumentation, Heat recovery equipment,
Electrical instrumentations, Fuel supply and storage, Sound attenuation,
Pollution controls, Fire protection, Backup systems, Equipment spares)
• Other Costs
(Installation and commissioning, Operating labour cost, Plant
maintenance, Plant insurance, Miscellaneous consumables such as
lubricating oil, water treatment chemicals and discharge costs, Credits
for the sale of energy)
• Salvage Value of Plant
Size of CHP Plant
40

Size of Cogeneration Plant

• < 1 MWe (Small)
• 1 to 10 MWe (Medium) (Most industries are sized within this range)
• > 10 MWe (Large)

Typical energy distribution of 5 MW CHP Plant:

Flue gas exhaust
Flue gas exhaust (Operation period) ➢ Heat to Power
Electric power
(Starting period)
Steam to
ratio = 8/5 = 1.6
output (5 MW, process plant ➢ Good Heat to
Eff. = 5/16  30%) 0 MW 3 MW
Power ratio  1.7
Steam
Gas Turbine (11x0.75  8 MW)
Waste heat Absorption
and Generator 11 MW boiler chiller
(Typical eff.  75%)

Natural gas Chilled water for

input (16 MW) air-conditioning and
process cooling
Details of a Typical 5 MW CHP Plant
41
Potential Layout for Gas Engine CHP Plant
42

Exhaust Exhaust

Steam

Makeup
water tank
Steam
drum
Vent
Steam
Bypass stack

Flash Steam

Main stack
tank
Deaerator
Blowdown

Fuel Heat Recovery

Steam Generator Condensate
Air Gas Engine (HRSG)
Generator
Jacket water
(Hot water) Condensate
tank
Potential Layout for Gas Turbine CHP Plant
43
Exhaust Exhaust

Steam

Makeup
water tank
Steam
drum
Vent
Generator

Steam
Bypass stack
Fuel
Flash Steam

Main stack
tank
Deaerator
Blowdown

Gas turbine
Air

Heat Recovery
Steam Generator Condensate
(HRSG)

Condensate
tank
Potential Layout for Gas Turbine CHP Plant
44

Exhaust Exhaust

Steam

Makeup
water tank
Steam
drum
Vent

Generator
Steam

Bypass stack
Fuel
Flash Steam

Main stack
tank
Deaerator
Blowdown

Gas turbine
Air

Heat Recovery Steam

Generator (HRSG) Condensate
Fuel and stabilizing air
for duct burner
• Duct burner to support additional steam demand
• Fuel flow rate of duct burner can be modulated to Condensate
tank
support variable demand of steam
Energy and Mass Balance
45

Exhaust Steam Exhaust

12.5 Ton/h
188oC, 12 bar
Makeup

95oC
water tank
7.5 m3/h
Steam
drum
Vent
Generator

Bypass stack Steam

5000 kW

Fuel
Flash Steam

Main stack
tank
Deaerator
Blowdown

Gas turbine
Eff. = 35%
Air
500oC
Air : Fuel = 57 : 1
Heat Recovery Steam Condensate
Generator (HRSG) 9 m3/h, 60oC
Fuel and stabilizing air
for duct burner
NG = 195 Sm3/h
Air = 360 kg/h Condensate
tank
Critical Load Consideration
46

Consideration of critical load and

non-critical load affects:
1) Connection options to the grid
2) Type of contingencies
3) Level of contracted capacity

Different possible connection options to grid:

Option-1:
• CHP is connected to non-critical
loads
• Contracted capacity is equal to
critical loads
• Contracted capacity can be
reduced significantly
Option-2:
• Grid connection is necessary for
backup purposes
• Contracted capacity is equal to
total loads (critical and non-critical)
• Contracted capacity is not reduced
Electricity Import Structure
47

Without Load Limiter With Load Limiter

Electricity Contracted Capacity Schemes
48

Capped Capacity
Scheme (CCS):
• Switchgear,
transformer, cable
etc. are designed
and installed by grid
authority to supply
requested electricity
to customer
• Customer installs
Load Limiter (120%
of Contracted
Capacity)
• 10 sec is given to
manage load
shedding
Electricity Contracted Capacity Schemes
49

Extended Capped Capacity Scheme (ECCS):