Simultaneous production of two forms of energy

– Thermal Energy
– Electricity / Mechanical Energy
 Loses up to
70%
Conventional
Fuel(100%) Plant Efficiency is
30-40%

Loses up to
10%
Cogeneration
Fuel(100% Plant Efficiency up
) to 70-90%
Source: IEA, CHP: Evaluating the Benefits of Greater Global Investment (2008).
Sector Potential, MW Realizable
Potential, MW

Distilleries 3500 2500

Cement 600 400
Chemicals 900 600
Fertilizers 1200 750
Metal Industry 1060 700
Sugar 5000 3000
Refineries 800 600
Paper & Pulp 1000 750
Textile 1200 800
BCHP 650 400
Other Sector 750 500
Total 16000 11500
Natural gas
Coal
Biomass
Bagasse (waste product from sugar cane processing)
Waste gas
Sludge gas from sewage treatment plant
Methane from landfills and coal bed methane
Liquid fuels (oil)
Renewable gases
Steam turbine
Gas turbine
Reciprocating engine
Other classifications:
Topping cycle
Bottoming cycle
Widely used in CHP applications
Oldest prime mover technology
Capacities: 50 kW to hundreds of MWs
Thermodynamic cycle is the “Rankine cycle”
that uses a boiler
Most common types
Back pressure steam turbine
Extraction condensing steam turbine
 Steam exits the turbine at a higher pressure that
the atmospheric

HP Steam

Fuel Boiler Turbine

Condensate LP
Process Steam

Figure: Back pressure steam turbine

 HP Steam

Steam obtained by
extraction from an
Turbine
intermediate stage Fuel
Boiler

Remaining steam is LP Steam

exhausted Condensate
Process

Relatively high
capital cost, lower Condenser
total efficiency
Control of electrical
power independent of
thermal load Figure: Extraction condensing steam turbine
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
 Exhaust
Open Brayton cycle: Gases

atmospheric air at Condensate

from Process
increased pressure to HRSG

combustor Steam to
Process
Old/small units: 15:1 Combustor
New/large units: 30:1 Fuel

Exhaust gas at 450-

600 oC
G
High pressure steam Generator

produced: can drive Compressor Turbine

steam turbine Air

Figure: Open cycle gas turbine cogeneration

 Heat Source

Working fluid circulates

Heat Exchanger
in a closed circuit and
does not cause G
corrosion or erosion Generator
Compressor Turbine
Any fuel, nuclear or
solar energy can be
used Condensate
from Process

Steam to
Process

Figure: Closed Cycle Gas Turbine Cogeneration System

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
Primary fuel produces high temperature thermal
energy
Rejected heat is used to generate power
Suitable for manufacturing processes
Increased efficiency of energy conversion and use
Reducing environmental impact
Conserving limited resources of fossil fuels
Saving money
On-site production of electricity generation
Promoting liberalization in energy markets
Industrial CHP
Sugar industry – bagasse CHP
Others
District system CHP
IT industry
Industrial parks
Mixed residential/commercial districts
Small Scale Systems
Depends very much on tariff system

Heat
Avoid cost of separate heat production

Electricity
1) Less purchase (kWh)
2) Sale of surplus electricity
3) Peak shaving (kW)
Carbon credits (future)
Lack of a clear definition of cogeneration or CHP
There has not been an economy-wide study of
CHP potential (and associated benefits)
Lack of an approved methodology for
calculating CO2 emission reductions from
CHP
Limited availability of competitively priced
turbines and engines for CHP
Lack of pipeline networks for district cooling
 e- Grid Ancillary Services

Bulk Power
e-
Power Quality
e-
and CHP

Remote Power and

e
-
CHP e-
e-

e
-
Energy Management,
future CHP and
Sell to Grid Base-load, and
Industrial Cooling, Heat and Power
Cogeneration improves energy efficiency…..…….if heat
is used in a proper way
www.cogeneration.org
www.uschpa.org
www.iea.org
www.cogenindia.org
www.ieachp.org