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
Whats 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
Conventional Generation (58%
Overall Efficiency)

36 Units
(Losses)

Combined Heat & Power (85%

Overall Efficiency)

60

24
Uni
ts

= 40%

68

100

40

34
Uni
ts

= 85%

6 Units
(Losses)

10 Units
(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
liberalization in energy markets

promoting

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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

Boiler

Advantages:
-Simple configuration
-Low capital cost
-Low need of cooling water
-High total efficiency

Turbine

Fuel
Condensate
Process

LP
Steam

Disadvantages:
-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

Turbine

Boiler
Fuel

Remaining steam is
exhausted

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

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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

Open Brayton (Joule) cycle:

compressor derives atmospheric air at
increased pressure to the combustor
Old/small units: 15:1
New/large units: 30:1

Exhaust
Gases
Condensate
from Process
HRSG
Steam to
Process

Combustor
Fuel

Exhaust gas at 450600 C

G

High pressure steam

produced that can
also drive a steam
turbine

Generator
Compressor

Turbine

Air

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
Fuel Oil Fired Boilers Evaporation Ratio
Fuel Oil Cost
G. C. V. of Fuel Oil
Enthalpy of Steam
Electricity Consumption
Electricity Cost
Plant Operating hrs per year

60 Tons/hr at 10kg/cm
1:14
US $ 500/Ton
10,200 KCal/kg
660 KCal/kg
12,000 KWh/hr
US $ 0.10/KWh
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, 380C, 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, 380C, 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 10 kCal/hr
Net Heat available for power Generation = 5,700 x 10 x 0.9 kCal/hr
= 5130 x 10kCal/hr
(We know 860kcal = 1kWh )
= 5130 x 10/860
= 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 ; 380C 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

instrumentation
3

12000

4 Structure and supports for Solar Frame

12000

Double Effect VAM of 30 TR with first charge of Lithium

Bromide
5

60000

Balance of Plant hot water pumps and piping, cooling

tower, cooling water pumps and piping.
6

67000

7 Solar Dish Erection and Commissioning

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

2300
18000
228300

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For further inquiries Contact

asthanaak@yahoo.co.in

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