Training Session on Energy

Equipment
Thermal Equipment/
Cogeneration

Cogeneration
Presentation from the
Energy Efficiency Guide for Industry in Asia
www.energyefficiency.asia.org

UNEP 2006

Training Agenda: Cogeneration

Thermal Equipment/
Cogeneration

Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities

UNEP 2006

Introduction

Thermal Equipement/
Cogeneration

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
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UNEP 2006

Introduction

Conventional Generation (58%

Overall Efficiency)

36 Units
(Losses)

60

= 40%

24
Uni
ts

Combined Heat & Power (85%

Overall Efficiency)

68

100

40

= 85%

34
Uni
ts

Thermal Equipment/
Cogeneration

Efficiency Advantage of CHP

6 Units
(Losses)

(UNESCAP, 2004)

10 Units
(Losses)

UNEP 2006

Introduction

Thermal Equipment/
Cogeneration

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

UNEP 2006

Training Agenda: Cogeneration

Thermal Equipment/
Cogeneration

Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities

UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

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

UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

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
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UNEP 2006

Type of Cogeneration Systems

Back Pressure Steam Turbine
Thermal Equipment/
Cogeneration

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

Figure: Back pressure steam turbine

Disadvantages:
-Larger steam turbine
-Electrical load and output
can not be matched

UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

Extraction Condensing Steam

Turbine
HP Steam

Steam obtained by
extraction from an
intermediate stage
Remaining steam is
exhausted
Relatively high
capital cost, lower
total efficiency
Control of electrical
power independent
of thermal load

Boiler

Turbine

Fuel
LP Steam
Condensate

Process

Condenser

Figure: Extraction condensing steam turbine

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UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

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

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UNEP 2006

Type of Cogeneration Systems

Open Cycle Gas Turbine
Thermal Equipment/
Cogeneration

Exhaust
Gases

Open Brayton cycle:

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

Condensate
from Process
HRSG
Steam to
Process
Combustor
Fuel

Exhaust gas at 450600 oC

G
Generator

High pressure steam

produced: can drive
steam turbine

Compressor

Turbine

Air

Figure: Open cycle gas turbine cogeneration

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UNEP 2006

Type of Cogeneration Systems

Closed Cycle Gas Turbine
Thermal Equipment/
Cogeneration

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

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UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

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)
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UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

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

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UNEP 2006

Type of Cogeneration Systems

Thermal Equipment/
Cogeneration

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

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UNEP 2006

Training Agenda: Cogeneration

Thermal Equipment/
Cogeneration

Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities

17

UNEP 2006

Assessment of Cogeneration
Systems
Performance Terms & Definitions
Thermal Equipment/
Cogeneration

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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UNEP 2006

Assessment of Cogeneration
Systems
Thermal Equipment/
Cogeneration

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 )

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UNEP 2006

Assessment of Cogeneration
Systems
Thermal Equipment/
Cogeneration

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

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UNEP 2006

Training Agenda: Cogeneration

Thermal Equipment/
Cogeneration

Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities

21

UNEP 2006

Energy Efficiency Opportunities

Steam Turbine Cogeneration System

Thermal Equipment/
Cogeneration

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

Boiler & steam see other chapters

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UNEP 2006

Energy Efficiency Opportunities

Gas Turbine Cogeneration System

Thermal Equipment/
Cogeneration

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

Air compressors see compressors chapter

Heat recovery system generator see waste
heat recovery chapter
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UNEP 2006

Training Session on Energy

Equipment
Thermal Equipment/
Cogeneration

Cogeneration
THANK YOU
FOR YOUR ATTENTION

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UNEP GERIAP

Disclaimer and References

Thermal Equipment/
Cogeneration

This PowerPoint training session was prepared as part of

the project Greenhouse Gas Emission Reduction from
Industry in Asia and the Pacific (GERIAP). While
reasonable efforts have been made to ensure that the
contents of this publication are factually correct and
properly referenced, UNEP does not accept responsibility for
the accuracy or completeness of the contents, and shall not
be liable for any loss or damage that may be occasioned
directly or indirectly through the use of, or reliance on, the
contents of this publication. UNEP, 2006.
The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
Full references are included in the textbook chapter that is
available on www.energyefficiencyasia.org
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UNEP 2006