Training Session on Energy

Equipment

Cogeneration
Thermal Equipment/
Cogeneration

Presentation from the

“Energy Efficiency Guide for Industry in Asia”
www.energyefficiency.asia.org

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© UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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© UNEP 2006
 Introduction

What’s a Cogeneration/CHP System?

Thermal Equipement/

• Generation of multiple forms of

Cogeneration

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

Efficiency Advantage of CHP

Thermal Equipment/

36 Units
Conventional Generation (58%
Cogeneration

(Losses)
Overall Efficiency)

Combined Heat & Power (85%

Overall Efficiency)

60  = 40%

Uni
24

ts
68
100

40

Uni
34
 = 85%

ts
6 Units 10 Units
(Losses) (Losses)

(UNESCAP, 2004) 4
© UNEP 2006
 Introduction

Benefits of Cogeneration / CHP)

Thermal Equipment/

• Increased efficiency of energy conversion and

Cogeneration

use
• Lower emissions, especially CO2
• Ability to use waste materials
• Large cost savings
• Opportunity to decentralize the electricity
generation
• Promoting liberalization in energy markets

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© UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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Thermal Equipment/ Type of Cogeneration Systems

• Steam turbine
Cogeneration

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

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 Type of Cogeneration Systems

Steam Turbine Cogeneration System

Thermal Equipment/

• Widely used in CHP applications

Cogeneration

• 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/

• Steam exits the turbine at a higher pressure

that the atmospheric
Cogeneration

HP Steam
Advantages:
-Simple configuration
-Low capital cost
Boiler Turbine -Low need of cooling water
-High total efficiency
Fuel

Disadvantages:
Condensate
Process
LP
Steam
-Larger steam turbine
-Electrical load and output
can not be matched

Figure: Back pressure steam turbine 9

© UNEP 2006
 Type of Cogeneration Systems

Extraction Condensing Steam

Turbine
Thermal Equipment/

HP Steam
Cogeneration

• Steam obtained by
extraction from an Boiler Turbine

intermediate stage Fuel

• Remaining steam is Condensate

LP Steam

Process
exhausted
• Relatively high
capital cost, lower Condenser

total efficiency
• Control of electrical
power independent of Figure: Extraction condensing steam turbine
thermal load 10
© UNEP 2006
 Type of Cogeneration Systems

Gas Turbine Cogeneration System

Thermal Equipment/
Cogeneration

• 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 11
© UNEP 2006
 Type of Cogeneration Systems

Open Cycle Gas Turbine

Exhaust
Thermal Equipment/

Gases
• Open Brayton cycle: Condensate
atmospheric air at
Cogeneration

from Process

increased pressure to HRSG

combustor Steam to
Process

• Old/small units: 15:1 Fuel

Combustor

New/large units: 30:1

• Exhaust gas at 450-
600 oC G

Generator

• High pressure steam Compressor Turbine

produced: can drive Air

steam turbine Figure: Open cycle gas turbine cogeneration

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 Type of Cogeneration Systems

Closed Cycle Gas Turbine

Thermal Equipment/

Heat Source
Cogeneration

• Working fluid circulates

in a closed circuit and Heat Exchanger

does not cause

corrosion or erosion G

Generator

• Any fuel, nuclear or Compressor Turbine

solar energy can be

used Condensate
from Process

Steam to
Process

Figure: Closed Cycle Gas Turbine Cogeneration System 13

© UNEP 2006
 Type of Cogeneration Systems

Reciprocating Engine Cogeneration

Systems
Thermal Equipment/

• Used as direct mechanical drives

Cogeneration

• Many advantages:
operation,
efficiency, fuel
costs
• Used as direct
mechanical drives
• Four sources of
usable waste heat
Figure: Reciprocating engine cogeneration system
(UNESCAP, 2000) 14
© UNEP 2006
 Type of Cogeneration Systems

Topping Cycle
Thermal Equipment/

• Supplied fuel first produces power

Cogeneration

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

Bottoming Cycle
Thermal Equipment/

• Primary fuel produces high

Cogeneration

temperature thermal energy

• Rejected heat is used to generate
power
• Suitable for manufacturing processes

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© UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

17
© UNEP 2006
 Assessment of Cogeneration
Systems

Performance Terms & Definitions

Thermal Equipment/

• Overall Plant Heat Rate (kCal/kWh):

Cogeneration

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

Steam Turbine Performance

Thermal Equipment/

• Steam turbine efficiency (%):

Cogeneration

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

Heat Recovery Steam Generator (HRSG)

Thermal Equipment/

Performance
Cogeneration

• Heat recovery steam generator efficiency

(%):
M s x ( hs  hw )
x 100
[ 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) 20
Maux = Auxiliary Fuel Consumption (kg/hr) © UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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© UNEP 2006
 Energy Efficiency Opportunities

Steam Turbine Cogeneration System

Thermal Equipment/

Steam turbine:
Cogeneration

• 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/

Gas turbine – manage the following parameters:

Cogeneration

• 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

• This PowerPoint training session was prepared as part of

the project “Greenhouse Gas Emission Reduction from
Thermal Equipment/

Industry in Asia and the Pacific” (GERIAP). While

reasonable efforts have been made to ensure that the
Cogeneration

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
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available on www.energyefficiencyasia.org
© UNEP 2006