Co-Generation
Introduction
Introduction 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
COGENERATION PLANT LAYOUT
TO POWER SUPPLY
Feed water
Fuel
BOILER
TURBINE
PRDS
ALTERNATOR
Air
TO PROCESS
CONDENSER TO COOLING TOWER
TO PROCESS
How Cogeneration Saves Energy
Introduction Efficiency Advantage of CHP
Conventional Generation (58% Overall Efficiency)
36 Units (Losses)
Combined Heat & Power (85% Overall Efficiency)
60 100
= 40%
24 Uni ts
68
34 Uni ts
40
= 85%
6 Units (Losses)
10 Units (Losses)
Introduction
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
Types of cogeneration systems
Type of Cogeneration Systems
Steam turbine Gas turbine Reciprocating engine Other classifications:
- Topping cycle - Bottoming cycle
Type of Cogeneration Systems 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
Type of Cogeneration Systems
Back Pressure Steam Turbine
Steam exits the turbine at a higher pressure than the atmospheric
HP Steam
Boiler
Turbine
Advantages: -Simple configuration -Low capital cost -Low need of cooling water -High total efficiency Disadvantages: -Larger steam turbine -Electrical load and output can not be matched
Fuel
Condensate Process
LP Steam
Figure: Back pressure steam turbine
Type of Cogeneration Systems
Extraction Condensing Steam Turbine
HP Steam
Steam obtained by extraction from an intermediate stage Remaining steam is exhausted
Boiler Fuel
Turbine
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
Type of Cogeneration Systems 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
Type of Cogeneration Systems
Open Cycle Gas Turbine
Open Brayton cycle: atmospheric air at increased pressure to combustor
Exhaust Gases Condensate from Process HRSG Steam to Process Combustor Fuel
Old/small units: 15:1 New/large units: 30:1
Exhaust gas at 450600 oC
G Generator Compressor Air Turbine
High pressure steam produced: can drive steam turbine
Figure: Open cycle gas turbine cogeneration
Type of Cogeneration Systems
Closed Cycle Gas Turbine
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
Type of Cogeneration Systems
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)
Type of Cogeneration Systems 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
Type of Cogeneration Systems Bottoming Cycle
Primary fuel produces high temperature thermal energy
Rejected heat is used to generate power Suitable for manufacturing processes
Assessment of cogeneration systems
UNEP 2006
Assessment of Cogeneration Systems 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 )
Assessment of Cogeneration Systems
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)
Assessment of Cogeneration Systems
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
Energy efficiency opportunities
Steam Turbine Cogeneration System Steam turbine:
Keep condenser vacuum at optimum value Keep steam temperature and pressure at optimum value Avoid part load operation and starting & stopping
Energy Efficiency Opportunities
Gas Turbine Cogeneration System
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
Trigeneration
Tri generation or combined cooling, heat and power (CCHP) is a more complex implementation of cogeneration. The recycled heat is used to activate chiller engine which operates by utilizing thermal as source of energy (regeneration system). This combination triggers tri generation which in turn simultaneously produces electricity, heating, and cooling.
This system enhances efficiency of fuel consumption and cooling system at the same time.
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