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P 1: O C S A: ART Verview of Ogeneration and Its Tatus in SIA
P 1: O C S A: ART Verview of Ogeneration and Its Tatus in SIA
1.1 Introduction
Industries and commercial buildings all over the world are the major energy end-users. In the
developing countries of the Asia-Pacific region, electricity accounts for only around 20 per
cent of the total energy demand of the industrial sector, the remaining demand being mostly
in the form of thermal energy. Likewise, as much as 60 per cent of the energy demand of
modern high-rise buildings in the tropical climate comes from comfort cooling. Typically,
state-owned power companies assure electricity supply whereas on-site boilers and chillers
meet the heating and cooling needs of the users, respectively.
Thermal power plants are a major source of electricity supply in many developing countries.
The conventional method of power generation and supply to the customer is wasteful in the
sense that about a quarter of the primary energy fed into the power plant is actually made
available to the user in the form of electricity. The major source of loss in the conversion
process is the heat rejected to the surrounding water or air due to the inherent constraints of
the different thermodynamic cycles employed in power generation. Moreover, users may be
far from the point of generation, which results in additional transmission and distribution
losses in the network. The concept of cogeneration is based on the principle of thermal
cascading which consists of generating power on site where a substantial fraction of waste
heat produced is recovered to satisfy the heating/cooling demand of the end-user. There is
thus a considerable enhancement of the overall conversion efficiency.
Though the concept of cogeneration has been in existence for over a century now, it found its
popularity and renewed interest during the later half of the 70s and the early 80s. The main
factors that attributed to this phenomenon are the two oil shocks that led to spiralling energy
prices and the availability of efficient and small-scale cogeneration systems which became
cost-effective and competed well with the conventional large-scale electricity generation
units. A variety of measures were undertaken by several national authorities to promote the
growth of cogeneration.
As energy prices started to fall during the mid-80s, some countries lost interest in this
technology, particularly those that had excess generating capacities. Taking the example of
Europe, a great diversity can be observed among the member countries; electricity produced
from cogeneration ranged from over 34 per cent in the Netherlands whereas it was less than
1.5 per cent in France.
The main reasons that have revived the interest in cogeneration once again are the rapidly
increasing demand for electricity, constraints faced by the national authorities to finance
additional power generating capacities, and the growing concern to limit the environmental
emission and pollution associated with the use of energy. Cogeneration is presently being
recommended when there is plan for expansion of existing facilities, development of new
industrial zones, replacement of outdated steam generation systems, or when the cost of
energy is high and there is scope for selling power.
4 Part I: Overview of cogeneration and its status in Asia
Cogeneration is defined as the sequential generation of two different forms of useful energy
from a single primary energy source, typically mechanical energy and thermal energy.
Mechanical energy may be used either to drive an alternator for producing electricity, or
rotating equipment such as motor, compressor, pump or fan for delivering various services.
Thermal energy can be used either for direct process applications or for indirectly producing
steam, hot water, hot air for dryer or chilled water for process cooling.
Electricity
Input for
Input Power
30
Energy Generation
Heat
100 86
50
Input
Heat Loss Energy
56
Heat Loss
20 Input for
Boiler 142
56
Heat Loss
6
(i) Cogeneration System (ii)Conventional System
Cogeneration makes sense from both macro and micro perspectives. At the macro level, it
allows a part of the financial burden of the national power utility to be shared by the private
sector; in addition, indigenous energy sources are preserved or the fuel import bill is reduced.
At the micro level, the overall energy bill of the users can be reduced, particularly when there
is a simultaneous need for both power and heat at the site, and a rational energy tariff is
practised in the country.
In Asian developing countries, it is not unusual to come across situations of grid power
supply interruptions either due to technical failure of the system or because the consumer
demand during a given time period exceeds the utility supply capacity. Industries and
commercial buildings normally adopt stand-by power generators for taking care of their
essential loads during these periods. It is essential to assure continuity of some activities to
minimize production losses or guarantee minimum comfort of the clients. The stand-by
generators have limited use in the year; moreover, these devices require investment and
The concept of cogeneration 5
incur operation and maintenance costs while contributing practically nothing to reduce the
overall energy bill of the site.
Since these generators serve the main purpose of assuring emergency power to priority
areas of the site, no financial analysis is carried out to assess their economic viability.
However, these generators offer the possibility of continuous power generation so that the
monthly power bill of the site can be reduced. Such benefits accrued can well justify the need
for higher investment that is associated with prime movers which are designed to operate
continuously and at higher efficiencies.
In a gas turbine or reciprocating engine, typically a third of the primary fuel supplied is
converted into power while the rest is discharged as waste heat at a relatively high
temperature, ranging between 300 and 500ºC. At sites having a need for thermal energy in
one form or the other, this waste heat can be recovered to match the quantity and level of
requirements. For instance, steam may be needed at low or medium pressures for process
applications. Any heat recovered from the exhaust gases of the prime movers will help to
save the primary energy that would have been otherwise required by the on-site conversion
facility such as boilers or dryers.
a) Utility cogeneration: caters to district heating and/or cooling. The cogeneration facility
may be located in industrial estates or city centres;
economic factors. The extraction points of steam from the turbine could be more than one,
depending on the temperature levels of heat required by the processes.
Steam
Steam
Fuel
Turbine
Fuel
Turbine
Boiler
Boiler
Condenser
Process
Process
Cooling
Water
Another variation of the steam turbine topping cycle cogeneration system is the extraction-
back pressure turbine that can be employed where the end-user needs thermal energy at two
different temperature levels. The full-condensing steam turbines are usually incorporated at
sites where heat rejected from the process is used to generate power.
The specific advantage of using steam turbines in comparison with the other prime movers is
the option for using a wide variety of conventional as well as alternative fuels such as coal,
natural gas, fuel oil and biomass. The power generation efficiency of the cycle may be
sacrificed to some extent in order to optimize heat supply. In backpressure cogeneration
plants, there is no need for large cooling towers. Steam turbines are mostly used where the
demand for electricity is greater than one MW up to a few hundreds of MW. Due to the
system inertia, their operation is not suitable for sites with intermittent energy demand.
Gas turbine cogeneration has probably experienced the most rapid development in the recent
years due to the greater availability of natural gas, rapid progress in the technology,
significant reduction in installation costs, and better environmental performance.
Furthermore, the gestation period for developing a project is shorter and the equipment can
be delivered in a modular manner. Gas turbine has a short start-up time and provides the
flexibility of intermittent operation. Though it has a low heat to power conversion efficiency,
more heat can be recovered at higher temperatures. If the heat output is less than that
required by the user, it is possible to have supplementary natural gas firing by mixing
additional fuel to the oxygen-rich exhaust gas to boost the thermal output more efficiently.
The concept of cogeneration 7
Flue Exhaust
Gases Heat (~ 150 °C)
(~ 500 °C)
Steam
Fuel Air
Water
Boiler
Electricity
Generator
Gas Turbine
On the other hand, if more power is required at the site, it is possible to adopt a combined
cycle that is a combination of gas turbine and steam turbine cogeneration. Steam generated
from the exhaust gas of the gas turbine is passed through a backpressure or extraction-
condensing steam turbine to generate additional power. The exhaust or the extracted steam
from the steam turbine provides the required thermal energy.
Though diesel has been the most common fuel in the past, the prime movers can also
operate with heavy fuel oil or natural gas. In urban areas where natural gas distribution
network is in place, gas engines are finding wider application due to the ease of fuel handling
and cleaner emissions from the engine exhaust.
These machines are ideal for intermittent operation and their performance is not as sensitive
to the changes in ambient temperatures as the gas turbines. Though the initial investment on
these machines is low, their operating and maintenance costs are high due to high wear and
tear.
Cogeneration systems are normally classified according to the sequence of energy use and
the operating schemes adopted.
8 Part I: Overview of cogeneration and its status in Asia
Exhaust ~ 200 °C
Heat
Steam or Hot Water
~ 450 °C
Boiler
I.C. Engine
Coolers
Process
Oil Air Water
Cogeneration systems can also be classified according to the operating scheme whose
choice is very much site-specific and depends on several factors, as described below:
While selecting cogeneration systems, one should consider some important technical
parameters that assist in defining the type and operating scheme of different alternative
cogeneration systems to be selected.
It is defined as the ratio of thermal energy to electricity required by the energy consuming
facility. Though it can be expressed in different units such as Btu/kWh, kcal/kWh, lb./hr/kW,
etc., here it is presented on the basis of the same energy unit (kW).
Basic heat-to-power ratios of the different cogeneration systems are shown in Table 1.1
along with some technical parameters. The steam turbine cogeneration system can offer a
large range of heat-to- power ratios.
requiring thermal energy at about 1450°C, a bottoming cycle cogeneration system can meet
both high quality thermal energy and electricity demands of the plant.
kW kW
kW
Time Time
Figure 1.5 Different heat and power demand patterns in two factories
A rice mill needs mechanical power for milling and heat for paddy drying. If a cogeneration
system were considered, the steam turbine system would be the first priority because it can
use the rice husk as the fuel, which is available as waste product from the mill.