COGENERATION

COMBINED HEAT AND POWER

PLANT
 CHP
• The sequential production of electricity
and thermal energy in the form of heat or
steam, or useful mechanical work, such as
shaft power, from the same fuel source
• Typically represented by two basic types
of power cycles, topping or bottoming.
• The topping cycle has the widest industrial
application.
 CHP
• Topping cycle utilizes the primary energy
source to generate electrical or
mechanical power
• Then the rejected heat, in the form of
useful thermal energy, is supplied to the
process
 CHP
• The cycle consists of
– a combustion turbine-generator, with the turbine
exhaust gases directed into a
– waste-heat-recovery boiler that converts the exhaust
gases heat into steam which drives
– a steam turbine, extracting steam to
– the process plant
– while driving an electric generator
• This cycle is commonly referred to as a
combined cycle arrangement
 CHP
• Combustion turbine-generators,
• steam turbine-generator sets,
• and reciprocating internal-combustion-
engine generators are representative of
the major equipment components utilized
in a topping cycle.
 CHP
• A bottoming cycle has the primary energy
source applied to a useful heating process.
• The reject heat from the process is then used to
generate electrical power.
• The typical bottoming cycle directs waste heat
from a process to a waste-heat-recovery boiler
• that converts this thermal energy to steam which
is supplied to a steam turbine,
• extracting steam to the process and also
generating electrical power.
 CHP
• Cogeneration for building and district space
heating and cooling purposes consists of
producing electricity and sequentially utilizing
useful energy in the form of steam, hot water, or
direct exhaust gases
• The two most common heating, ventilating, and
air-conditioning cycles are the vapor
compression cycle and the absorption cycle
 CHP
• Conventional power plants emit the heat created as a
byproduct of electricity generation into the environment
through cooling towers, as flue gas, or by other means.
• CHP captures the byproduct heat for domestic or
industrial heating purposes, either very close to the
plant, or for distribution through pipes to heat local
housing (district heating).
• Byproduct heat at moderate temperatures (100 to 180
oC) can also be used in absorption chillers for cooling,
that is production of "cold".
• A plant producing electricity, heat and cold is sometimes
called trigeneration or more generally: polygeneration
plant.
 CHP
• Cogeneration is thermodynamically the
most efficient use of fuel.
• In separate production of electricity some
energy must be rejected as waste heat,
whereas in cogeneration the potential for
production of high quality energy
(electricity or work) is enhanced
 CHP
• By capturing the excess heat, CHP allows
a more total use of energy than
conventional generation
• Potentially reaching an efficiency of 70%,
compared with approximately 35% for the
conventional plants.
• This means that less fuel needs to be
consumed to produce the same amount of
useful energy
 CHP
• CHP is most efficient when the heat can be used
on site or very close to it.
• Overall efficiency is reduced when the heat must
be transported over longer distances.
• This requires heavily insulated pipes, which are
expensive and inefficient; whereas electricity can
be transmitted along a comparatively simple
wire, and over much longer distances for the
same energy loss
 CHP
• A car motor becomes a CHP plant in
winter, when the reject heat is useful for
warming the interior of the vehicle.
• This example scores the point that
deployment of CHP depends on heat uses
in the vicinity of the heat engine
 CHP
• Cogeneration plants are commonly found in
– district heating systems of big towns,
– hospitals,
– prisons,
– oil refineries,
– paper mills,
– wastewater treatment plants,
– thermal enhanced oil recovery wells and industrial
plants with large heating needs.
 Plant Design

Process Plant Design, Power

Plant Design, etc.
 Plant Design
• Refers to the automation technologies,
work practices and business rules
supporting the design and engineering of
process and power plants
• Such plants can be built for chemical,
petroleum, utility, shipbuilding, and other
facilities
 Plant Design
• This is often further differentiated by the
type of industry sector targeted
• Thus such terms as
– Beverage Plant Design
– Chemical Plant Design
– Dairy Plant Design
– Food Plant Design
– Nuclear Plant Design
– Offshore Stuctures Plant Design
 Plant Design
– Paper Plant Design
– Petrochemical Plant Design (Petro Chemical
Plant Design
– Pharmaceutical Plant Design
– Power Plant Design
– Pulp Plant Design
– Refinery Plant Design
 Plant Design
– Sanitary Plant Design
– Ship Design (Shipbuilding Plant Design)
– Utility Plant Design
– Water Treatment Plant Design
– Wastewater Plant Design
 Plant Design
• Design disciplines are also used to differentiate
areas of plant design
• Reference is often made to
– Process Design (Process Plant Design)
– Piping Design (Piping Plant Design)
– HVAC Design (HVAC Plant Design)
– Structural Design (Structural Plant Design)
– Electrical Design (Electrical Plant Design)
– Instrumentation Design (Instrumentation Plant
Design)
 Plant CAD
• Plant CAD or Computer Aided Plant
Design refers to Computer Aided Design
• (CAD) CAD software tailored to the design
of process and power plants
 Document Management for Plant
Design
• Document Management for Plant Design
refers to document management software
tailored to the design and support of
process and power plants
 Internet & Intranet
• Internet, Intranet for Plant Design refers to using
Internet technologies for the design and support
of process and power plants
• Internets refer to the technology applied to open
internet connections and Intranets refer to
closed, private connections
• Internet/Intranet for Plant Design supports the
many design and Maintenance, Repair, and
Operations (MRO) work practices needed in the
typical process or power plant
 Enterprise Resource Planning
(ERP) for Plant Design
• Enterprise Resource Planning (ERP) for
Plant Design refers to centralized business
software and databases for the design and
support of process and power plants
• ERP technology both supports enterprises
that design the plants and owner/operators
that run them
 Plant Layout Design
• This plays an important part in the design
and engineering phases of any industrial
facility
• The plant layout designer is skilled
primarily in the development of equipment
arrangements and piping layouts for
process industries
 Plant Layout Design
• This position offers an opportunity to
demonstrate technical ability along with a
creative talent and common-sense approach to
problem solving
• Process facilities must be designed and
engineered within extremely short schedules
while adhering to maintenance, safety and
quality standards
• The design must take construct-ability,
economics and operation in account
 Plant Layout Design
• Layout documents must be developed
during conceptual and study phases of the
project
• The skills needed are:
– Common sense and the ability to reason
– Knowledge of what a particular plant is
designed to do
– A general understanding of how process
equipment is maintained and operated
 Plant Layout Design
– The ability to generate a safe, comprehensive
layout within a specified time and cost-
effectively
– Creativity
– Sufficient experience to avoid reinventing the
wheel
– Knowledge of the principal roles of other
design and engineering groups and the ability
to use input from these other disciplines
 Plant Layout Design
• The ability to resolve unclear or
questionable data
• Willingness to compromise in the best
interest of the projects
• The ability to generate clear and concise
documents
• The ability to defend designs when
challenged
 Designer’s role
• Insure that time and care spent during
engineering shorten construction
schedules and thereby lower projects
costs
• The designer must be conscious of the
construct-ability of every layout
 Principal functions
• Include the conceptual and preliminary
development of the process unit plot plans
• Setting all equipment positions
• Designing all structures and positioning
associated stairways, laddering, platforms etc.
• Make provisions to satisfy all operational,
maintenance and safety requirements for access
to and clearance around equipment
 Principal functions
• Planning unobstructed areas for
necessary structures that facilitates all
plant maintenance requirements
• Establishing all equipment locations that
satisfy all process, utility and instrument
requirement
• Locating all safety items (e.g. fire
hydrants, monitors and safety shower
stations
 Principal functions
• Locating all miscellaneous items (e.g.
filters, silencers and analyser houses)
 Principal functions
• All these activities are closely coordinated
among all who will be involved in the
engineering and construction phases of a
project to
– reduce costly rework and
– enable the plant layout designer to generate
the optimum design on schedule