CHAPTER 4

COGENERATION POWER PLANT SYSTEM

Cogeneration or Combined Heat and Power (CHP) is defined as the sequential

generation of two different forms of useful energy from a single primary energy source,

typically mechanical 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 and for hot air for dryer.

Cogeneration provides a wide range of technologies for application in various domain of

economic activities. The overall efficiency of energy use in cogeneration mode can be up

to 85 per cent and above in some cases (Rein, 2007).

For this chapter, selected CHP system is stated as well as the other technical

options recommended by most designers in choosing the most effective system to attain

well-suited cogeneration.

4.1 Cogeneration Cycles

The type of cycle is chosen based on the production requirements (e.g. steam and

electricity requirements) of the manufacturing plant. The following are the basic heat and

power necessity of a typical sugar mill and refinery:

 For heating purposes, low temperature and pressure must be observed to

avoid sticking of juice on the vessel walls; and

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 Electricity for driving the motors and equipments and for supplying power for

the whole plant.

4.1.1 Topping Cycle

A cogeneration system can be classified as either a topping or bottoming

cycle on the basis of the sequence of energy used. In a topping cycle, the fuel

supplied is used to first produce power and then thermal energy, which is the by-

product of the cycle and is used to satisfy process heat ot other thermal

requirements. Topping cycle cogeneration is widely used and is the most popular

method of cogeneration. Figure 4.1 below shows the typical process of topping

cycle.

Low temperature
Electric Generator Industrial Process
Low pressure Steam

Steam
Generator

Condenser
Pump

Figure 4.1 Typical Topping Cycle

4.1.2 Bottoming Cycle

In bottoming cycle, the primary fuel produces high temperature thermal

energy and heat rejected from the process is used to generate power through a

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 recovery boiler and a turbine generator. Bottoming cycle is the reverse of the

topping cycle in the sense that excess steam from manufacturing process is used

to generate electricity. This type of system is common in industries that use very

high temperature furnaces, such as glass and metal industries. Figure 4.2 below

shows the typical bottoming cycle process.

Low temperature
Industrial Process Electric Generator
Low pressure Steam

Steam
Generator

Condenser
Pump

Figure 4.2 Typical Bottoming Cycle

4.1.3 Selected Cogeneration Cycle

The sugar mill and refinery uses a low pressure and low temperature steam

to avoid the sugar being “overcooked”. In this manner, topping cycle is the most

appropriate one to use. With topping cycle being utilized, more electricity can be

generated by letting first the superheated steam reached the turbo generator.

4.2 Steam Turbine Cogeneration System

Steam turbines are widely used for combined heat and power (CHP) applications.

The thermodynamic cycle for the steam turbine is the Rankine cycle. The cycle is the

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basis for conventional power generating stations and consists of a heat source (boiler)

that converts water to high-pressure steam (Woodruff et. al. 2004).

Cogeneration power plant using bagasse as fuel focuses on the utilization of steam

turbine cogeneration system, which will only be the type of system that will be discussed

for this design. The two types of steam turbines most widely used are the back pressure

and the extraction-condensing types. The choice between the backpressure turbine and

the extraction-condensing turbine depends mainly on the quatities of power and heat,

quality of heat, and 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.

Figure 4.3 below shows the schematic diagram of the backpressure turbine and

extraction-condensing turbine.

Source: turbines.info

Figure 4.3 Schematic diagram of Backpressure and Extraction-Condensing

Turbine

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4.2.1 Back Pressure Steam Turbine

In back pressure steam turbine, steam enters the turbine chamber at high

pressure and expands to low or medium pressure for processes. Enthalpy

difference is used for generating power/work.

Figure 4.4 below shows the schematic diagram of the back pressure steam

sturbine.

Source: Turbines Info

Figure 4.4 Back Pressure Steam Turbine Diagram

The efficiency of a back pressure steam turbine cogeneration system is the

highest among the other system. In this type of steam turbine system, one can

achieve efficiency as high as 90% having an efficient boiler but cannot achieve

higher electrical output.

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4.2.2 Extraction Condensing Turbine

In this type, steam entering at high pressure is extracted at an intermediate

pressure in the turbine for process use while the remaining steam continues to

expand and condenses in a surface condenser and work is done till it reaches the

condensing pressure.

The overall thermal efficiency of an extraction condensing turbine

cogeneration system is proven to be lower than that of back pressure turbine

system. This is because the exhaust heat cannot be utilized which is normally

considered as a loss in the cooling water circuit. Figure 4.5 below shows the

schematic diagram of the extraction condensing turbine.

Source: Turbines Info

Figure 4.5 Extraction Condensing Steam Turbine Diagram

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 The extraction condensing turbines have higher power to heat ratio in

comparison with backpressure turbines. Although condesing systems need more

auxiliary equipment, better amount of electrical power and heat demand can be

obtained . In spite of its less thermal efficiency, extraction condensing cogeneration

systems produce more electricity which results to more excess power as presented

on Table 4.1 below.

Table 4.1 Steam Turbine CHP System Comparison

Turbine type (at 8.2 Mpa Process Steam in Excess Power in

& 480 °C) tons/100 tons of cane kWh/tons of cane

Back Pressure 50 20-40

Extraction Condensing 34 80-100

Source: Linero et. al. 2001

4.2.3 Selected Steam Turbine Configuration

In order to choose the appropriate configuration of steam turbine, the

designer must consider the needs and goal of the proposed plant. In this manner,

it is necessary to achieve a much higher electric generation in order to drive the

electric motors for sugar manufacturing and for plant others necessities.

Obviously, the extraction condensing turbine is the most appropriate

configuration of steam turbine to be used. From Table 4.1, a much higher excess

power can be approximately achieved using the given configuration.

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4.3 Combustion Technology

Plant efficiency and performance depends on the combustion technology chosen

by the designer. Combustion technology is very essential for designing a cogeneration

power plant. The basic parameter for choosing the technology is the type and size of fuel

to be burned as well as its ash disposal and equipment maintenance. In this manner,

bagasse is the fuel which has a feed size of up to 25mm when cane prepration is poor.

The existing combustion technology used for sugar CHP plant using bagasse as fuel will

be discussed hereafter.

4.3.1 Travelling Grate

Travelling grate Furnaces are built of grate bars forming an endless band

(like moving staircase) moving through the combustion chamber. Fuel is supplied

at one end of the combustion chamber onto the grate, by e.g. screw conveyor, or

is distributed over the grate by spreader stockers injecting the fuel into the

combustion chamber. The fuel bed itself does not move, but is transported through

the combustion chamber by the grate, contrary to moving grate furnaces where

the fuel bed is moved over the grate.

At the end of the combustion chamber the grate is cleaned of ash and dirt

while the band turns around (automatic ash removal). On the way back, the grate

bars are cooled by primary air in order to avoid overheating and to minimized wear

out. The speed of the travelling grate is continuously adjustable in order to achieve

complete charcoal burnout (Sjaak van Loo et. al. 2008).

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 The fuel bagasse is fed on to one end of a moving steel grate which moves

along the length of the furnace. The said fuel will burn before dropping off at the

end as ash. A fuel gate is used to control the rate at which fuel is fed into the

furnace by controlling the thickness of the fuel bed. Fuel must be uniform in size

as large lumps will not burn out completely by the time they reach the end of the

grate (Energy Efficiency Asia).

Shown in Figure 4.6 is the diagram of the of the traveling grate furnace.

Source: Energy Efficiency Asia

Figure 4.6 Travelling Grate Furnace Construction

Travelling grates stoker is a type of spreader stoker firing which can handle

fuels from .02 in. (.51mm) to 2 in. (50.8mm) in size (Rosendahl et. Al, 2008). When

used for burning bagasse with high ash degree, the said firing is considered as the

best alternative for trustfulness steam and electric generation and when the degree

of ashes in fuel requires a continuing movement of the grate. This motion assures

the automatic rejection of ashes without any type of modification in the flow or the

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produced steam. Thus, the main result is an effective grate with less maintenance

cost and high burning efficiency.

Advantages of Travelling Grate Furnace

1. Uniform combustion conditions for wood, bagasse, chips and pallets;

2. Low dust emissions due to stable and almost unmoving bed of embers;

3. Maintenance or replacement of grate bars is easy to handle;

4. Motion assures the automatic rejection of ashes without any type of

modification in the flow or the produced steam; and

5. High burning efficiency.

4.3.2 Fluidized Bed Furnace

Fluidized bed combustion which has a capability to burn a wide range of

fuels is a result of the turbulent mixing that is found in the fluid beds, resulting in

good heat and mass transfer. These characteristics not only improve the

combustion process but also allow the burning to take place at temperature

ranging between 1500 to 1600oF instead of normal combustion temperatures of

3000 to 3500oF. (Woodruff et al. 2004). The ability to burn fuels at this lower

temperature is important because it make makes possible to burn low-quality fuels

that do not have a high enough heating value to support combustion at high

temperatures.

In fluidized bed combustion, fuel is burned in a bed of hot particles that are

suspended by an upward flow of fluidizing gas. The fuel is generally a solid fuel

such as coal, wood chips, etc. The fluidizing gas is a combination of the

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 combustion air and the flue gas products of combustion. When sulphur capture is

not required, the fuel ash may be supplemented by an inert material such as sand

to maintain the bed. Bed use of a heat-absorbing surface within or enclosing the

bed (Woodruff et. al. 2004):

Advantages of Fluidized Bed Furnace

1. Ability to burn wide range of fuels at lower temperature;

2. Can handle solid fuels;

3. Good heat and mass transfer; and

4. Cleanly burns the fuel.

Table 4.2 below shows the summary of the comparison of two combustion

technology.

Table 4.2 Travelling Grate vs. Fluidized Bed

Parameters Fluidized bed Grate and Stoker Remarks

combustion Combustion

Grate No grate Fixed or moving Since bagasse has

grate an uneven size
ranges from 5 – 25
Fuel Size 1 to 10 mm Can handle solid
mm, Grate and
fuel up to .51mm to
Stoker is more
50.8mm in size.
appropriate to use.
Combustion - Fuel particles are - The combustion is Bagasse produces
in fluidized state better version of a large amount of
and there is pile combustion. ash, therefore ash
must be removed

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 adequate mixing of - Heavier size mass for a continuous
fuel and air. falls on the grate. basis to prevent the
- The fly ash which - Ash is removed building up of
is produced by the on a continuous clinker. In this case,
combustion basis and therefore Stoker and grate is
remains the chances of more suitable.
suspended. clinker formation
are less.

Operating 800-870 ℃ 1000-1640 ℃ Most common

Temperature furnace
temperature for
bagasse
combustion is
approximately
1110℃ (Hugot,
1986). Grate and
stoker is more
appropriate to use.

Moisture It can handle fuels Combustion The moisture

with high moisture condition not very content of the
condition up to 45- much to interfere bagasse before
50% with 4-5% increase firing is
in moisture approximately 7-
8%. Grate and
stoker can be use.

Source: Woodruff et al. 2004

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4.3 Selected Combustion Technology, summary

From the said parameters, the proponents selected the travelling grate as the

combustion technology for this proposed CHP plant. The reason why travelling grate is

more efficient because the selected technology can burn bagasse .51mm to 50.8mm in

size compared to fluidized bed combustion which only requires a very fine fuel 6.35mm

in size.

Most of the sugar mill and refinery in the country today had undergone series of

optimization maintaining only 1 to a maximum of three (3) boilers, which is for economic

reasons, instead of their existing installations having five(5) or even more. Therefore, the

furnace maintenance could be avoided with the said selected combustion technology to

assure that the plant can sustain the energy requirements at any time compared to

fluidized bed maintenance. In addition, even if a fluidized bed firing has a lower pollution

potential, through the enhanced pollution facility of a travelling grate furnace, mainly the

ash rejection facility, scrubbers and others, still, emission rates can be efficiently

controlled.

4.4. Summary of the Selected Systems

The systems are being selected to meet the manufacturing plant requirements and

to come up a suitable design for cogeneration power plant. Shown in Table 4.3 are the

selected systems in the whole design of the combine heat plant (CHP).

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 Table 4.3 Summary of Selected System

Systems Selected System

Cogeneration Cycle Cogeneration System Topping Cycle

Cogeneration System Steam Turbine Cogeneration System

Steam Turbine Configuration Extracting Condensing Steam turbine

Combustion Technology Travelling Grate

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