INTRODUCTION

TO
COGENERATION
BIBIN CHIDAMBARANATHAN
 COGENERATION
❖ Cogeneration is also called combined heat power (CHP).
❖ Cogeneration works based on the concept of producing two different forms of energy by
using a single source of fuel.
❖ Out of these two forms, one must be heat or thermal energy and other one is either
electrical or mechanical energy.
❖ Cogeneration is the most optimum, reliable, clean and efficient way of utilizing energy.
❖ The fuel used may be natural gas, oil, diesel, propane, wood, bagasse, coal etc.
 Need for cogeneration

❖ Cogeneration helps to improve the efficiency of the plant.

❖ Cogeneration reduces air emissions of particulate matter, nitrous oxides,
sulphur dioxide, mercury and carbon dioxide which would lead to
greenhouse effect.
❖ It reduces the cost of production. Also, it improves the productivity.
❖ Cogeneration system helps to save water consumption and water costs.
❖ Cogeneration system is more economical as compared to conventional
power plants.
 COGENERATION PRINCIPLES

❖ In cogeneration plants, the fuel is used to generate electricity and the

process heat is used to boil the water to produce steam for space heating
and even for cooling buildings.
❖ Combined heat and power refers to the arrangement in which the cycle
produces work along with heat utilization for process heating.
❖ This cogeneration concept is applied in many fields where both power and
process heats are simultaneously required.
 Applications of Cogeneration

In recent years cogeneration has become an attractive and practical

proposition for a wide range of applications.
❖ These include the process industries (pharmaceuticals, paper and board,
ceramics, brick, cement, food, textile, minerals etc.), commercial and
public sector buildings (hotels, hospitals, leisure centres, swimming pools,
universities, airports, offices, barracks (lodgings/ housings/ quarters), etc.)
and district heating schemes.
 Benefits of Cogeneration

❖ Increased efficiency of energy conversion and use

❖ Lower emissions to the environment, in particular of CO2, the main
greenhouse gas
❖ In some cases, biomass fuels and some waste materials such as refinery
gases, process or agricultural waste are used. These substances which
serve as fuels for cogeneration schemes increase the cost-effectiveness
and reduces the need for waste disposal.
❖ Large cost savings, providing additional competitiveness for industrial and
commercial users while offering affordable heat for domestic users also.
 Types of cogeneration power plants

There are two types of cogeneration power plants such as

❖ Topping cycle power plant.

❖ Bottoming cycle power plant

 Topping cycle power plant
❖ In a topping cycle, power is generated prior to the delivery of thermal energy to the process.
❖ Power generation is done from recovery of excess thermal energy (combined cycle steam turbine
output generation).
❖ Power generation is derived from exothermic process reactions and heat recovery from kilns,
process heaters and furnaces.
Gas turbine topping Combined Heat power (CHP) plant

In This topping plant a natural gas fired turbine is used to drives a synchronous generator to
produce electricity.
The exhaust gas is sent to a heat recovery boiler where it is used to convert water into steam, or
to make usable heat for heating purposes.
Types of gas turbine cogeneration systems

❖ Open-cycle gas turbine cogeneration systems

❖ Closed-cycle gas turbine cogeneration systems
Open-cycle gas turbine cogeneration systems
Closed-cycle gas turbine cogeneration systems
Steam turbine topping Combined Heat Power (CHP) plant
In this the fuel is burned to produce steam, which generates power.
The exhaust steam is then used as low-pressure process steam to heat water for
various purposes.
Types of Steam turbine cogeneration

❖ Back Pressure Steam Turbine

❖ Extraction-condensing turbine
Back Pressure Steam Turbine
Extraction-condensing turbine
Reciprocating Engine Cogeneration System
Combined Joule – Rankine Cycle Systems
❖ In this type of plant, the fuel is first burnt in a steam boiler.
❖ The steam produced in a boiler is used to drive turbine.
❖ A synchronous generator which is coupled to the turbine produces electrical energy.
❖ The exhaust from the turbine can be used either for process heating or heating the
building in winter or heating a recovery system to generate steam.
❖ It is further used to drive a secondary steam turbine.
Fuel Cell Cogeneration Systems
❖ A fuel cell is an electrochemical device, which converts the chemical energy of fuel into electricity
directly, without intermediate stages of combustion and production of mechanical work.

❖ Fuel cells produce power electrochemically from hydrogen delivered to the negative pole (anode) of
the cell and oxygen delivered to the positive pole (cathode).

❖ The hydrogen can come from a variety of sources, but the most economic method is by reforming of
natural gas or liquid fuels.
Water turbine topping CHP Plant

❖ In this type of CHP plant a jacket of cooling water is run through a heat
recovery system to generate steam or hot water for space heating.
Stirling Engine Cogeneration System
 Bottoming Cycle Power Plant
• Bottoming cycle is exactly opposite of topping cycle.
• In this type of CHP plant the excess heat from a manufacturing process is used to generate steam,
and this steam is used for generating electrical energy.
• In this type of cycle no extra fuel is required to produce electricity, as fuel is already burnt in
production process.
 PROBLEM
ON
COGENERATION
01
BIBIN CHIDAMBARANATHAN
PROBLEM 01:
The steam enters the turbine of a cogeneration plant at 8 Mpa and 500°C. Two-third of
the steam is extracted from the turbine at 660 KPa pressure for process heating. The
remaining steam continues to expand to 8 KPa. The extracted steam is then condensed
and mixed with feed water at constant pressure and mixture is pumped to the boiler
pressure of 8 MPa. The mass flow rate of steam through the boiler is 25 kg/s.
Disregarding any pressure drops and heat losses in the piping, and assuming the
turbine and the pump to be isentropic, determine the net power produced and
utilization factor of the plant.
 Given Data:
𝒎ሶ 𝒔 𝟏
𝑝1 = 𝑝𝑏 = 8 𝑀𝑝𝑎 = 80 𝑏𝑎𝑟 𝑇1 = 500°𝐶 Boiler Turbine
2 1 𝒎ሶ 𝟏
𝑚ሶ 1 = 𝑚ሶ 𝑠 𝑚ሶ 2 = 𝑚ሶ 𝑠
3 3
𝟐 𝟑 𝒎ሶ 𝟐
𝑝2 = 𝑝6 = 𝑝𝑅 = 𝑝7 = 660 𝑘𝑃𝑎 = 6.6 𝑏𝑎𝑟 𝒎ሶ 𝒔 𝟖 Process
Heater Condenser
𝑝3 = 𝑝4 = 𝑝𝑐 = 8 𝑘𝑃𝑎 = 0.08 𝑏𝑎𝑟
𝒎ሶ 𝟏 𝟔
𝟒 𝒎ሶ 𝟐
𝑘𝑔 𝒎ሶ 𝒔 𝟓
𝑚ሶ 𝑠 = 25 Mixing
𝑠 Chamber
𝟕 𝒎ሶ 𝟐
Pump 2 Pump 1
To find:
Net power produced Wnet =?

Utilization factor of the plant 𝜖𝑐𝑜𝑔𝑒𝑛 =?

Formula
𝑊𝑛𝑒𝑡 + 𝑄𝑝
𝑈𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 (𝜖𝑐𝑜𝑔𝑒𝑛 ) =
𝑄𝑠

𝑁𝑒𝑡 𝑤𝑜𝑟𝑘𝑑𝑜𝑛𝑒 𝑜𝑟 𝑃𝑜𝑤𝑒𝑟 (𝑊𝑛𝑒𝑡 ) = 𝑊𝑇 − 𝑊𝑝

𝐻𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑡𝑜 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 ℎ𝑒𝑎𝑡𝑒𝑟 (𝑄𝑝 ) = 𝑚ሶ 1 ℎ2 − ℎ6

𝐻𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑏𝑜𝑖𝑙𝑒𝑟 (𝑄𝑠 ) = 𝑚ሶ 𝑠 ℎ1 − ℎ8

𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝑊𝑜𝑟𝑘 (𝑊𝑇 ) = 𝑚ሶ 𝑠 ℎ1 − ℎ2 + 𝑚ሶ 2 (ℎ2 − ℎ3 )

𝑁𝑒𝑡 𝑃𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 (𝑊𝑝 ) = 𝑊𝑝1 + 𝑊𝑝2

Formula

𝑃𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 1 (𝑊𝑝1 ) = 𝑚ሶ 2 × (ℎ5 −ℎ4 ൯

ℎ5 − ℎ4 = 𝑣𝑓𝑐 𝑝𝑅 − 𝑝𝑐

𝑃𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 2 (𝑊𝑝2 ) = 𝑚ሶ 𝑠 ℎ8 − ℎ7

ℎ8 − ℎ7 = 𝑣𝑓𝑅 𝑝𝑏 − 𝑝𝑅

𝐸𝑛𝑒𝑟𝑔𝑦 𝑏𝑎𝑙𝑎𝑛𝑐𝑒 𝑖𝑛 𝑚𝑖𝑥𝑖𝑛𝑔 𝑐ℎ𝑎𝑚𝑏𝑒𝑟 𝑚ሶ 𝑠 ℎ7 = 𝑚ሶ 1 ℎ6 + 𝑚ሶ 2 ℎ5

 2
𝑚ሶ 1 = 𝑚ሶ 𝑠
3 𝑘𝑔
𝑚ሶ 𝑠 = 25
𝑠
2
𝑚ሶ 1 = × 25
3
𝒌𝒈
𝒎ሶ 𝟏 = 𝟏𝟔. 𝟔𝟕
𝒔

1
𝑚ሶ 2 = 𝑚ሶ 𝑠
3
1
𝑚ሶ 2 = × 25
3
𝒌𝒈
𝒎ሶ 𝟐 = 𝟖. 𝟑𝟑
𝒔
@ state 1; 𝐏𝟏 = 𝟖𝟎 𝐛𝐚𝐫 𝑻𝟏 = 𝟓𝟎𝟎°𝐂 𝑺𝒖𝒑𝒆𝒓 𝒉𝒆𝒂𝒕𝒆𝒅 @ state 2; 𝐏𝟐 = 𝟔. 𝟔 𝐛𝐚𝐫
ℎ1 = 3410 𝑘 𝐽Τ𝑘 𝑔 1 @ state 3; 𝐏𝟑 = 𝟎. 𝟎𝟖 𝐛𝐚𝐫

ℎ2 = 2810 𝑘 𝐽Τ𝑘 𝑔 2

𝒉𝟏 = 𝟑𝟒𝟏𝟎 𝒌 𝑱Τ𝒌 𝒈

ℎ3 = 2150 𝑘 𝐽Τ𝑘 𝑔 3 𝒉𝟐 = 𝟐𝟖𝟏𝟎 𝒌 𝑱Τ𝒌 𝒈

𝒉𝟑 = 𝟐𝟏𝟓𝟎 𝒌 𝑱Τ𝒌 𝒈
@ State 4; 𝐏𝟒 = 𝟎. 𝟎𝟖 𝐛𝐚𝐫

Source : Steam Tables with Mollier Diagram by R.S.Khurmi

𝒌𝑱
𝒉𝟒 = 𝒉𝒇𝟒 = 𝟏𝟕𝟑. 𝟗
𝒌𝒈
 𝐏𝑪 = 𝟎. 𝟎𝟖 𝐛𝐚𝐫

Source : Steam Tables with Mollier Diagram by R.S.Khurmi

𝒗𝒇𝒄 = 𝟎. 𝟎𝟎𝟏𝟎𝟎𝟖 𝒎𝟑 /𝒌𝒈

𝑝𝑢𝑚𝑝 1
𝑘𝐽
ℎ4 = ℎ𝑓4 = 173.9
𝑘𝑔
𝑤𝑝 = 𝑣𝑓𝑐 𝑝𝑅 − 𝑝𝑐
𝑣𝑓𝑐 = 0.001008 𝑚3 /𝑘𝑔
𝑤𝑝 = ℎ5 − ℎ4

ℎ5 − ℎ4 = 𝑣𝑓𝑐 𝑝𝑅 − 𝑝𝑐 𝑝2 = 𝑝6 = 𝑝𝑅 = 𝑝7 = 660 𝑘𝑃𝑎

𝑝3 = 𝑝4 = 𝑝𝑐 = 8 𝑘𝑃𝑎
ℎ5 − 173.9 = 0.001008 660 − 8

𝒉𝟓 = 𝟏𝟕𝟒. 𝟓𝟓 𝒌𝑱/𝒌𝒈
@ State 6; 𝐏𝟔 = 𝟔. 𝟔 𝐛𝐚𝐫

Source : Steam Tables with Mollier Diagram by R.S.Khurmi

𝒌𝑱
𝒉𝟔 = 𝒉𝒇 𝟔 = 𝟔𝟖𝟔. 𝟖
𝒌𝒈
 𝒎ሶ 𝟏 𝑘𝑔
𝟔 𝑚ሶ 1 = 16.67
𝑠
𝒎ሶ 𝒔 𝟓 𝑘𝑔
Mixing
𝑚ሶ 2 = 8.33
Chamber 𝑠
𝟕 𝒎ሶ 𝟐
𝑘𝑔
𝑚ሶ 𝑠 = 25
𝑚ሶ 𝑠 ℎ7 = 𝑚ሶ 1 ℎ6 + 𝑚ሶ 2 ℎ5 𝑠
ℎ5 = 174.55 𝑘𝐽/𝑘𝑔
25 × ℎ7 = 16.67 × 686.8 + 8.33 × 174.55
𝑘𝐽
ℎ6 = 686.8
𝑘𝑔
𝒌𝑱
𝒉𝟕 = 𝟓𝟏𝟔. 𝟏𝟐
𝒌𝒈
 𝐏𝑹 = 𝟔. 𝟔 𝐛𝐚𝐫

Source : Steam Tables with Mollier Diagram by R.S.Khurmi

𝒗𝒇𝑹 = 𝟎. 𝟎𝟎𝟏𝟏𝟎𝟓 𝐦𝟑 /𝐤𝐠

𝑝𝑢𝑚𝑝 2
𝑘𝐽
ℎ7 = 516.12
𝑘𝑔
ℎ8 − ℎ7 = 𝑣𝑓𝑅 𝑝𝑏 − 𝑝𝑅
𝑣𝑓𝑅 = 0.001105 m3 /kg

𝑝𝑏 = 8 𝑀𝑝𝑎 = 8000 𝑘𝑃𝑎

ℎ8 − 516.12 = 0.001105 8000 − 660

𝑝2 = 𝑝6 = 𝑝𝑅 = 𝑝7 = 660 𝑘𝑃𝑎
𝒌𝑱
𝒉𝟖 = 𝟓𝟐𝟒. 𝟐𝟑
𝒌𝒈
 𝑘𝑔
𝑚ሶ 2 = 8.33
𝑃𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 1 (𝑊𝑝1 ) = 𝑚ሶ 2 × (ℎ5 −ℎ4 ൯ 𝑠
𝑘𝐽
ℎ4 = ℎ𝑓4 = 173.9
𝑘𝑔
𝑊𝑝1 = 8.33 × (174.55 − 173.9൯
ℎ5 = 174.55 𝑘𝐽/𝑘𝑔
𝑾𝒑𝟏 = 𝟓. 𝟒𝟏 𝒌𝑾
𝑘𝑔
𝑚ሶ 𝑠 = 25
𝑠
𝑃𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 2 (𝑊𝑝2 ) = 𝑚ሶ 𝑠 ℎ8 − ℎ7 𝑘𝐽
ℎ7 = 516.12
𝑘𝑔
𝑊𝑝2 = 25 × 524.23 − 516.12 𝑘𝐽
ℎ8 = 524. 23
𝑘𝑔
𝑾𝒑𝟐 = 𝟐𝟎𝟐. 𝟕𝟓 𝒌𝑾
𝑁𝑒𝑡 𝑃𝑢𝑚𝑝 𝑤𝑜𝑟𝑘 (𝑊𝑝 ) = 𝑊𝑝1 + 𝑊𝑝2 𝑊𝑝1 = 5.41 𝑘𝑊

𝑊𝑝2 = 202.75 𝑘𝑊
𝑊𝑃 = 5.41 + 202.75

𝑾𝒑 = 𝟐𝟎𝟖. 𝟏𝟔 𝒌𝑾
 𝑘𝑔
𝑇𝑢𝑟𝑏𝑖𝑛𝑒 𝑊𝑜𝑟𝑘 (𝑊𝑇 ) = 𝑚ሶ 𝑠 ℎ1 − ℎ2 + 𝑚ሶ 2 (ℎ2 − ℎ3 ) 𝑚ሶ 𝑠 = 25
𝑠

𝑘𝑔
𝑚ሶ 2 = 8.33
𝑠
𝑊𝑇 = 25 × 3410 − 2810 + 8.33 × (2810 − 2150)
ℎ1 = 3410 𝑘 𝐽Τ𝑘 𝑔

ℎ2 = 2810 𝑘 𝐽Τ𝑘 𝑔
𝑾𝑻 = 𝟐𝟎𝟒𝟗𝟕. 𝟖 𝒌𝑾 ℎ3 = 2150 𝑘 𝐽Τ𝑘 𝑔
𝑁𝑒𝑡 𝑤𝑜𝑟𝑘𝑑𝑜𝑛𝑒 𝑜𝑟 𝑃𝑜𝑤𝑒𝑟 (𝑊𝑛𝑒𝑡 ) = 𝑊𝑇 − 𝑊𝑝
𝑊𝑇 = 20497.8 𝑘𝑊

𝑊𝑝 = 208.16 𝑘𝑊
𝑊𝑛𝑒𝑡 = 20497.8 − 208.16

𝑾𝒏𝒆𝒕 = 𝟐𝟎𝟐𝟖𝟗. 𝟔𝟒 𝒌𝑾

Answer
𝑃𝑜𝑤𝑒𝑟 𝑑𝑒𝑣𝑒𝑙𝑜𝑝𝑒𝑑 𝑊𝑛𝑒𝑡 = 20289.64 𝑘𝑊
 𝑘𝑔
𝑚ሶ 1 = 16.67
𝐻𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑡𝑜 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 ℎ𝑒𝑎𝑡𝑒𝑟 (𝑄𝑝 ) = 𝑚ሶ 1 ℎ2 − ℎ6 𝑠

ℎ2 = 2810 𝑘 𝐽Τ𝑘 𝑔
𝑄𝑝 = 16.67 × (2810 − 686.8)
𝑘𝐽
ℎ6 = 686.8
𝑘𝑔
𝑸𝒑 = 𝟑𝟓𝟑𝟗𝟑. 𝟕𝟒 𝒌𝑾
𝑘𝑔
𝑚ሶ 𝑠 = 25
𝑠
𝐻𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑏𝑜𝑖𝑙𝑒𝑟 (𝑄𝑠 ) = 𝑚ሶ 𝑠 ℎ1 − ℎ8
ℎ1 = 3410 𝑘 𝐽Τ𝑘 𝑔
𝑄𝑠 = 25 × (3410 − 524.23) 𝑘𝐽
ℎ8 = 524. 23
𝑘𝑔
𝑸𝒔 = 𝟕𝟐𝟏𝟒𝟒. 𝟐𝟓 𝒌𝑾
 𝑊𝑛𝑒𝑡 + 𝑄𝑝
𝑈𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 (𝜖𝑐𝑜𝑔𝑒𝑛 ) =
𝑄𝑠 𝑊𝑛𝑒𝑡 = 20289.64 𝑘𝑊

𝑄𝑝 = 35393.74 𝑘𝑊
20289.64 + 35393.74
𝜖𝑐𝑜𝑔𝑒𝑛 =
72144.25
𝑄𝑠 = 72144.25 𝑘𝑊

𝝐𝒄𝒐𝒈𝒆𝒏 = 𝟎. 𝟕𝟕𝟏𝟖

Answer

𝑈𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 (𝜖𝑐𝑜𝑔𝑒𝑛 ) = 0.7718

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