Training Session on Energy

Equipment

Cogeneration
Thermal Equipment/
Cogeneration

Presentation from the

Energy Efficiency Guide for Industry in Asia
www.energyefficiency.asia.org

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UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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 Introduction

Whats a Cogeneration/CHP System?

Thermal Equipement/

Generation of multiple forms of

Cogeneration

energy in one system: heat and

power
Defined by its prime movers
Reciprocating engines
Combustion or gas turbines,
Steam turbines
Microturbines
Fuel cells
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UNEP 2006
 Introduction

Efficiency Advantage of CHP

Thermal Equipment/

36 Units
Conventional Generation (58%
Cogeneration

(Losses)
Overall Efficiency)

Combined Heat & Power (85%

Overall Efficiency)

60 = 40%

Uni
24

ts
68
100

40

Uni
34
= 85%

ts
6 Units 10 Units
(Losses) (Losses)

(UNESCAP, 2004)
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UNEP 2006
 Introduction

Benefits of Cogeneration / CHP)

Thermal Equipment/

Increased efficiency of energy conversion and

Cogeneration

use
Lower emissions, especially CO2
Ability to use waste materials
Large cost savings
Opportunity to decentralize the electricity
generation
Promoting liberalization in energy markets

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UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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UNEP 2006
Thermal Equipment/ Type of Cogeneration Systems

Steam turbine
Cogeneration

Gas turbine
Reciprocating engine
Other classifications:
- Topping cycle
- Bottoming cycle

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 Type of Cogeneration Systems

Steam Turbine Cogeneration System

Thermal Equipment/

Widely used in CHP applications

Cogeneration

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
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UNEP 2006
 Type of Cogeneration Systems

Back Pressure Steam Turbine

Thermal Equipment/

Steam exits the turbine at a higher pressure

that the atmospheric
Cogeneration

HP Steam
Advantages:
-Simple configuration
-Low capital cost
Boiler Turbine -Low need of cooling water
-High total efficiency
Fuel

Disadvantages:
Condensate
Process
LP
Steam
-Larger steam turbine
-Electrical load and output
can not be matched

Figure: Back pressure steam turbine

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 Type of Cogeneration Systems

Extraction Condensing Steam

Turbine
Thermal Equipment/

HP Steam
Cogeneration

Steam obtained by
extraction from an Boiler Turbine

intermediate stage Fuel

Remaining steam is Condensate

LP Steam

Process
exhausted
Relatively high
capital cost, lower Condenser

total efficiency
Control of electrical
power independent Figure: Extraction condensing steam turbine
of thermal load 10
UNEP 2006
 Type of Cogeneration Systems

Gas Turbine Cogeneration System

Thermal Equipment/
Cogeneration

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
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 Type of Cogeneration Systems

Open Cycle Gas Turbine

Exhaust
Thermal Equipment/

Gases
Open Brayton cycle: Condensate
atmospheric air at
Cogeneration

from Process

increased pressure to HRSG

combustor Steam to
Process

Old/small units: 15:1 Fuel

Combustor

New/large units: 30:1

Exhaust gas at 450-
600 oC G

Generator

High pressure steam Compressor Turbine

produced: can drive Air

steam turbine Figure: Open cycle gas turbine cogeneration

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 Type of Cogeneration Systems

Closed Cycle Gas Turbine

Thermal Equipment/

Heat Source
Cogeneration

Working fluid circulates

in a closed circuit and Heat Exchanger

does not cause

corrosion or erosion G

Generator

Any fuel, nuclear or Compressor Turbine

solar energy can be

used Condensate
from Process

Steam to
Process

Figure: Closed Cycle Gas Turbine Cogeneration System 13

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 Type of Cogeneration Systems

Reciprocating Engine Cogeneration

Systems
Thermal Equipment/

Used as direct mechanical drives

Cogeneration

Many advantages:
operation,
efficiency, fuel
costs
Used as direct
mechanical drives
Four sources of
usable waste heat
Figure: Reciprocating engine cogeneration system
(UNESCAP, 2000) 14
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 Type of Cogeneration Systems

Topping Cycle
Thermal Equipment/

Supplied fuel first produces power

Cogeneration

followed by thermal energy

Thermal energy is a by product used
for process heat or other
Most popular method of cogeneration

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 Type of Cogeneration Systems

Bottoming Cycle
Thermal Equipment/

Primary fuel produces high

Cogeneration

temperature thermal energy

Rejected heat is used to generate
power
Suitable for manufacturing processes

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UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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 Assessment of Cogeneration
Systems

Performance Terms & Definitions

Thermal Equipment/

Overall Plant Heat Rate (kCal/kWh):

Cogeneration

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 )
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 Assessment of Cogeneration
Systems

Steam Turbine Performance

Thermal Equipment/

Steam turbine efficiency (%):

Cogeneration

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 )

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 Assessment of Cogeneration
Systems

Heat Recovery Steam Generator (HRSG)

Thermal Equipment/

Performance
Cogeneration

Heat recovery steam generator efficiency

(%):
M s x ( hs hw )
x 100
[ 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) 20
UNEP 2006
 Training Agenda: Cogeneration

Introduction
Thermal Equipment/

Types of cogeneration systems

Cogeneration

Assessment of cogeneration systems

Energy efficiency opportunities

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UNEP 2006
 Energy Efficiency Opportunities

Steam Turbine Cogeneration System

Thermal Equipment/

Steam turbine:
Cogeneration

Keep condenser vacuum at optimum value

Keep steam temperature and pressure at
optimum value
Avoid part load operation and starting &
stopping

Boiler & steam see other chapters

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 Energy Efficiency Opportunities

Gas Turbine Cogeneration System

Thermal Equipment/

Gas turbine manage the following parameters:

Cogeneration

Gas temperature and pressure

Part load operation and starting & stopping
Temperature of hot gas and exhaust gas
Mass flow through gas turbine
Air pressure

Air compressors see compressors chapter

Heat recovery system generator see waste
heat recovery chapter
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UNEP 2006
 Training Session on Energy
Equipment

Thermal Equipment/

Cogeneration
Cogeneration

THANK YOU
FOR YOUR ATTENTION

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UNEP GERIAP
 Disclaimer and References

This PowerPoint training session was prepared as part of

the project Greenhouse Gas Emission Reduction from
Thermal Equipment/

Industry in Asia and the Pacific (GERIAP). While

reasonable efforts have been made to ensure that the
Cogeneration

contents of this publication are factually correct and

properly referenced, UNEP does not accept responsibility for
the accuracy or completeness of the contents, and shall not
be liable for any loss or damage that may be occasioned
directly or indirectly through the use of, or reliance on, the
contents of this publication. UNEP, 2006.
The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
Full references are included in the textbook chapter that is
available on www.energyefficiencyasia.org 25
UNEP 2006