Dr.

Walid Abdelghaffar

Cogeneration

Introduction Types of cogeneration systems Assessment of cogeneration systems Energy efficiency opportunities

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Background
Cogeneration first appeared in Europe and in the U.S.A. during the early parts of the 20th century. In addition to decreased fuel consumption, cogeneration results in a decrease of pollutant emissions.

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

What is Cogeneration? Cogeneration is on-site generation and utilisation of energy in different forms simultaneously by utilising fuel energy at optimum efficiency in a cost-effective and environmentally responsible way. Cogeneration systems are of several types and almost all types primarily generate electricity along with making the best practical use of the heat, which is an inevitable by-product.
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

What is Cogeneration? The most prevalent example of cogeneration is the generation of electric power and heat. The heat may be used for generating steam, hot water, or for cooling through absorption chillers. In a broad sense, the system, that produces useful energy in several forms by utilising the energy in the fuel such that overall efficiency of the system is very high, can be classified as Cogeneration System or as a Total Energy System.
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

What is Cogeneration?
Conventional utility power plants utilise the high potential energy available in the fuels at the end of combustion process to generate electric power. However, substantial portion of the low-end residual energy goes to waste by rejection to cooling tower and in the form of high temperature flue gases. On the other hand, a cogeneration process utilises first the high-end potential energy to generate electric power and then capitalises on the low-end residual energy to work for heating process, equipment or such similar use.
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Introduction Benefits of Cogeneration / CHP)

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

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Cogeneration

Introduction Types of cogeneration systems Assessment of cogeneration systems Energy efficiency opportunities

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Type of Cogeneration Systems

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

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Type of Cogeneration Systems Steam Turbine Cogeneration System

Widely used in CHP applications 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
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Type of Cogeneration Systems Back Pressure Steam Turbine

Steam exits the turbine at a higher pressure that the atmospheric
HP Steam

Boiler

Turbine

Advantages: -Simple configuration -Low capital cost -Low need of cooling water -High total efficiency Disadvantages: -Larger steam turbine -Electrical load and output can not be matched
Dr. Walid Abdelghaffar

Fuel

Condensate Process

LP Steam

Figure: Back pressure steam turbine

Thermal Equipment/Cogeneration

Type of Cogeneration Systems Extraction Condensing Steam Turbine

Steam obtained by extraction from an intermediate stage Remaining steam is exhausted Relatively high capital cost, lower total efficiency Control of electrical power independent of thermal load
Figure: Extraction condensing steam turbine
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar Fuel LP Steam Condensate Process HP Steam

Boiler

Turbine

Condenser

Type of Cogeneration Systems Gas Turbine Cogeneration System

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

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Typical Heat-to-Power Ratios for Energy Intensive Industries

Industry Breweries Pharmaceuticals Minimum 1.1 1.5 Maximum 4.5 2.5 Average 3.1 2.0

Fertilizer Food Paper

0.8 0.8 1.5

3.0 2.5 2.5

2 1.2 1.9

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Gas turbine based cogeneration system

This type of system works on the basic principle of Bryton cycle of thermodynamics. Air drawn from the atmosphere is compressed and mixed in a predetermined proportion with the fuel in a combustor, in which the combustion takes place. The flue gases with a very high temperature from the combustor are expanded through a gas turbine, which drives electric generator and air compressor. A portion of mechanical power is used for compression of the combustion air: the balance is converted into electric power. The exhaust flue gases from the gas turbine, typically at a high temperature of 480-540 C, acts as a heat source from which the heat is recovered in the form of steam or hot air for any desired industrial application.
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Gas turbine based cogeneration system

Industrial gas turbine based power plants installed to generate only electric power operate at the thermal efficiency of 25-35% only depending of type and size of gas turbine. Aero derivative gas turbines operate at marginal higher efficiency than the conventional industrial heavy-duty machines. With recovery of heat in exhaust flue gases in a waste heat recovery boiler (WHRB) or heat recovery steam generator (HRSG) to generate the steam, overall plant efficiency of around 85-90% is easily achieved. As an alternative, the heat of exhaust flue gases can also be diverted to heat exchanger to generate hot water or hot air (District Heating purpose in foreign countries) instead of generating steam. The Figure shows a schematic of Gas Turbine based cogeneration system.
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Gas turbine based cogeneration system with supplementary fired WHRB

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Gas turbine based cogeneration system

Compared to steam turbine based cogeneration system, the gas turbine based cogeneration system is ideal for the chemical process industries where the demand of steam is relatively high and fairly constant in comparison to that of steam. Gas turbine based cogeneration system gives a better performance with clean fuels like natural gas, or non-ash bearing or low ash bearing liquid hydrocarbon fuels like Naphtha, High speed Process Consumer diesel, etc. Though high ash bearing hydrocarbon based fuels like fuel oil, crude oil or residual fuel oil can also be fired in the gas turbines, but with some inherent problems like frequent cleaning of gas turbine, more maintenance and spares, etc.
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Type of Cogeneration Systems Open Cycle Gas Turbine

Open Brayton cycle: atmospheric air at increased pressure to combustor Old/small units: 15:1 New/large units: 30:1 Exhaust gas at 450600 oC High pressure steam produced: can drive steam turbine
Compressor Air Turbine Combustor Fuel Exhaust Gases Condensate from Process HRSG Steam to Process

G Generator

Figure: Open cycle gas turbine cogeneration

Dr. Walid Abdelghaffar

Thermal Equipment/Cogeneration

Type of Cogeneration Systems Closed Cycle Gas Turbine

Heat Source

Working fluid circulates in a closed circuit and does not cause corrosion or erosion Any fuel, nuclear or solar energy can be used

Heat Exchanger

G Generator Compressor Turbine

Condensate from Process

Steam to Process

Figure: Closed Cycle Gas Turbine Cogeneration System

Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Type of Cogeneration Systems Reciprocating Engine Cogeneration Systems

Used as direct mechanical drives Many advantages: operation, efficiency, fuel costs Used as direct mechanical drives Four sources of usable waste heat
Figure: Reciprocating engine cogeneration system (UNESCAP, 2000)
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Type of Cogeneration Systems Topping Cycle

Supplied fuel first produces power followed by thermal energy Thermal energy is a by product used for process heat or other Most popular method of cogeneration

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Type of Cogeneration Systems Bottoming Cycle

Primary fuel produces high temperature thermal energy Rejected heat is used to generate power Suitable for manufacturing processes

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Cogeneration

Introduction Types of cogeneration systems Assessment of cogeneration systems Energy efficiency opportunities

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Assessment of Cogeneration Systems Performance Terms & Definitions

Overall Plant Heat Rate (kCal/kWh):
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 )
Thermal Equipment/Cogeneration
Dr. Walid Abdelghaffar

Assessment of Cogeneration Systems

Steam Turbine Performance
Steam turbine efficiency (%):
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 )

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Assessment of Cogeneration Systems

Heat Recovery Steam Generator (HRSG) Performance
Heat recovery steam generator efficiency (%):
M s x ( hs hw ) [ 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)
Dr. Walid Abdelghaffar

x 100

Thermal Equipment/Cogeneration

Cogeneration

Introduction Types of cogeneration systems Assessment of cogeneration systems Energy efficiency opportunities

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Energy Efficiency Opportunities

Gas Turbine Cogeneration System
Gas turbine manage the following parameters: Gas temperature and pressure Part load operation and starting & stopping Temperature of hot gas and exhaust gas Mass flow through gas turbine Air pressure

Thermal Equipment/Cogeneration

Dr. Walid Abdelghaffar

Dr. Walid Abdelghaffar