1

Training Session on Energy

Equipment

Cogeneration

Presentation from the
Energy Efficiency Guide for Industry in Asia
www.energyefficiency.asia.org
UNEP 2006
2

UNEP 2006
Training Agenda: Cogeneration
Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities
3

UNEP 2006
Introduction
Generation of multiple forms of
energy in one system: heat and
power
Defined by its prime movers
Reciprocating engines
Combustion or gas turbines,
Steam turbines
Microturbines
Fuel cells
Whats a Cogeneration/CHP System?
4

UNEP 2006
Introduction
Efficiency Advantage of CHP
100
68
24
Uni
ts
34
Uni
ts
6 Units
(Losses)
60
40
36 Units
(Losses)
= 85%
= 40%
10 Units
(Losses)
Conventional Generation (58%
Overall Efficiency)
Combined Heat & Power (85%
Overall Efficiency)
(UNESCAP, 2004)
5

UNEP 2006
Introduction
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
Benefits of Cogeneration / CHP)
6

UNEP 2006
Training Agenda: Cogeneration
Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities
7

UNEP 2006
Type of Cogeneration Systems
Steam turbine
Gas turbine
Reciprocating engine
Other classifications:
- Topping cycle
- Bottoming cycle

8

UNEP 2006
Type of Cogeneration Systems
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
Steam Turbine Cogeneration System
9

UNEP 2006
Steam exits the turbine at a higher pressure
that the atmospheric
Back Pressure Steam Turbine
Fuel
Figure: Back pressure steam 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
Boiler
Turbine
Process
HP Steam
Condensate
LP
Steam

Type of Cogeneration Systems
10

UNEP 2006
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
Extraction Condensing Steam
Turbine
Boiler
Turbine
Process
HP Steam
LP Steam
Condensate
Condenser

Fuel
Figure: Extraction condensing steam turbine
Type of Cogeneration Systems
11

UNEP 2006
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
Gas Turbine Cogeneration System
Type of Cogeneration Systems
12

UNEP 2006
Open Brayton cycle:
atmospheric air at
increased pressure to
combustor
Open Cycle Gas Turbine
Air
G
Compressor
Turbine
HRSG
Combustor
Fuel
Generator
Exhaust
Gases
Condensate
from Process
Steam to
Process
Old/small units: 15:1
New/large units: 30:1
Exhaust gas at 450-
600
o
C
High pressure steam
produced: can drive
steam turbine
Figure: Open cycle gas turbine cogeneration
Type of Cogeneration Systems
13

UNEP 2006
Working fluid circulates
in a closed circuit and
does not cause
corrosion or erosion
Any fuel, nuclear or
solar energy can be
used
Closed Cycle Gas Turbine
Heat Source
G
Compressor
Turbine
Generator
Condensate
from Process
Steam to
Process
Heat Exchanger
Figure: Closed Cycle Gas Turbine Cogeneration System
Type of Cogeneration Systems
14

UNEP 2006
Used as direct mechanical drives
Reciprocating Engine Cogeneration
Systems
Figure: Reciprocating engine cogeneration system
(UNESCAP, 2000)
Many advantages:
operation,
efficiency, fuel
costs
Used as direct
mechanical drives
Four sources of
usable waste heat
Type of Cogeneration Systems
15

UNEP 2006
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
Topping Cycle
Type of Cogeneration Systems
16

UNEP 2006
Bottoming Cycle
Primary fuel produces high
temperature thermal energy
Rejected heat is used to generate
power
Suitable for manufacturing processes
Type of Cogeneration Systems
17

UNEP 2006
Training Agenda: Cogeneration
Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities
18

UNEP 2006
Assessment of Cogeneration
Systems
Overall Plant Heat Rate (kCal/kWh):




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)
Performance Terms & Definitions
) (
) (
kW Output Power
hw hs x Ms
) (
) / ( *
kW Output Power
hr kg n Consumptio Fuel
19

UNEP 2006
Steam turbine efficiency (%):
Steam Turbine Performance
Gas Turbine Performance
Overall gas turbine efficiency (%) (turbine
compressor):

100
) / (
) / (
x
kg kCal Turbine the across drop Enthalpy Isentropic
kg kCal Turbine the across Drop Enthalpy Actual
100
) / ( ) / (
860 ) (
x
kg kCal Fuel of GCV x hr kg Turbine Gas for Input Fuel
x kW Output Power
Assessment of Cogeneration
Systems
20

UNEP 2006
Heat recovery steam generator efficiency
(%):


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 (
0
C)
t-out = Outlet Temperature of Flue Gas (
0
C)
Maux = Auxiliary Fuel Consumption (kg/hr)
Heat Recovery Steam Generator (HRSG)
Performance
100
)] / ( [ )] ( [
) (
x
kg kCal Fuel of GCV x M t t Cp x M
h h x M
aux out in f
w s s


Assessment of Cogeneration
Systems
21

UNEP 2006
Training Agenda: Cogeneration
Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities
22

UNEP 2006
Energy Efficiency Opportunities
Steam turbine:
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
Steam Turbine Cogeneration System
23

UNEP 2006
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

Air compressors see compressors chapter
Heat recovery system generator see waste
heat recovery chapter
24
Training Session on Energy
Equipment

Cogeneration


THANK YOU
FOR YOUR ATTENTION

UNEP GERIAP

25

UNEP 2006
Disclaimer and References
This PowerPoint training session was prepared as part of
the project Greenhouse Gas Emission Reduction from
Industry in Asia and the Pacific (GERIAP). While
reasonable efforts have been made to ensure that the
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 GERI AP project was funded by the Swedish
I nternational Development Cooperation Agency (Sida)
Full references are included in the textbook chapter that is
available on www.energyefficiencyasia.org