Cogeneration

Cogeneration and distribution network

Flue gases Exhaust heat

(~ 550 °C) (~150 °C)
Fuel Steam
Air
Fuel HRSG Water
Electricity
Generator

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 Cogeneration

Standby power generation

Gas Turbine
Fuel supply 100 (or) 33 Stand-by Power
Diesel Engine

67
Exhaust Heat
(300 - 500 °C)

• Meet essential loads in case of failure in grid supply

• Operation only during a few hours per year
• Can be employed during utility peak period
• Investment with no economic returns
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 Cogeneration

Cogeneration vs. separate generation

 40% potential for energy savings

Electricity
30 Input for
Input
Energy Power
Energy
Needs of a Generation
100 Facility
86
Heat Heat Loss Input
45 56 Energy
Heat Loss Input for
25 140
Boiler
54
Heat Loss
9
(i) Cogeneration System (ii) Separate Generation
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 Cogeneration

Environmental benefit of cogeneration

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 Cogeneration

Steam turbine cogeneration

Boiler 10
Losses

BOILER

TURBINE
60 b ALTERNATOR
480°C
93%
11
90
Electricity

7 bar 1
Electro-mechanical
78 Losses
90%
Fuel
Heat
100 Utilisation

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 Cogeneration

Example: steam turbine cogeneration

Steam: 100 bar/450 oC

12.73 t/h (11.47 MW)
Electricity
Fuel 800 kW
10.6 MW Boiler
= 90% ST
130 cC, 12.73 t/h, (1.93 MW)

Steam: 12 bar/237 oC
Water: 70 oC Steam to Process
1.23 t/h (0.99 MW)
11.5 t/h, 12 bar/237 oC
(0.94 MW) 6 t/h (4.84 MW)

56 bar/380 oC
5.5 t/h (4.79 MW)

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 Cogeneration

Reciprocating engine cogeneration

13 Exhaust
BOILER Losses

Fuel
100 Steam
32 or
Hot Water

ALTERNATOR

38

Electricity

RECIPROCATING
ENGINE
5 10
Low Temperature 2
Losses Water
(40° - 65°C) Losses

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 Cogeneration

Gas turbine cogeneration

Exhaust Recovery Unit

Exhaust
Losses
450 to 550°C 900°C

Gas Turbine

C T
Air

Steam or
Hot Water

Emergency Fan
Water

Fuel

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 Cogeneration

Example: gas turbine cogeneration

160 oC 56 bar/271 OC
5.5 t/h,
(4.26 MW)

HRSG
Fuel
16.7 MW
Air
Exhaust
18.8 kg/s 12 bar/188 OC
545 oC 6 t/h,
4700 kW Supplementary (4.64 MW)
Firing
Fuel: 200 kW
C T Steam
56 bar/271OC
1.05 t/h,
(0.81 kW)
Efficiency:
Water: 70 oC
Gas Turbine: 28%
11.5 t/hr
Total Thermal: 75%
(0.94 MW)
Load Point: Water
Process Steam 120 OC
11.5 t/h 12.55 t/h (1.76 kW)

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 Cogeneration

Cogeneration with cold post-combustion

Exhaust Steam or
Hot Water

Recovery Unit
Waste
Heat
450 to 550°C 150 to 200°C

Gas Turbine
Conventional
C T Boiler
Air

Steam or
Hot Water

Water Water

Fuel

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 Cogeneration

Example: combined cycle cogeneration

Stack
8.8%, 34.3 MW

Fuel: 100%

HRSG
11.7%: 315.1 MW Water
88.3%: 3114.6 MW

Air
238.7 64.2%
Comb. MW 3 83.5 MW
HP Steam:
6.8%: 26.3 MW
C T MP Steam:
13.9%: 53.8 MW

Electricity Cooling Water

27%: 335 MW 12.3%: 47.8 MW 31.2%: 121.4 MW
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 Cogeneration

Cogeneration: technical parameters

• Heat to power ratio

• Quality of thermal energy needed
• Load pattern
• Fuel availability
• Required system reliability
• Local environmental regulations
• Grid dependency
• Option to export electricity to the grid

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 Cogeneration

Cogeneration: economic parameters

• Investment on cogeneration plant

• Quality of thermal energy needed
• Fuel cost
• Electricity rate (buy & sale)
• Operation & Maintenance costs
• Depreciation
• Taxes and insurance costs
• Land for cogeneration facility

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 Cogeneration

Concept of trigeneration

STEAM

Heat HOT
Exchanger
WATER
Steam
Hot Chiller CHILLED
Gases WATER
HRSG
Steam Steam
Turbine

Generator
AIR ELECTRICITY
Generator
Gas Turbine
FUEL
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 Cogeneration

Cooling with vapour absorption chiller

Cooling water

Heat
input
Cooling water

Chilled water

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 Cogeneration

Cooling with vapour absorption chiller

1325 kW
1000 kW
325 kW

Fuel Input Generator

4373 kW Gas Turbine Compression
Exhaust Chiller 500 RT
Cooling

1000 kW

Fuel Input Generator

3300 kW Gas Turbine
2.25 Tons/hr 500 RT
Absorption Cooling
Recovery of Steam Chiller
Boiler
Exhaust
16 Heat
 Cogeneration

Thermal energy storage

• Peak cooling demand: 1 500 RT

• Chiller size to meet the peak demand: 1 500 RT
1600
1500
Column 1
1200
Cooling load (RT)

800

400

0
2 4 6 8 10 12 14 16 18 20 22 24
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 Cogeneration

Thermal energy storage

• Downsize the chiller to 625 RT and install a cool

thermal storage (continuous operation over 24 hours)
1600
200 – 625 RT
Average load (RT)
1200
Cooling load (RT)

800 Chiller

400

0 – 425 RT 0 – 875 RT
0 Thermal Storage

2 4 6 8 10 12 14 16 18 20 22 24
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 Cogeneration

District energy (heating/cooling) network

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 Cogeneration

Benefits of district energy network

• Larger cogeneration system – economy of scale

• System expansion to users for whom individual
facility cannot be justified
• Improvement in the overall system efficiency
• Increased reliability and availability of utility
services

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 Cogeneration

Benefits of district energy network

• Pooling of maintenance personnel and reduction in

manpower cost
• Saving of mechanical room space in the user
buildings
• Purchase of fuel at more competitive rate
• Better negotiation with the Power Utility for the
purchase/sale of electricity

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 Cogeneration

Typical cogeneration applications

• Industrial cogeneration
– Processes requiring low-temperature process heat
• Food processing
• Pharmaceutical
• Pulp & Paper
• Textile
– Processes requiring high temperature process heat
• Steel
• Cement
• Glass
• Ceramic
• Utility cogeneration
– District heating and cooling

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 Cogeneration

Example: cogeneration in a paper mill

Site: Paper Mill

Energy Demand: Electricity and process steam

Existing Facility: 3 Coal and fuel oil fired boilers

1 Turbo-alternator of 3.5 MVA

System : Gas turbine with alternator (4500 kW)

Exhaust gas at 510oC used as combustion
air in existing boiler (8 t/h steam)

Performance: Overall Efficiency (80%)

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 Cogeneration

Cogeneration in sugar industry

Process energy required:

25-30 kWh/tonne of sugarcane
0.4 tonne of steam
1 tonne of
sugarcane 100-120 kg
Sugar

Waste:
290 kg Bagasse ~ 100 kWh
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 Cogeneration

Cogeneration in a sugar mill

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 Cogeneration

Cogeneration in rice industry

Process energy required:

Paddy milling and drying: 30-60 kWh/tonne paddy

650-700 kg
1 tonne of
White rice
Paddy

Waste:
220 kg Husks ~ 90 -125 kWh
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 Cogeneration

Cogeneration in a rice mill

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 Cogeneration

Cogeneration in palm oil industry

Process energy required:

20-25 kWh/t
0.73 tonne of steam
1 tonne of fresh
fruit bunches

200 kg
palm oil
Waste:
600-700 kg POME ~ 20 m3 biogas
190 kg fibers + shells }
~ 120 kWh
230 kg empty fruit bunches }

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 Cogeneration

Cogeneration in palm oil industry

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 Cogeneration

Cogeneration in wood industry

process steam cooling

deaerator tower
condenser
water
treatment turbine turbine
No. 1 No. 2
600 kW receiver 900 kW
(6 bar) chimney

dust collector
ID fan

SILO 2

SILO 1 superheater

conveyor boiler
screws

boiler screws
conveyor belts
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 Cogeneration

Cogeneration in an industrial estate

• Cogeneration company created in October 1993

• 300 MW gas-fired combined cycle power plant
– In 2 phases: 3 x 35 MW gas turbines with heat recovery
steam generator + 1 x 50 MW steam turbine
– Production in each phase: 150 MW electricity and 145 T/h
steam (6 T/h at 52 Bar & 425°C; 85 T/h at 19 Bar & 250°C)
– Sale of steam, electricity and demineralised water to
industrial customers; sale of surplus power to utility grid
• Power generation efficiency
– Combined cycle: 45.14%
– Overall efficiency: 69.5%
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 Cogeneration

Cogeneration in an industrial estate

• Long-term natural gas supply agreement

• Promotional support from the Board of Investment
– Duty exemption or reduction on machinery imported
– Income tax exemption for 8 years
– Income tax deduction on dividends to shareholders

• Low capital cost: about 3/4th of the steam power

plant
• Short implementation time with pre-engineered
modules

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