Cogeneration

Rangan Banerjee
Energy Systems Engineering
IIT Bombay

Lecture at NITIE on March 18, 2004

 Utility options

PROCESS Electricity
Heat
Electricity
Heat
Fuel Heat
BOILER
Cogen Plant

Electricity
Fuel
Power Plant Fuel
Cogeneration
SHP
Cogeneration Concept
„ Boiler η 90% Power plant η 40%
„ Where is the scope for improvement?
„ Cogeneration- Simultaneous generation
of heat and power (motive power or
electricity) – CHP- Total Energy
„ Second Law of Thermodynamics –
Concept of Exergy
Early 19th century Cogeneration plant
Selection of Cogen Option
„ Heat/Power Ratio X (Range of values)
„ Fuel Availability
„ Costs

Decreasing X
„ Steam Turbine 5.9 ( 3-7)
„ Gas Turbine 1.5
„ Combined Cycle 1.2
„ D.G. Set 0.7
Evaluation Criteria
„ Relative Fuel Savings Rf – Fuel savings over
separate heat & power generation
Rf = ( Fnc – Fc) / Fnc
Fnc = Fboiler + Fpower plant
„ Fuel Chargeable to Power (FCP) – The
incremental fuel in cogeneration is charged to
the power generation.
FCP =( Fc – Fboiler)/ W
kg of oil/kWh, kJ/kWh, Nm3 gas/kWh,
kg of bagasse/kWh
Cogeneration Concept
„ Process boiler , sat steam at 180 °C
η 90% (1st law eff)
Tu= 180+273 =453 K, T0 = 300 K
„ ηII=Qu(1- T0 / Tu)/ Qinθ (for fuel θ≅ 1.0)
=0.9(1-300/453) =0.3 (30%)
„ Increase generation temperature to 400 °C
and pass through an expansion turbine
 Back Pressure Steam Turbine System
HP Steam

Fuel Electricity
ST
Air
BOILER

Water

LP Steam to
Process
Steam Turbine Cogen

Configuration X

Decreasing X
Boiler ∞
BPT with extraction 10
Back Pressure Turbine
Condensing Turbine 3
Condensing Power Plant 0
 Steam Turbine Calculations

Specific ηis = h1-h2

Enthalpy h1-h2i
1
h1

h2
2
h2i 2i

Specific Entropy s
Example Problem
A process boiler generates 25T/hour of
saturated steam at 10 bar absolute. The
fuel used is LSHS. The boiler efficiency
is 90%. The power requirement of the
industry is 2.5 MW.
Evaluate the viability of using a high
pressure boiler generating steam at 50
bar 400° C and a back pressure turbine
 GAS TURBINE BASED COGEN

Fuel
CC
Power

C GT ∼ Steam to
Process

Air

Stack
WHRB
Suppl Fuel
Feed water
Gas Turbine Cogeneration
„ Unfired Heat Recovery Steam Generator
(HRSG)
„ Supplementary Fired (Duct Burners)
„ Fully Fired HRSG
„ Steam Injected Gas Turbines (STIG)
„ Combined Cycle
Cogeneration
„ Self generated electricity in Chemical – 42%
of total elec, 86% from cogeneration plants
„ Average price – only 57% of grid price
„ Purchased electricity declining (-0.4%), self
generated elec increasing at 21.3% per year
„ Evaluate viability of Cogeneration
„ If heat/power loads small-Cogeneration for
group of industries
Operating Strategy
„ Standalone/ Isolated
„ Grid Interconnection
„ Parallel with Grid – Only Buying from grid
„ Buying and Selling to Grid

„ Thermal Load Following

„ Electrical Load Following
„ Maximum Cogeneration
 2 2 a ta 5 8 T /h r
330o C

FEED
W ATER 2 7 T /h r
4 .5 T /h r 2 6 T /h r
F eed w ater
B O IL E R
0 .5 T /h r

PRDS
BA G A SSE
0 .5 T /h r
M IL L IN G

PRDS

6 a ta

P ro cess 2 .5 M W
STEA M
F la s h e d T U R B IN E
2 a ta
C o n d e n sa te

P ro cess

S c h e m a tic o f ty p ic a l 2 5 0 0 tc d S u g a r fa c to r y
Options
„ A- Replace mill turbines by motors + power
turbine by efficient motor
„ B- New Boiler 43 ata 480 C + additional TG
„ C- HP Boiler 65 ata 480 C + additional TG
„ D – C+ replace mill turbines with TG
„ E – similar to D but with condensing
extraction turbine
 B O IL E R
F e e d w a te r
75 TPH , 65 STEA M
a ta , 4 8 0 O C T U R B IN E
9 .5 M W
13 M W P ow er export
BA G A SSE
( A lt e r n a t e f u e l) ~

6 a ta
4 .5 T P H 1 .0 M W

Condenser
M ill
PR O C ESS d r iv e s
2 a ta CO NDENSER
2 a ta
2 .5 M W
C a p tiv e
BFP lo a d
PR O C ESS

P R O P O S E D P L A N T C O N F IG U R A T IO N : O P T IO N 2
Comparison of Options
Case Output Export kWh
export /tc
A 5.4 MW 1.9 MW 18
B 7.5 MW+M 5.0 MW 48
C 6.8 MW+M 4.3 MW 41
D 10.7 MW 7.2 MW 69
E 13 MW 9.5 MW 91
Optimal Cogeneration Strategy
„ Decisions
„ Grid Electricity Bought/Sold
„ Equipment Mass Flow rates
„ Electric/Steam Drive
„ Constraints
„ Equipment Characteristics – Min/Max
„ Process Steam & Electricity Loads
„ Grid Interconnection
„ Objective Function
„ Minimise annual operating cost (Maximise
revenue)
 Stack
Fuel, HSD WHRB-1
5.9 T/h G 136 T/h
1
20 MW
Gas turbine -1 Supp. Firing
LSHS 5.6 T/h
Grid Process Load,
Fuel, HSD WHRB-2 136 T/h 7.52 MW 60 MW
5.9 T/h
G
1
Gas turbine -2 20 MW Supp. Firing BUS
LSHS 5.6 T/h
SHP Steam 100 bar,500o C

60.6 T/h
131.7 T/h 117.1 Process Load,150 T/h 76.2 T/h
T/h 12.5
Boiler
MW

ST
Fuel, LSHS Process Load,125 T/h G4
PRDS-1
9.64 T/h PRDS-2
HP Steam 41b,400 oC 20 T/h
MP Steam 20b, 300 oC

Process Load 40 T/h 49.5 T/h 40 T/h 16.2 T/h

PRDS-3
LP Steam 5. 5 b, 180 oC
53.4 T/h

Process Load Deaerator

40 T/h Feed water Condenser
426.5 T/h Make up water,357 T/h
 Import Power from Grid with
Cogeneration for a Petrochemical Plant

flat tariff TOU tariff

Import power MW

25 21.6
20 17.6 peak
period
15 demand
10
11 MW
5
0
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time hours
 Export power to the grid with
Cogeneration for a Petrochemical Plant
Peak
Export Power MW

40 period
flat tariff TOU tariff
30 demand

20 9.7 MW
10

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time hours
Summing Up
„ Even in industries with cogen – Retrofits for
additional power generation
„ Sugar –2500 tcd plant can generate 9.5 MW
surplus by using high pressure boilers
„ Grid Agreement –Parallel, Buying/Selling
„ Optimal operating strategy – can result in
significant savings
„ Significant potential in process industries
Thank You