Power Plant Engineering (22566) UNIT - IV

UNIT – IV
WASTE HEAT RECOVERY,
COGENERATION AND
TRIGENERATION
(14 Marks)
Waste heat recovery, cogeneration and Trigeneration
4.1 Waste heat recovery in thermal power plants need, opportunities,
present practices
4.2 Cogeneration : need, opportunities, present practices
4.3 Trigeneration : need, opportunities, present practices

Mr. YUGAL V. BHAISARE (LME) Page 1

Power Plant Engineering (22566) UNIT - IV

UNIT – IV
WASTE HEAT RECOVERY, COGENERATION
AND TRIGENERATION
 Waste heat :
1. Waste heat is heat, which is generated in a process by way of fuel combustion or
chemical reaction, and then “dumped” into the environment even though it could still
be reused for some useful and economic purpose.
2. The essential quality of heat is not the amount but rather its “value”. The strategy of
how to recover this heat depends in part on the temperature of the waste heat gases
and the economics involved.

 Waste Heat Recovery :

1. Waste heat recovery can be defined as. the process of collecting the heat created as an
undesired byproduct of a process or operation of an equipment or machinery, so that,
it can be used to fulfill energy requirements of some other processes or applications."
2. Waste heat recovery can also be defined as. "the process of recovering heat from hot
streams having high energy content such as hot flue gases from a thermal power plant,
gas turbine power plant, internal combustion engines, diesel generator etc or even
waste water from different cooling processes such as steel cooling.'

 Need of Waste Heat Recovery :

The need of waste Heat Recovery is due to this benefits :

Benefits of 'waste heat recovery' can be broadly classified in two categories:

Direct Benefits: Recovery of waste heat has a direct effect on the efficiency of the process.
This is reflected by reduction in the utility consumption & costs, and process cost.

Indirect Benefits:

a) Reduction in pollution: A number of toxic combustible wastes such as carbon monoxide

gas, sour gas, carbon black off gases, oil sludge, Acrylonitrile and other plastic chemicals etc,
releasing to atmosphere if/when burnt in the incinerators serves dual purpose i.e. recovers
heat and reduces the environmental pollution levels.

b) Reduction in equipment sizes: Waste heat recovery reduces the fuel consumption, which
leads to reduction in the flue gas produced. This results in reduction in equipment sizes of all
flue gas handling equipments such as fans, stacks, ducts, burners, etc.

c) Reduction in auxiliary energy consumption: Reduction in equipment sizes gives

additional benefits in the form of reduction in auxiliary energy consumption like electricity
for fans, pumps etc..

d) To reduce operating costs:

By recycling and reusing the waste heat energy, there will be less consumption of fuel. It
will reduce the operating cost of industry. This can help to save money on operating costs.

Mr. YUGAL V. BHAISARE (LME) Page 2

Power Plant Engineering (22566) UNIT - IV

e) To decrease waste and emissions:

By capturing and repurposing waste heat with a waste heat recovery unit, we can
significantly decrease the waste and emissions generated by industry, More and more
governments around the world will probably start charging industries for
emitting C02 and NOx.

f) To make huge savings and earn high profit:

By switching to the most energy-efficient technology available, companies can make huge
savings and significantly reduce environmental impact, o In other words, industry will gain
higher profit.

g) Increased demand:
In the "World Energy Outlook" report, the International Energy Agency (IEA) predicts world
energy demand to increase by 45% over the next 20 years,
In that situation, it is also predicted that, the supply of fossil fuels will not be able to meet this
demand.

h) To challenge and face higher energy prices:

o Day by day, prices of fossil fuels and other sources of energy are increasing.
o Therefore, if energy is not saved and conserved by adopting various technologies including
the waste heat recovery method, it will be difficult for the industries to run and sustain in
competition to other industries.

The only disadvantage of waste heat recovery is that system has high initial cost.

 Classification of Waste Heat Recovery :

The waste heat is generally classified into two categories:
1. High grade heat above 300 C:
o The high grade waste heat carried away by flue gases can be recovered with the help of
property
designed heat transfer equipment,
o The use of high grade waste heat is the result of technical necessity rather than economical
reasons.
 Source: High grade waste heat is in the form of flue gases and can be readily
recovered through heat transfer equipments.

2. Low grade heat below 300 C:

o Low grade waste heat is usually in the form of process steam and drain waters, o
Previously, this type of heat was not considered to be economical and feasible,
o But now-a-days due to energy shortages and higher energy prices, a number of
economically
feasible methods have been identified due to development of new energy storage system,
 Source: Low grade heat is in the form of process steam and rain water, commonly
found in many industrial plants like food processing chemical industries.

Mr. YUGAL V. BHAISARE (LME) Page 3

Power Plant Engineering (22566) UNIT - IV

 Sources of Waste Heat and Quality :

 Heat Recovery Methods :

a) Sensible heat method
b) Latent heat method

a) Sensible heat method :

The most commonly used sensible heat recovery devices are:
1. Recuperator, 2. Counter flow type gas-air heaters, 3. Regenerators, 4. Heat pipe.

1. Recuperator :
1. Recuperator is a form of heat exchanger.
2. The tubes carry and other side contains waste heat stream (i.e. flue gases).
3. A metallic recuperator consists of two concentric metal tubing. Refer fig. 5.1,
showing parallel flow type and counter flow type "tube in tube" recuperator.

Mr. YUGAL V. BHAISARE (LME) Page 4

Power Plant Engineering (22566) UNIT - IV

4. The inner tube carries hot exhaust flue gases, while the external annular area carries
the combustion air from the atmosphere going to the inlet of furnace burners.
5. The air needed for combustion is preheated with the help of heat carried by exhaust
flue gases. Now, the combustion air carries additional energy (heat) while entering
into the combustion chamber. This reduces the energy to be supplied by the fuel in the
combustion chamber; which reduces less quantity of fuel to be burnt for same furnace
loading.

 Factors deciding the application of waste heat recovery

The usefulness of heal sources for the purpose of waste heat recovery depends upon
1. Temperature: The higher the temperature of the medium, the higher its entropy, which
allows a larger portion of the heal to be converted to useful work.
2. Available amount of heat.
3. Amount of heat, which can be recovered.

 Applications of waste heat recovery

Common applications of waste heat recovered are:

1. Pre-heating combustion air for boilers, ovens and furnaces.
2. Pre-heating fresh air used to ventilate the building.
3. Hot water generation including preheating boiler feed water.
4. Direct steam generation for process or power generation.
5. Space heating.
6. Drying.
Special applications of waste heat recovered are:
1. Animal shelters.
2. Aqua-cultural uses.
3. Green houses.
4. Agricultural uses.
5. Process heating.

 COGENERATION
1. cogeneration is also called as combined heat and power or combine heat and
power. As it name indicates cogeneration works on concept of producing two
different form of energy by using one single source of fuel.
2. Out of these two forms one must be heat or thermal energy and other one is either
electrical or mechanical energy.
3. Cogeneration is the most optimum, reliable, clean and efficient way of utilizing
fuel. The fuel used may be natural gas, oil, diesel, propane, wood, bassage, coal
etc.

 Working principle of cogeneration

1. Definition of cogeneration : the term cogeneration is defined as sequential

generation or the combination of two energies forms of useful energy from a
single primary energy source used for the generation of electrical energy as
well as heat.

Mr. YUGAL V. BHAISARE (LME) Page 5

Power Plant Engineering (22566) UNIT - IV

2. This is an most efficient method of energy utilization in which 40% energy

saving when we compared by the separate acquire of electricity from the
national grid as well as a gas boiler.
3. Combine heat and power plants are normally situated near to the consumer end
so the transportation and distribution losses will be reduced thus it improve
permormance in the electricity transmission and distribution.
4. For power consumers where the safety of supply is a significant factor for their
power selection manufacture apparatus and gas is plentiful.
5. The cogeneration system based on gas are preferably suited as captive power
plants.

 Opportunities for Cogeneration :

1. In India present liberalized economy, the several and growth of small scale
industry largely depends on its ability to innovate, improve operational
efficiently and increase productivity.
2. The following areas are critical for obtaining best results from cogeneration:
a. Improve technical and operating efficiency of the existing plant.
b. Replacing inefficient machinery with new energy efficient equipment.
c. Adopting various means of energy conservation
d. Optimal design and effective implementation of cogeneration projects.

 Need for cogeneration

Cogeneration helps to improve the efficiency of the plant.
1. Cogeneration reduce air emissions of particulate matter, nitrous oxides, sulphur
dioxide, mercury and carbon dioxide which would otherwise leads to greenhouse
effect.
2. It reduces cost of production and improve productivity.
3. Cogeneration system helps to save water consumption and water costs.
4. Cogeneration system is more economical as compared to conventional power plant.

Mr. YUGAL V. BHAISARE (LME) Page 6

Power Plant Engineering (22566) UNIT - IV

 Classification of Cogeneration System :

There are basically two types of cogeneration power plants, such as-

 Topping cycle power plant

 Bottoming cycle power plant

 Topping Cycle Power Plant

In this type of Combine Heat and Power plant electricity is generated first and then waste or
exhaust steam is used to heating water or building. There are basically four types of topping
cycles.

1. Combined-cycle topping CHP plant-

a. In this type of plant the fuel is firstly burnt in a steam boiler.
b. The steam so produced in a boiler is used to drive turbine and hence synchronous
generator which in turn produces electrical energy.
c. The exhaust from this turbine can be either used to provide usable heat, or can be send
to a heat recovery system to generate steam, which maybe further used to drive a
secondary steam turbine.
d. In the initial stages, combustion gases are produced in the combustion chamber by
burning fuel and supplying air for combustion.
e. Mechanical and then electrical power is conventionally produced.

2. Steam-turbine topping CHP Plant-

a. In this the fuel is burned to produce steam, which generates power.
b. The exhaust steam is then used as low-pressure process steam to heat water for various
purposes.
c. High pressure drives the steam turbine which drives the generator. From the generator,
Boiler HP useful electrical energy is produced.
d. Now doing the work by high pressure steam in the turbine, steam outlet from turbine is
a steam at low pressure. It can be used other purposes.

Mr. YUGAL V. BHAISARE (LME) Page 7

Power Plant Engineering (22566) UNIT - IV

3. Water turbine topping CHP Plant / Heat Recovery Topping System-

a. In this type of CHP plant a jacket of cooling water is run through a heat recovery
system to generate steam or hot water for space heating.
b. This is the system of diesel engine which is used to produce electrical energy.
c. After doing the necessary work of driving the generator, the heat is exhausted from the
engine and its heat energy is reused for jacket cooling water water and in heat recovery
boiler.
d. In this way, co-generation is met with and it helps in energy conservation.

4. Gas turbine topping CHP plant-

a) In This topping plant a natural gas fired turbine is used to drives
a synchronous generator to produce electricity.
b) The exhaust gas is sent to a heat recovery boiler where it is used to convert
water into steam, or to make usable heat for heating purposes.
c) Gas turbine requires gas at high pressure.
d) This gas is obtained by firing the fuel in combustion chamber in which fuel is
fired and air intake is supplied in the chamber.
e) High pressure gas from the combustion chamber enters in the gas turbine.
Turbine shaft rotates which in turn rotates the generator to produce useful
electrical energy output.
f) After doing the useful work in the turbine, gas is out at low pressure.

Mr. YUGAL V. BHAISARE (LME) Page 8

 Power Plant Engineering (22566) UNIT - IV

 Bottoming Cycle Power Plant

As its name indicate bottoming cycle is exactly opposite of topping cycle. In this type of CHP
plant the excess heat from a manufacturing process is used to generate steam, and this steam
is used for generating electrical energy. In this type of cycle no extra fuel is required to
produce electricity, as fuel is already burnt in production process.
The main equipments are :
(1) Turbine as a prime mover of generator
(2) AC generator
(3) Heat recovery boiler
(4) Exhaust gas carrying arrangement
(5) Plant processor
 Useful heat is produced by fuel firing.
 Heat recovery boiler recovers the rejected heat and fed to turbine. Mechanical energy of
turbine rotates the generator and electrical energy is produced.
 A big plant has left over gases which are recovered and used for co-generation.
 The process of co-generation is shown in Figure

Mr. YUGAL V. BHAISARE (LME) Page 9

Power Plant Engineering (22566) UNIT - IV

 Factors Influencing the choice of type of Cogeneration power plant :

Following various factors of the cogeneration system as:

1. Electrical load matching :

o In the base electrical load matching, size of cogeneration plant is chosen to fulfill
minimum demand curve. The remaining power need is satisfied by purchasing from the
utility.

2. Thermal load matching :

o In base thermal load matching, minimum heat requirement of the premises is considered
while sizing of the cogeneration plant. auxiliary boilers can supply heat in case of
additional heating needs. If excess thermal energy is available it can be exported to the
needy places.

3. Thermal to electrical energy ratio:

o This is also called as heat to power ratio.
o Heat to power ratio is one of the most influential technical parameters which can govern
the selection of cogeneration system.

4. Quality of required thermal energy:

o Quality of thermal energy refers to the temperature and pressures of the steam which can
be an attributing factor for the selection of cogeneration scheme.

5. Fuel availability:
o The type of readily available fuel is also an important consideration while choosing a
cogeneration system. Almost every fuel can be used by a system having compatibility
with the same.

6. Installation and available space:

o cogeneration system may depend upon whether it’s a retrofit or new installation.

7. Grid-connected/independent system:
o Technical design of cogeneration plant may depend upon whether its connected to grid
or it’s a standalone system.

8. Operational costs :
o Operational cost is amongst the key factors to be considered while choosing a type
of cogeneration system.

9. Pollution concern:
o These factors are gaining importance in the recent times, needs more attention in the
thickly populated area.

Advantages of Cogeneration :
 Energy efficiency and high yields
 Quality and safety in the power supply (reducing energy dependence)
 Distributed generation, with an independent main network and no transport losses
 High operational availability (also in stand-alone systems)
 Industrial competitiveness (its efficiency enhances economic growth and
employment)

Mr. YUGAL V. BHAISARE (LME) Page 10

Power Plant Engineering (22566) UNIT - IV

 Respect for the environment, linked to the reduction in energy consumption and the
use of cleaner fuels

Disadvantages of cogeneration :
 High capital cost.
 Moderate efficiency, if it runs at part load instead of full load.

Applications of cogeneration :
 Waste water treatment
 Military
 Industry
 Data centers
 Hotels
 Hospitals
 Prisons
 Education establishements
 Horticulture
 Buildings
 Sports centers
 Swimming pools
 Nursing homes

 TRIGENERATION
1. Trigeneration is the production of combined cooling, heat, and power from a single generator
or process. The trigeneration system produces electricity and useful heat which is utilised for
hot water, space heating or steam production, as well as energy efficient cooling.
2. Trigeneration is sometimes referred to as CCHP or combined cooling, heat and power.

Mr. YUGAL V. BHAISARE (LME) Page 11

Power Plant Engineering (22566) UNIT - IV

 Working Principle of Trigeneration :

1. Defination : Trigeneration is defined as the production of electricity in the simultaneous
process of cooling, heating and power generation from onlu one fuel input in the one
process.
2. Typically gas fired generators are used to produce electricity. The by-product is waste
heat, which is then directed to absorption chillers and boilers for space cooling, hot water
and related purpose.
3. India’s growing access to natural gas, a typical input for trigeneration system and the
cleanest burning hydrocarbon, will greatly enable wider adoption of trigeneration.
4. A VAR system to produce cooling, the device thus facilitates combined heat power and
cooling form a single fuel input.
5. The heat produced by cogeneration can be deliverd through various mediums, including
warm water e.g., for space heating and hot water system , steam or hot air e.g. for
commercial and industrial uses.

 Opportunities of trigeneration :
1. Trigeneration technology is a transformative cost effective solution that enables
localized, reliable and stable power supply, using a single fuel.
2. This technology has been successful in international markets in enhancing operating
efficiency of an industrial application by atleast 60%, saving industries and
institutions 30-40% in operating energy costs and reducing greenhouse gas emission
by upto 30% due to inherent efficiencies in energy generation.
3. The technology has direct relevance to hostels, hospitals, airports and integrated
commercial and residential complex that require all forms of building energy
simultaneously.
4. At 60-80% efficiency, trigeneration system, which can use natural gas as fuel, are
highly efficient and be installed, started and stopped quickly.

Mr. YUGAL V. BHAISARE (LME) Page 12

Power Plant Engineering (22566) UNIT - IV

5. Tri generation system will especially benefit one of India’s most energy intense
industry-buildings, which annually constitute over 30% of the total electricity
consumed in India annually.
6. The demand for air conditioning, heating and electricity in these buildings are large
institutions can be met by installing trigeneration system that not only generate energy
saving by also reduce carbon emission.
7. The current installed capacity in India is less than 1000 MW and operating capacity is
no more than half of this.

 Need for Trigeneration :

Trigeneration is need because of following Benefits

1. Energy savings – reduced power costs by utilising the existing waste heat produced
during electricity generation to heat water or use as central heating, as well as produce
cooling for air conditioning systems or refrigeration units.
2. Reduced environmental impact – trigeneration is an energy efficient method of power
creation, offering around 30% reduction in greenhouse gas emissions compared with
mains grid power production.
3. Trigen can be used either as the main source of power, heat and cooling for your
property or business or as a backup measure in case of mains power outages.
4. It’s ideal for remote area use or use in areas which experience extreme weather events
such as cyclones, tropical storms, or flooding reducing the risk of power outs.
5. Reliable independent power source – you control the electricity, heat, and cooling
generation removing the inconvenience of grid peak management interruptions.
6. Trigen offers a range of fuel choices – trigeneration systems can be set up to operate
using fuels such as natural gas, diesel, biogas, or LPG as well as dual fuel
combinations.
7. Variable output – trigeneration systems can provide for varied and constantly
changing power, heat, and cooling requirements.
8. Increased fuel efficiency – from a single fuel 3 essential systems are supplied.
9. Reduced energy costs – reduced energy costs due to the removal of reliance on costly
mains grid peak tariffs.

Mr. YUGAL V. BHAISARE (LME) Page 13

Power Plant Engineering (22566) UNIT - IV

 Advantages of trigeneration systems over conventional refrigeration

technology
1. Operated with heat, utilizing relatively inexpensive “excess energy”
2. Produced electricity can be fed into the public grid or used to cover electricity
requirements of the plant
3. During cold seasons the heat can be utilized to cover heat requirements
4. No moving parts in absorption chillers, no wear and therefore low maintenance
expenses
5. Noiseless operation of the absorption system
6. Low operating costs and life-cycle costs
7. Water as refrigerant, no use of ozone-damaging substances Absorption-type
refrigeration technology offers the most established and economic solution for
reduced emission, air conditioning systems.

 Disadvantages of trigeneration systems

1. High capital cost
2. More research work is needed
3. Intense planning is required for the designing of trigeneration
4. Applicability differs with each project.

 Applications of trigeneration systems

1. Data centers
2. Food processing industries
3. Manufacturing units
4. College and universities
5. Theaters
6. Resort
7. Casinos
8. Airports
9. Shopping centers
10. Military complex

Mr. YUGAL V. BHAISARE (LME) Page 14

Power Plant Engineering (22566) UNIT - IV

Frequently asked questions in MSBTE

Sr Question Session Marks
no.
1 State the necessity of waste heat recovery in
w-19, W-22 2
thermal power plant.
2 Explain the working principle of cogeneration
W-19 4
with neat sketch.
3 Explain the concept of trigeneration and enlist the
W-19 4
opportunity in thermal power plant.
4 State the present practices in cogeneration. W-22 4
5 Explain the term trigeneration. W-22 4

Assignment 04
1. State the necessity of waste heat recovery in thermal power plant.
2. Explain the working principle of cogeneration with neat sketch.
3. Explain the concept of trigeneration and enlist the opportunity in thermal power plant.
4. State the present practices in cogeneration.
5. Explain the term trigeneration.

____________________________

Mr. YUGAL V. BHAISARE (LME) Page 15