SEMINAR ON

Cogeneration
Training Agenda: Cogeneration

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

What’s a Cogeneration/CHP System?

• 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
Introduction

Efficiency Advantage of CHP

36 Units
Conventional Generation (58% (Losses)
Overall Efficiency)

Combined Heat & Power (85%

Overall Efficiency)
24
60  = 40% Uni
ts 68
100

34
40 Uni
 = 85% ts

6 Units 10 Units
(Losses) (Losses)
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
Training Agenda: Cogeneration

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

6
Type of Cogeneration Systems

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

Back Pressure Steam Turbine

• Steam exits the turbine at a higher pressure
that the atmospheric
HP Steam
Advantages:
-Simple configuration
-Low capital cost
Boiler Turbine -Low need of cooling water
-High total efficiency
Fuel

Disadvantages:
Condensate
Process
LP
Steam
-Larger steam turbine
-Electrical load and output
can not be matched

Figure: Back pressure steam turbine

 Type of Cogeneration Systems

Extraction Condensing Steam

Turbine HP Steam

• Steam obtained by
extraction from an Boiler Turbine

intermediate stage Fuel

• Remaining steam is Condensate

LP Steam

Process
exhausted
• Relatively high
capital cost, lower Condenser

total efficiency
• Control of electrical
power independent of Figure: Extraction condensing steam turbine
thermal load
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
Type of Cogeneration Systems

Open Cycle Gas Turbine

Exhaust
Gases
• Open Brayton cycle: Condensate
atmospheric air at from Process

increased pressure to HRSG

combustor Steam to
Process

• Old/small units: 15:1 Fuel

Combustor

New/large units: 30:1

• Exhaust gas at 450-
600 oC G

Generator

• High pressure steam Compressor Turbine

produced: can drive Air

steam turbine Figure: Open cycle gas turbine cogeneration

Type of Cogeneration Systems

Closed Cycle Gas Turbine

Heat Source

• Working fluid circulates

in a closed circuit and Heat Exchanger

does not cause

corrosion or erosion G

Generator

• Any fuel, nuclear or Compressor Turbine

solar energy can be

used Condensate
from Process

Steam to
Process

Figure: Closed Cycle Gas Turbine Cogeneration System

 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)
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
Type of Cogeneration Systems

Bottoming Cycle
• Primary fuel produces high
temperature thermal energy
• Rejected heat is used to generate
power
• Suitable for manufacturing processes
Training Agenda: Cogeneration

Introduction
Types of cogeneration systems
Assessment of cogeneration systems
Energy efficiency opportunities
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 )
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 )
Assessment of Cogeneration
Systems

Heat Recovery Steam Generator (HRSG)

Performance
• Heat recovery steam generator efficiency
(%):
M s x ( hs  hw )
x 100
[ 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)
Training Agenda: Cogeneration

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

Steam Turbine Cogeneration System

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

 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
 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 GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is
available on www.energyefficiencyasia.org