COGENERATION

By
NATIONAL PRODUCTIVITY COUNCIL
INDIA
Principle of Cogeneration
Through separate heat and power route
primary energy input in power plant will be 60 units
(24/0.40)
If a separate boiler is used for steam generation then the
fuel input to boiler will be 40 units (34/0.85).

If the plant had cogeneration then the fuel input will be only
68 units (24+34)/0.85 to meet both electrical and thermal
energy requirements

It can be observed that the losses, which were 42 units in

the case of, separate heat and power has reduced to 10
units in cogeneration mode

Along with the saving of fossil fuels, cogeneration also

allows to reduce the emission of greenhouse gases
(particularly CO2 emission). The production of electricity
being on-site, the burden on the utility network is reduced
and the transmission line losses eliminated
Steam turbine cogeneration systems
 Steam turbine cogeneration features

• The choice between backpressure turbine and extraction-condensing

turbine depends mainly on the quantities of power and heat, quality of
heat, and economic factors
• option for using a wide variety of conventional as well as alternative fuels
such as coal, natural gas, fuel oil and biomass
• power generation efficiency of the cycle may be sacrificed to some extent
in order to optimize heat supply
• In backpressure cogeneration plants, there is no need for large cooling
towers
• Steam turbines are mostly used where the demand for electricity is
greater than one MW up to a few hundreds of MW
• Due to the system inertia, their operation is not suitable for sites with
intermittent energy demand
 Classification of Cogeneration Systems

• A cogeneration system can be classified as either a topping or a

bottoming cycle on the basis of the sequence of energy use
• In a topping cycle, the fuel supplied is used to first produce power
and then thermal energy, which is the by-product of the cycle and
is used to satisfy process heat or other thermal requirements
• In a bottoming cycle, the primary fuel produces high temperature
thermal energy and the heat rejected from the process is used to
generate power through a recovery boiler and a turbine
generator
Combined-cycle topping system
Steam-turbine topping system
Diesel engine topping cycle
Gas-turbine topping system
Bottoming Cycle
 Heat-to-power ratio
• Heat-to-power ratio is one of the most important technical parameters
influencing the selection of the type of cogeneration system
• The heat-to-power ratio of a facility should match with the characteristics
of the cogeneration system to be installed
• It is defined as the ratio of thermal energy to electricity required by the
energy consuming facility
• Though it can be expressed in different units such as Btu/kWh, kcal/kWh,
lb./hr/kW, etc., here it is presented on the basis of the same energy unit
(kW)
• The steam turbine cogeneration system can offer a large range of heat-to-
power ratios.
• The proportions of heat and power needed (heat: power ratio) vary from
site to site, so the type of plant must be selected carefully and appropriate
operating schemes must be established to match demands as closely as
possible
 Heat-to-power ratios and other parameters of
cogeneration systems

Cogeneration System Heat-to-power Power output Overall

ratio (kWth / (as per cent of efficiency
kWe) fuel input) (per cent)
Back-pressure steam turbine 4.0-14.3 14-28 84-92
Extraction-condensing steam 2.0-10.0 22-40 60-80
turbine
Gas turbine 1.3-2.0 24-35 70-85
Combined cycle 1.0-1.7 34-40 69-83
Reciprocating engine 1.1-2.5 33-53 75-85
 Typical Heat: Power Ratios for Certain Energy
Intensive Industries

Industry Minimum Maximum Average

Breweries 1.1 4.5 3.1
Pharmaceuticals 1.5 2.5 2.0
Fertilizer 0.8 3.0 2.0
Food 0.8 2.5 1.2
Paper 1.5 2.5 1.9
?

Q= 69- 4.7- 47.9

=16.4
The schematic and operating data of a steam turbine cogeneration plant with a back
pressure turbine is given below.
Enthalpy of steam at 180 bar, 550 0C – 3420 kJ/kg

Exhaust steam enthalpy at isentropic expansion from 180 bar to 2 bar – 2430 kJ/kg

Enthalpy of boiler feed water – 504.7 kJ/kg

Efficiency of boiler - 80 %

Calorific value of coal – 4500 kcal/kg

Steam flow rate into the Turbine - 91 TPH

Turbine isentropic efficiency - 90 %

Generator efficiency - 97 %

Gear box efficiency - 98 %

Calculate:

a) Electrical output from the generator in MW

b) Fuel consumption in Boiler in TPH

c) Energy Utilization factor of the cogeneration plant

d) Heat to power ratio of the cogeneration plant, kCal/kW

 Cogeneration is likely to be most attractive if

• The demand for both steam and power is balanced

i.e. consistent with the range of steam: power output
ratios that can be obtained from a suitable
cogeneration plant.
• A single plant or group of plants has sufficient
demand for steam and power to permit economies
of scale to be achieved.
• Peaks and troughs in demand can be managed or, in
the case of electricity, adequate backup supplies can
be obtained from the utility company
 Quality of thermal energy needed

• The quality of thermal energy required (temperature

and pressure) also determines the type of
cogeneration system
• For a sugar mill needing thermal energy at about
120°C, a topping cycle cogeneration system can meet
the heat demand
• On the other hand, for a cement plant requiring
thermal energy at about 1450°C, a bottoming cycle
cogeneration system can meet both high quality
thermal energy and electricity demands of the plant
Load patterns
 Fuels available
• Depending on the availability of fuels, some potential
cogeneration systems may have to be rejected
• The availability of cheap fuels or waste products that can be
used as fuels at a site is one of the major factors in the
technical consideration because it determines the
competitiveness of the cogeneration system.
• A rice mill needs mechanical power for milling and heat for
paddy drying.
• If a cogeneration system were considered, the steam turbine
system would be the first priority because it can use the rice
husk as the fuel, which is available as waste product from the
mill.
 System reliability
• Some energy consuming facilities require very
reliable power and/or heat
• for instance, a pulp and paper industry cannot
operate with a prolonged unavailability of process
steam
• In such instances, the cogeneration system to be
installed must be modular, i.e. it should consist of
more than one unit so that shut down of a specific
unit cannot seriously affect the energy supply
 Grid dependent system versus independent system

• A grid-dependent system has access to the grid to buy or sell

electricity
• The grid-independent system is also known as a “stand-alone”
system that meets all the energy demands of the site
• It is obvious that for the same energy consuming facility, the
technical configuration of the cogeneration system designed as a
grid dependent system would be different from that of a stand-
alone system.
 Retrofit versus new installation

• If the cogeneration system is installed as a

retrofit, the system must be designed so that
the existing energy conversion systems, such
as boilers, can still be used
• In such a circumstance, the options for
cogeneration system would depend on
whether the system is a retrofit or a new
installation
 Electricity buy-back
• The technical consideration of cogeneration
system must take into account whether the
local regulations permit electric utilities to buy
electricity from the cogenerators or not
• The size and type of cogeneration system
could be significantly different if one were to
allow the export of electricity to the grid
 Local environmental regulation

• The local environmental regulations can limit

the choice of fuels to be used for the
proposed cogeneration systems
• If the local environmental regulations are
stringent, some available fuels cannot be
considered because of the high treatment cost
of the polluted exhaust gas and in some cases,
the fuel itself
Back pressure Steam Turbine
Extraction condensing Steam Turbine
Gas Turbine
 Cogeneration Heat Rate and Efficiency
Assessment -Illustrative Case
Co-generation Plant Features
• Boiler
– Coal Fired FBC Water Tube Type, 35 TPH, 66 ata, 505  5 OC and
– 1537 m2. Heating Surface Area,
– 79% efficiency;

• Turbine
– Bleed Cum Extraction Cum Condensing,
– 6000 kW Alternator,
– 63 kg / cm2 (g) Steam inlet pressure at 500 OC and 34800 kg/hr Flow,
– Extraction Pressure of 8 kg/cm2, Extraction Flow of 13470 kg/hr,
– Bleed extraction Pressure of 1.4 kg/cm2 and Flow of 3550 kg/hr for deaerator,
– Exhaust Pressure of 0.10 ata,
– Turbine rpm 8280 and Alternator rpm 1500.

• Surface Condenser
– Fixed Tube, Two Pass (Divided Type) Condenser,
– Steam Load 22000 kg/hr @ 0.095 ata and 40OC,
– CW Flow 1514 m3/hr,
– HT Area 649.2 m2.
S.No. Item Reference Case-1 Case-2 Case-3
1.0 Operating 6 MW output & 6 MW output & 6 MW output &
conditions Max. flow to normal flow to Min. flow to
process process process
2.0 Operating Parameters
2.1 Steam condition 36 TPH 64 ATA 34.8 TPH 64 ATA 35.525 TPH 64
at TSV 500OC 500OC ATA 500OC
(4963.35 kJ/kg) (4963.35 kJ/kg) (4963.35 kJ/kg)

2.2 Steam conditions 15.42 TPH 9 ATA 13.47 TPH 9 ATA 9.635 TPH 9 ATA
to process 281OC 281OC 281OC
extraction (5027.49 kJ/kg) (5027.49 kJ/kg) (5027.49 kJ/kg)

2.3 Steam condition 3.7 TPH 2.26 ATA 3.55 TPH 2.26 3.25 TPH 2.26 ATA
to deaerator 186 OC ATA 186 OC 186 OC
(Bleed) (4991.26 kJ/kg) (4991.26 kJ/kg) (4991.26 kJ/kg)

2.4 Exhaust steam 16.88 TPH 0.1 17.775 TPH 0.1 19.64 TPH 0.1 ATA
Conditions ATA 45.45OC ATA 45.45OC 45.45OC
(190.25 kJ/kg) (190.25 kJ/kg) (190.25 kJ/kg)
 Case 1: Turbine heat rate with 6 MW output,
maximum flow to process
[( Q1  H1 )  (Q3  H 3 )  (Q7  H 7 )]kJ
Turbine Heat rate =
6000 kWh

(34800  4963.35)  (13475 293)  (17775 190.25)kJ


6000 kWh

(172724580 3948175 3381693.75)kJ


6000 kWh

= 27565.77 kJ/kWh

Cogeneration system heat rate inclusive of boiler

27565.77
 = 34893.37 kJ/kWh
Boiler efficiency(0.79)
 Case 2: Turbine heat rate with 6 MW output, normal
flow to process
[( Q1  H1 )  (Q 3  H 3 )  (Q 7  H 7 )]kJ
Heat rate =
6000 kWh

(36000 4963.35)  (15420 293)  (16880 190.25)kJ


6000 kWh

(178680600 4518060 3211420)kJ


6000 kWh
= 28491.85 kJ/kWh
Cogeneration system heat rate inclusive of boiler

28491.85
 = 36065.63 kJ/kWh
Boiler efficiency(0.79)
 Case 3: Turbine heat rate with 6 MW output,
minimum flow to process
[( Q1  H1 )  (Q 3  H 3 )  (Q 7  H 7 )]kJ
Heat rate =
6000 kWh

(35525  4963.35)  (9635 293)  (19640 190.25)kJ


6000 kWh

(176323008.75  2823055 3736510)kJ


6000 kWh

= 28293.9 kJ/kWh
Cogeneration system heat rate inclusive of boiler

28293.9
 = 35815 kJ/kWh
Boiler efficiency(0.79)

•It can be noticed that the cogen system heat rate is lowest when process flows are maximum and
highest when process flows are minimum.

•Another factor of importance is extent of return condensate. Higher the return

condensate, lower will be the heat rate.
 Cogeneration Efficiency Calculations Based on
Energy Balance
• Heat input to turbine = Q1.H1
• Useful heat output from turbine = Q2.H2 + Q4.H4 + Q7.H7 + (Power output in
kW x 3600 kJ/kW)
• [Note: Condenser heat rejection component is not useful output]
• Efficiency of Cogeneration system in the illustrative configuration above
[Q 2 .H 2  Q 4 .H 4  Q 7 .H 7  (6000 3600)] 100

Q1 .H1
 Trigeneration
• Trigeneration refers to simultaneous
generation of steam (heat), power
and refrigeration through integrated
systems used in industries such as
food processing and cold storages.
• A combined cycle trigeneration plant
could typically consist of a gas
turbine generator, waste heat
recovery boiler, steam turbine,
generator, and absorption chiller, to
meet 100% of the facility energy
needs.
• Whenever the power is surplus, it is
sold to the grid.
 Microturbine
• Used to generates electricity from pressure energy wasted in the steam
pressure reducing valves.
• Pressure reduction in a PRV is an isoenthalpic process, but steam has
lesser enthalpy after producing shaft horsepower in a steam turbine.
• Since the steam supplied to the process has a lower enthalpy, an
additional amount of steam is required to ensure the same available heat
duty. This additional amount of steam has an associated cost. Hence,
power generated from a backpressure steam turbine is not free.
 Example : Pressure reducing valve versus back
pressure turbine
• A chemical plant generates steam at 17.6 kg/cm2 (g) which is further reduced to 1.8 kg/cm2
(g) through a pressure reducing valve, for utilization in the process. The process requires
5189 MCal/hr of heat. The plant has planned to replace the PRV with a back pressure steam
turbine. Calculate the net savings per annum if the plant operates 8000 hrs/annum with the
following data and the data provided in the schematic diagrams.
• Calorific value of fuel - 10,000 kCal/kg,
• Fuel cost - Rs. 25,000/Tonne,
• Grid cost of electricity charge - Rs. 6/kWh.
• Gear box efficiency - 98%
• Alternator efficiency - 98%
• Mechanical efficiency of turbine - 97%
Solution:

Fuel consumption with PRV operation

9072 (668  94.5) = 612.1 kg/hr

0.8510000

Fuel consumption with steam turbine

9767 (668  94.5)
 = 659 kg/hr
0.8510000
Additional cost of fuel
 (659  612.1)  Rs. 25.0 / kg = Rs. 1172.5 /hr
9767 (668  627)  0.98 0.98 0.97 = 434 kW
Power generated  a) Boiler and PRV operation
860
Grid electricity savings

 434 6 = Rs. 2604/hr

Net Savings = (2604 – 1172.5) x 8000

= Rs. 114.5 Lakh/annum

b) Boiler and Micro turbine operation