Contents What is cogeneration? Benefits of Co-generation

Contents What is cogeneration? Benefits of Co-generation
Cogeneration systems Gas turbines Steam Turbines Reciprocating Engines New Technologies Micro-turbines Fuel cel Integrated Gasification Combined Cycle Wood Cogeneration System Trigeneration Applications of Cogeneration Assessment of Cogeneration Systems

What is Modern Bioenergy?
Bioenergy is energy of biological and renewable origin, normally derived from purpose-grown energy crops or by-products of agriculture. Examples of bioenergy resources are wood, straw, bagasse and organic waste. The term bioenergy encompasses the overall technical means through which biomass is produced, converted and used. Modern bio-energy refers to some technological advances in biomass conversion combined with significant changes in energy markets that allow exploring an increased contribution of biomass to our energy needs, whether throughout traditional and emerging technological areas (e.g. from combustion to liquid biofuels).

What is cogeneration? Many industries require energy input in the form of heat, called process heat. Process heat in these industries is usually supplied by steam at 5 to 7 atm and 150 to 200°C. Energy is usually transferred to the steam by burning coal, oil, natural gas, or another fuel in a furnace. Industries that use large amounts of process heat also consume a large amount of electric power. It makes sense to use the already-existing work potential to produce power instead of letting it go to waste. The result is a plant that produces electricity while meeting the process-heat requirements of certain industrial processes (cogeneration plant) A simple process-heating plant. Cogeneration: The production of more than one useful form of energy (such as process heat and electric power) from the same energy source.

What is cogeneration? The utilization of biomass for heat production in direct or co-firing processes is economically the least profitable manner of converting chemical energy into useful energy. A more effective way is conversion conducted in cogeneration and trigeneration systems, because of their superior proficiency. Cogeneration or Combined Heat and Power (CHP) is defined as the sequential generation of two different forms of useful energy from a single primary energy source, typically mechanical energy and thermal energy. Mechanical energy may be used either to drive an alternator for producing electricity, or rotating equipment such as motor, compressor, pump or fan for delivering various services. Thermal energy can be used either for direct process applications or for indirectly producing steam, hot water, hot air for dryer or chilled water for process cooling.

Cogeneration synonims
Combined Heat and Power (CHP) Cooling, Heating and Power (CHP) Trigeneration systems (Trigen) Integrated Energy Systems (IES) Building Cooling, Heating, and Power (BCHP) CHP for Buildings (CHPB)

What is cogeneration? Combined Heat and Power Cooling, Heating & Power
Total energy systems Cogeneration / trigeneration Energy recycling It is an Integrated System that: Supplies electrical or mechanical power A way of local energy production Is located at or near user Uses thermal output for space or water heating, cooling, dehumidification, or process heat Way to use energy more efficient Can serve a single facility or district energy system Different areas of application Different technologies

What is cogeneration? Definition
“where a fuel source (eg. gas, biomass), produces energy (electricity), at the same time as producing thermal energy (heat), in one process”. Cogeneration: simultaneous production of power and heat, with a view to the practical application of both products Cogeneration = COGEN = CHP, (Combined Heat & Power) It encompasses a range of technologies, but always includes an electricity generator and a heat recovery system.

What is cogeneration? Definition (interpreted)
Should not be confused with Waste Heat Recovery technology, with an efficiency of approximately 58 %. Production of cooling is also possible under CHCP = trigeneration. COGEN will achieve an overall efficiency up to 90%, (vs 35% of a conventional coal power plant). Typically generated on-site at industries, or off-site for district heating (cold climates) and/ or district cooling, (hot climates) and needs a fuel source that may be procured separately, eg. piped gas or available on-site, eg. bagasse at sugar mills, which has some value, (can be fossil-based or renewable)!

What is cogeneration? Tri-generation Comparison:
Conventional power generation, on average, is only 35% efficient – up to 65% of the energy potential is released as waste heat. Combined cycle generation can improve efficiency to 55%, excluding losses for the transmission and distribution of electricity. Through the utilisation of the heat, the efficiency of cogeneration plant can reach 90% or more. Tri-generation A tri-generation system produces electricity and utilizes the waste heat to produce heating in the winter. With the addition of an absorption/bromine chiller this system will also provide cooling for the building.

What is cogeneration?

What is cogeneration? Cogeneration solutions simply reduce waste, with only 10%-15% losses, compare that with the 55% or more using traditional generation methods and it is clear that cogeneration uses fuel more efficiently.

How CHP Saves Energy?

What is cogeneration? Cogeneration is an attractive option for facilities with high electric rates and buildings that consume large amounts of hot water and electricity every month. Cogeneration - A process in which an industrial facility uses its waste energy to produce heat or electricity. Cogeneration is an energy-efficient, environmentally-friendly method of producing electricity (power), steam and/or hot water at the same time, in one process, with one fuel. is the use of a power station to simultaneously generate both heat and electricity. Conventional power plants emit the heat created as a byproduct of electricity generation into the environment through cooling towers, as flue gas, or by other means. CHP captures the excess heat for domestic or industrial heating purposes.

Benefits of Co-generation
Biomass fuels are typically used most efficiently and beneficially when generating both power and heat through a Combined Heat and Power (or Cogeneration) system. A cogeneration system utilizes exhaust heat which is dumped in generating electricity, and so makes the most of the limited resources. Because it reduces the amount of exhausting greenhouse gas such as CO2 (Carbon Dioxide) and NOx (Nitrogen Oxides), it can contribute a lot to prevention of global warming. A typical CHP system provides: Distributed generation of electrical and/or mechanical power, Waste-heat recovery for heating, cooling, or process applications, Seamless system integration for a variety of technologies, thermal applications, and fuel types into existing building infrastructure.

Cogeneration installations are usually sited as near as possible to the place where the heat is consumed and, ideally, are built to a size to meet the heat demand. Otherwise an additional boiler will be necessary, and the environmental advantages will be partly hindered. This is the central and most fundamental principle cogeneration. The benefits of cogeneration are: Increased efficiency of energy conversion and use, and thus large cost savings, providing additional competitiveness for industrial and commercial users, and offering affordable heat for domestic users Lower emissions to the environment, in particular of CO2 An opportunity to move towards more decentralised forms of electricity generation, and to improve local and general security of supply

Synthesis Improves energy efficiency Conserves natural resources (fossil fuels) Lower emissions (including CO2) Lower energy costs If heat fits demand, cheapest way of electricity production Improves security of supply Reduces transmission and distribution losses Enhances competition

Cogeneration systems Each cogeneration system is adapted to meet the needs of an individual building or facility. System design is modified based on the location, size, and energy requirements of the site. Cogeneration is not limited to any specific type of facility but is generally used in operations with sustained heating requirements. Most CHP systems are designed to meet the heat demand of the energy user since this leads to the most efficient systems. Larger facilities generally use customized systems, while smaller-scale applications can use prepackaged units.

Classification of cogeneration systems
Cogeneration systems are normally classified according to the sequence of energy use and the operating schemes adopted. 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. Topping cycle cogeneration is widely used and is the most popular method of cogeneration.

Topping cycle Topping-cycle systems produce electricity first, then recover the excess thermal energy for heating or cooling applications.

Topping cycle By contrast, bottoming-cycle systems, also known as “waste heat to power,” are a process whereby waste heat from an existing process is used to produce electricity.

Topping cycle A gas turbine or diesel engine producing electrical or mechanical power followed by a heat recovery boiler to create steam to drive a secondary steam turbine. This is called a combined-cycle topping system.

Cogeneration systems A cogeneration plant consists of 4 basic elements: a prime mover (engine), an electricity generator, a heat recovery system and a control system. Cogeneration systems are categorized according to their prime movers (the heat engines), though the systems also include generators, heat recovery, and electrical interconnection components. The prime mover consumes (via combustion, except in the case of fuel cells) fuel (such as coal, natural gas, or biomass) to power a generator to produce electricity, or to drive rotating equipment. There are currently five primary, commercially available prime movers: gas turbines, steam turbines, reciprocating engines, microturbines, and fuel cells.

Cogeneration systems Steam turbines and gas, or combustion turbines are the prime movers (heat engines) best suited for industrial processes due to their large capacity and ability to produce the medium- to high-temperature steam typically needed in industrial processes. New developments are bringing new technologies towards the market. Stirling engine and micro-turbines will become economically available.

Gas turbines Gas turbines typically have capacities between 500 kilowatts (kW) and 250 megawatts (MW), can be used for high-grade heat applications, and are highly reliable. Gas turbines operate similarly to jet engines—natural gas is combusted and used to turn the turbine blades and spin an electrical generator. The cogeneration system then uses a heat recovery system to capture the heat from the gas turbine’s exhaust stream. This exhaust heat can be used for heating (e.g., for generating steam for industrial processes) or cooling (generating chilled water through an absorption chiller). Two types: open and closed cycle

Gas turbines Gas turbine cogeneration systems can produce all or a part of the energy requirement of the site, and the energy released at high temperature in the exhaust stack can be recovered for various heating and cooling applications. Though natural gas is most commonly used, other fuels such as light fuel oil or diesel can also be employed. Gas turbine cogeneration has probably experienced the most rapid development in the recent years due to the greater availability of natural gas, rapid progress in the technology, significant reduction in installation costs, and better environmental performance. Gas turbine has a short start-up time and provides the flexibility of intermittent operation. Though it has a low heat to power conversion efficiency, more heat can be recovered at higher temperatures.

Gas turbines If the heat output is less than that required by the user, it is possible to have supplementary natural gas firing by mixing additional fuel to the oxygen-rich exhaust gas to boost the thermal output more efficiently. Steam generated from the exhaust gas of the gas turbine is passed through a backpressure or extraction-condensing steam turbine to generate additional power. The exhaust or the extracted steam from the steam turbine provides the required thermal energy. Most of the currently available gas turbine systems operate on the open Brayton cycle where a compressor takes in air from the atmosphere and derives it at increased pressure to the combustor. The air temperature is also increased due to compression.

Gas turbines Gas Turbine or Engine with Heat Recovery Unit
The heat recovery unit capturing exhaust heat from the turbine, and converting that to thermal energy for other uses.

Condensate from Process
Gas turbines Open Cycle Gas Turbine Cogeneration System Open Brayton cycle: atmospheric air at increased pressure to combustor Air G Compressor Turbine HRSG Combustor Fuel Generator Exhaust Gases Condensate from Process Steam to Process Most of the currently available gas turbine systems operate on the open Brayton cycle where a compressor takes in air from the atmosphere and derives it at increased pressure to the combustor. This is also called Joule cycle when irreversibilities are ignored. The air temperature is also increased due to compression.

Gas turbines Open Cycle Gas Turbine Cogeneration System
Older and smaller units operate at a pressure ratio in the range of 15:1, while the newer and larger units operate at pressure ratios approaching 30:1. The air is delivered through a diffuser to a constant-pressure combustion chamber, where fuel is injected and burned. Combustion takes place with high excess air and the exhaust gases exit the combustor at high temperature and with oxygen concentrations of up to 15-16%. The highest temperature of the cycle appears at this point; with current technology this is about 1300°C. The high pressure and high temperature exhaust gases enter the gas turbine and produce mechanical work to drive the compressor and the load.

Gas turbines Open Cycle Gas Turbine Cogeneration System
The exhaust gases leave the turbine at a considerable temperature ( °C), which makes high-temperature heat recovery ideal. This makes it appropriate not only for thermal processes but also for driving a steam turbine thus producing additional power. A gas turbine operates under exacting conditions of high speed and high temperature. A gas turbine operates under exacting conditions of high speed and high temperature. The hot gases supplied to it must therefore be clean (i.e. free of particulates which would erode the blades) and must contain not more than minimal amounts of contaminants, which would cause corrosion under operating conditions.

Condensate from Process
Gas turbines Closed Cycle Gas Turbine Cogeneration System Heat Source G Compressor Turbine Generator Condensate from Process Steam to Process Heat Exchanger Working fluid circulates in a closed circuit and does not cause corrosion or erosion Any fuel, nuclear or solar energy can be used In the closed-cycle system, the working fluid is usually helium or air and it circulates in a closed circuit. It is heated in a heat exchanger before entering the turbine, and it is cooled down after the exit of the turbine releasing useful heat. This way the working fluid remains clean and it does not cause corrosion or erosion. Source of heat can be the external combustion of any fuel. Nuclear energy or solar energy can also be used.

Steam Turbines Steam turbines systems can use a variety of fuels, including natural gas, solid waste, coal, wood, wood waste, and agricultural by-products Steam turbines are highly reliable and can meet multiple heat grade requirements. Steam turbines typically have capacities between 50 kW and 250 MW and work by combusting fuel in a boiler to heat water and create high-pressure steam, which turns a turbine to generate electricity. The low-pressure steam that subsequently exits the steam turbine can then be used to provide useful thermal energy. Ideal applications of steam turbine-based cogeneration systems include medium- and large-scale industrial or institutional facilities with high thermal loads and where solid or waste fuels are readily available for boiler use.

Steam Turbines The thermodynamic cycle for the steam turbine is the Rankine cycle. This cycle is the basis for conventional power generating stations and consists of a heat source that converts water to high-pressure steam. The developed condensate from the process returns to the feedwater pump for continuation of the cycle. The two types of steam turbines most widely used: Back pressure steam turbine Extraction condensing steam turbine The choice between backpressure turbine and extraction-condensing turbine depends mainly on the quantities of power and heat, quality of heat, and economic factors.

Steam Turbines The extraction points of steam from the turbine could be more than one, depending on the temperature levels of heat required by the processes. The specific advantage of using steam turbines in comparison with the other prime movers is the option for using a wide variety of conventional as well as alternative fuels such as coal, natural gas, fuel oil and biomass. The power generation efficiency of the cycle may be sacrificed to some extent in order to optimize heat supply

Steam Turbines Steam Boiler with Steam Turbine
Cogeneration system that is primarily heat based, can also be used to generate electricity.

Steam Turbines Back Pressure Steam Turbine
Steam exits the turbine at a higher pressure that the atmospheric Boiler Turbine Process HP Steam Condensate LP Steam Advantages: Simple configuration Low capital cost Low need of cooling water High total efficiency Disadvantages: Larger steam turbine Electrical load and output can not be matched Fuel Fuel

Steam Turbines Back Pressure Steam Turbine
Steam enters the turbine chamber at High Pressure and expands to Low or Medium Pressure. Enthalpy difference is used for generating power / work. Depending on the pressure (or temperature) levels at which process steam is required, backpressure steam turbines can have different configurations . In extraction and double extraction backpressure turbines, some amount of steam is extracted from the turbine after being expanded to a certain pressure level. Back pressure steam turbine is the most simple configuration. Steam exits the turbine at a pressure higher or at least equal to the atmospheric pressure. This is why the term backpressure is used. After the steam exits the turbine, it is fed to the load where it releases heat and is condensed. The condensate then returns to the system. Fuel

Steam Turbines Extraction Condensing Steam Turbine
Boiler Turbine Process HP Steam LP Steam Condensate Condenser Fuel Steam obtained by extraction from an intermediate stage Remaining steam is exhausted Relatively high capital cost, lower total efficiency Control of electrical power independent of thermal load

In this type, steam entering at High / Medium Pressure is extracted at an intermediate pressure in the turbine for process use while the remaining steam continues to expand and condenses in a surface condenser and work is done till it reaches the Condensing pressure (vacuum). In Extraction cum Condensing steam turbine as shown in Figure, high Pressure steam enters the turbine and passes out from the turbine chamber in stages. In an extraction condensing steam turbine system, the steam for the thermal load is obtained through extraction from one or more intermediate stages at appropriate pressure and temperature. The remaining steam is exhausted to the pressure of the condenser

In a two stage extraction cum condensing turbine MP steam and LP steam pass out to meet the process needs. The extraction condensing turbines have higher power to heat ratio in comparison with backpressure turbines. Although condensing systems need more auxiliary equipment such as the condenser and cooling towers, better matching of electrical power and heat demand can be obtained where electricity demand is much higher than the steam demand and the load patterns are highly fluctuating. The overall thermal efficiency of an extraction condensing turbine cogeneration system is lower than that of back pressure turbine system .

Basically because the exhaust heat cannot be utilized (it is normally lost in the cooling water circuit). However, extraction condensing cogeneration systems have higher electricity generation efficiencies. Advantage is that the extraction condensing steam turbine can control the electrical power independent of the thermal load by proper regulation of the steam flow rate through the turbine to a certain extent. Disadvantage the condensing type turbine has a higher capital cost and generally a lower total efficiency.

Reciprocating Engines
It is also known as internal combustion (IC) engines IC are the most widespread technology for power generation, found in the form of small, portable generators as well as large industrial engines that power generators of several megawatts. These cogeneration systems have high power generation efficiencies in comparison with other prime movers. Reciprocating engines are well suited for CHP in commercial and light industrial applications of less than 5 MW. Smaller engine systems produce hot water. Larger systems can be designed to produce low-pressure steam. Multiple reciprocating engines can be used to increase system capacity and enhance overall reliability

Reciprocating Engine Cogeneration Systems Used as direct mechanical drives

There are two sources of heat for recovery: exhaust gas at high temperature and engine jacket cooling water system at low temperature as shown in the fig. As heat recovery can be quite efficient for smaller systems, these systems are more popular with smaller energy consuming facilities, particularly those having a greater need for electricity than thermal energy and where the quality of heat required is not high, e.g. low pressure steam or hot water. These machines are ideal for intermittent operation and their performance is not as sensitive to the changes in ambient temperatures as the gas turbines. Though the initial investment on these machines is low, their operating and maintenance costs are high due to high wear and tear.

Turbine Efficiency is the ratio of actual work output of the turbine to the net input energy supplied in the form of fuel. For stand alone Gas Turbines, without any heat recovery system the efficiency will be as low as 35 to 40%. Since Exhaust gas from the Gas Turbine is high, it is possible to recover energy from the hot gas by a Heat Recovery Steam Generator and use the steam for process. This system provides process heat or steam from engine exhaust. The engine jacket cooling water heat exchanger and lube oil cooler may also be used to provide hot water or hot air. There are, however, limited applications for this.

Advantages: Reciprocating engines start quickly. It has good part-load efficiencies. Generally have high reliabilities. In many cases, multiple reciprocating engine units further increase overall plant capacity and availability. higher electrical efficiencies than gas turbines of comparable size, and therefore lower fuel-related operating costs. It used extensively as direct mechanical drives in applications such as water pumping, air and gas compression and chilling/refrigeration. Disadvantages: As these engines can use only fuels like HSD, distillate, residual oils, natural gas, LPG etc. and as they are not economically better than steam/gas turbine, their use is not widespread for co-generation. One more reason for this is the engine maintenance requirement.

Micro - turbines Micro-turbines are small, compact, lightweight combustion turbines that typically have power outputs of 30 to 300 kW. A heat exchanger recovers thermal energy from the micro-turbine exhaust to produce hot water or low-pressure steam. The thermal energy from the heat recovery system can be used for potable water heating, absorption cooling, desiccant dehumidification, space heating, process heating, and other building uses. Micro-turbines can burn a variety of fuels including natural gas and liquid fuels.

Fuel cell Fuel cells are an emerging technology with the potential to serve power and thermal needs with very low emissions and with high electrical efficiency. Fuel cells use an electrochemical or battery-like process to convert the chemical energy of hydrogen into water and electricity. Fuel cells use an electrochemical or battery-like process to convert the chemical energy of hydrogen into water and electricity. The hydrogen can be obtained from processing natural gas, coal, methanol, and other hydrocarbon fuels. Fuel cells can produce electricity continuously for as long as these inputs are supplied. Fuel cells have high capital costs, an immature support infrastructure, and technical risk for early adopters. The advantages of fuel cells include low emissions and low noise, high power efficiency over a range of load factors, and modular design.

Integrated Gasification Combined Cycle
Advanced technologies include biomass integrated gasification combined cycle (IGCC) systems, co- firing, pyrolysis and second generation biofuels. Second generation biofuels can make use of biochemical technologies to convert the cellulose to sugars which can be converted to bioethanol, biodiesel, dimethyl ester, hydrogen and chemical intermediates in large scale bio-refineries. IGCC power plants can achieve major CO2 reduction by effectively capturing the feedstock's carbon inventory from the syngas, before it is combusted in the gas turbine. Significant overall integration know-how on the processes that prepare the gasified fuel for combustion enables the design of optimized IGCC plants, the maximization not only of efficiency and low emissions parameters, but also the life-cycle electricity costs and reliability.

Typical Cogeneration Performance Parameters

Steam spins the turbine blades Rotating magnets create electricity
Turning Biomass into Electricity Boiler Biomass High Heat Steam Steam spins the turbine blades Rotating magnets create electricity

Wood Cogeneration System
Wood Cogeneration System (WCS) converts wood chips into biomass electricity and warmth with high efficiency. The systems are run using natural wood chips and provide attractive cost advantages and/or increased power yields according to location conditions. The compact wood cogeneration systems (HV30-V1.1 and HV45-V1.1) make it possible to fit the systems in rooms with a minimum standard ceiling height (of 2.50m). Technical advantages of a wood cogeneration plant: High efficiency – The principle of CHP in a WCS system makes optimum use of wood as a natural resource via the wood carburettor. Natural wood chips as fuel – WCS is fuelled with conventional wood chips, and can use forest wood just as easily as wood from short rotation coppices.

Trigeneration ELECTRICAL POWER COOL USEFUL HEAT

Trigeneration Module TRIGENERATION Power-Heat-Cool-Coupling Engine
watercooling- / -oil Heat Exchanger Electricity 3-Way- catalyst Fuel Air Exhaust Gas- Heat Exchanger Exhaust Gas Heat- Storage Cooling Absorptions- cooling plant CoolEnergy- Storage TRIGENERATION Power-Heat-Cool-Coupling

TRIGENERATION STATE OF THE ART
Existing installations: - medium to large-scale - Prime movers: Internal Conmbustion engines and turbines - Cooling: absorption chillers Challenges in small-scale applications - Cooling technology? - Costs? - Fuel and emissions?

Reheat Improves Efficiency
Integrating a steam reheat system into a biomass plant is one of the best ways to increase overall plant performance. Increasing Cycle Efficiency with Reheat

Applications of Cogeneration
There are 4 broad categories of cogeneration applications: small-scale cogeneration schemes, usually designed to meet space and water heating requirements in buildings, based on spark ignition reciprocating engines large-scale cogeneration schemes, usually associated with steam raising in industrial and large buildings applications, and based on compression ignition reciprocating engines, steam turbines or gas turbines large scale cogeneration schemes for district heating based around a power station or waste incinerator with heat recovery supplying a local heating network Cogeneration schemes fuelled by renewable energy sources, which may be at any scale. Significant technological progress has been made to enable engine and turbine technology to be widely implemented and promote more decentralised forms of cogeneration and power generation. There are an increasing number of varied applications in industry and residential areas and which can be used in heating and cooling applications.

Applications of Cogeneration
Typical Cogeneration Applications Industrial cogeneration wood and agro-industries, food processing, pharmaceutical, pulp and paper, oil refinery, textile industry, steel industry, cement industry, glass industry, ceramic industry Residential/commercial/institutional cogeneration hospitals, schools and universities, hotels, houses and apartments, stores and supermarkets, office buildings

Assessment of Cogeneration Systems
Performance Terms & Definitions Overall Plant Heat Rate (kCal/kWh): 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)

Steam Turbine Performance Steam turbine efficiency (%): Gas Turbine Performance Overall gas turbine efficiency (%) (turbine compressor):

Heat Recovery Steam Generator (HRSG) Performance Heat recovery steam generator efficiency (%): 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)

Electrical efficiency Heat efficiency Overall efficiency (also called “Cogeneration efficiency or “Total efficiency)

Power-to-Heat Ratio Where is: Qe – Gross electrical output, kWe Qheat – Usefull heat output, kWth Qfuel – Fuel energy input (based on Net Caloric Value (Lower Heating Value: LHV)), kWth

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Contents What is cogeneration? Benefits of Co-generation

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