COGENERATION AND DISTRIBUTED RESOURCES

COGENERATION AND DISTRIBUTED RESOURCES
Professor Akhtar Kalam Victoria University 10/11/2018 Cogeneration and Distributed Resources

Cogeneration and Distributed Resources
* A secure supply of power and heat is of paramount importance, and it must be provided at the lowest possible cost * The privatisation of the electricity supply industry has brought competition in to the market place for electricity supply and buyers. 10/11/2018 Cogeneration and Distributed Resources

EcoGeneration in Australia
Based on industry growth trends and current government initiatives, by 2010 EcoGeneration should almost double to represent approximately 14 per cent (7000 MW) of total installed generation capacity in Australia compared to 7.8 per cent (3390 MW) at the end of 1999 (AEA’s estimate). Of this total, renewables should quadruple form 530 MW to approximately 2100 MW by Non-renewable EcoGeneration should increase by some 70 per cent to approximately 4900 MW. These growth rates reflect international trends where ecologically sustainable power production technologies are recording by far the highest growth rates. 10/11/2018 Cogeneration and Distributed Resources

EcoGeneration: EcoGeneration includes cogeneration, renewables, waste-to-energy and distributed generation technologies. EcoGeneration is a natural grouping of environmentally sustainable energy delivery technologies as they offer similar benefits and face similar challenges in the National Electricity Market. 10/11/2018 Cogeneration and Distributed Resources

Cogeneration (also known as combined heat and power - CHP): Cogeneration involves the production of combined heat and power. Heat that would otherwise be wasted is recovered and used in commercial and industrial applications. Cogeneration is typically two to three times more efficient than major conventional, coal-fired, centralised power stations. On average it produces one-third the greenhouse gas emissions of conventional power production. 10/11/2018 Cogeneration and Distributed Resources

Renewable generation: Renewable generated power produces no net greenhouse emissions. Includes power generated from natural resources such as biomass, hydro, wind, solar and tidal. It also includes power generated using certain wastes. 10/11/2018 Cogeneration and Distributed Resources

Waste-to-energy: This is electricity produced using waste fuels, some of which may otherwise cause local environmental challenges. A number of waste fuels are deemed to be renewable including: cane residue (bagasse) from the sugar industry; sludge gas from sewage treatment plants; and methane from landfill sites. Fossil fuel-based waste streams include coal waste methane, refinery waste gases and coal tailings. 10/11/2018 Cogeneration and Distributed Resources

Distributed generation: This is power generation generally located close to where it is consumed, for example, supplying electricity on-site or over-the-fence. Also referred to as decentralised, embedded or localised generation. Can be as small as a 1 kWe solar photovoltaic system, or even larger than a 450 MW industrial on-site cogeneration system. 10/11/2018 Cogeneration and Distributed Resources

Embedded generation: This refers to smaller-scale generators that are connected to electricity distribution networks. This is in contrast to large-scale coal-fired generators that are connected to very high voltage electricity transmission networks. 10/11/2018 Cogeneration and Distributed Resources

THE TECHNOLOGY Cogeneration - is essentially a philosophy. It describes the use of technology, that combines the generation of heat (Mechanical energy) and electricity (Electrical energy) in a single unit in a way that is more efficient than producing heat and electricity separately in boiler plant and at the power station. 10/11/2018 Cogeneration and Distributed Resources

In other words, cogeneration is the energy process whereby waste heat, produced during the generation of electricity, is utilised for steam raising or heating. This is no different than any other power stations. The only difference being that the waste heat from the electricity generating plant is harnessed & made used of rather than being thrown away in the form of Waste Heat. 10/11/2018 Cogeneration and Distributed Resources

The mechanical energy can be used for any mechanical application such as driving motors, compressors, extruders, etc. The electrical energy can be used to meet in-house demand and any surplus sold back to the electricity grid. The thermal energy can be converted to steam or hot water for process application, or for drying purposes. 10/11/2018 Cogeneration and Distributed Resources

In brown coal and gas fired power stations, 28% to 35% of the energy in the fuel is converted to electricity, the other 65% to 72% becomes heat which must be disposed of. In cogeneration, both the recovered heat and the electricity or mechanical energy are used, so efficiency increases to 70% to 82% depending on the prime mover used. This utilisation is well over twice that of a large conventional power station. 10/11/2018 Cogeneration and Distributed Resources

10/11/2018 Cogeneration and Distributed Resources

WASTE HEAT STEAM Hot Water (Industrial Process) (Space heating in a commercial building or district heating scheme) 10/11/2018 Cogeneration and Distributed Resources

CONVENTIONAL PLANT WASTE HEAT rejected to the environment Capturing this will result in η of 90% to be achieved cf. 36% (Conventional plant) 52% (Combined Cycle Gas Turbine) 10/11/2018 Cogeneration and Distributed Resources

The economics of cogeneration schemes are most compelling for organisations with a high heat requirement. Units range from as little as 20kW to hundreds of MW and can be linked to public and commercial buildings, industrial sites and community heating schemes. 10/11/2018 Cogeneration and Distributed Resources

Cogeneration has a very wide application in the industrial and commercial sectors, and also in public institutions. In the industrial sector potential exists in manufacturing (petroleum, chemical, food and beverage, textiles, paper, iron and steel, motor vehicles, glass and clay), mining and forestry. 10/11/2018 Cogeneration and Distributed Resources

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There are two obvious times to consider investing in cogeneration: first, when existing boiler capacity needs to be replaced and second, when new buildings are being planned. Hospitals, for example are already being designed to include a cogeneration system from inception. 10/11/2018 Cogeneration and Distributed Resources

Once the economics have been worked out and the investment has been made, financial savings quickly offset the initial additional costs incurred, giving a payback in as little as two or three years. The life of a cogeneration system can exceed fifteen years, so the savings accrue long after the initial capital costs have been recouped. 10/11/2018 Cogeneration and Distributed Resources

Cogeneration cycles TOPPING BOTTOMING COMBINED-CYCLE 10/11/2018 Cogeneration and Distributed Resources

In a topping-cycle system, fuel is burned to generate electricity; the thermal energy exhausted from this process is then used either in an industrial application or for space heating. 10/11/2018 Cogeneration and Distributed Resources

In a bottoming-cycle system, the waste heat is recovered from an industrial process application and used to generate electricity. 10/11/2018 Cogeneration and Distributed Resources

Combined-cycle systems generally use a topping-cycle gas turbine; the exhaust gases are then used in a bottoming-cycle steam turbine to generate more electricity and process thermal energy. Heat pumps may also be used with a cogeneration system to upgrade low-temperature heat for process use. 10/11/2018 Cogeneration and Distributed Resources

Cogeneration plants vary widely in size and packaged micro-cogen units in the size range 20kW to 60kW are commercially available for suitable office buildings, restaurants, hotels, etc. For units below 800kW, diesel and gas engines are the most common type of prime motor. From approximately 800kW to 10MW, gas turbines or large reciprocating engines can be used. Steam cycles (steam turbines) can also be used especially in coal, waste gas or biomass fired cogeneration systems. For applications above 10MW, gas and steam turbines are generally used. 10/11/2018 Cogeneration and Distributed Resources

THE MARKET The recent privatisation of the electricity supply industry (ESI), together with a number of business and technical changes, have provided new impetus to the development of cogeneration. It is not these factors alone that are providing renewed interest in cogeneration, but their conjunction at this time. Taken together, the factors provide a window of opportunity for the exploitation of cogeneration. The development of cogeneration has increased since the restructure of the ESI, but there is still a long way to go to catch on to the rest of the world. 10/11/2018 Cogeneration and Distributed Resources

HEAT AND POWER PRODUCTION - A BRIEF HISTORY

Cogeneration is not a new idea Old days  Factories  Had their own power stations  Supplied their own Heat + Power 1965  66% of the electricity consumed in the UK paper industry was generated on-site from COGEN schemes 1990  66% went down to 20% Grid systems (CEGB)  reliable supply + real lower prices REASONS (acted against Cogeneration in the last 2 decades  decline) Development in Boiler plants Relatively cheap oil 10/11/2018 Cogeneration and Distributed Resources

The Situation Today Recent years  Renaissance 1990  privatisation of ESI  competition  Gas used for generation   Since 1989  1500MWe of new COGEN capacity (U.K.) 10/11/2018 Cogeneration and Distributed Resources

ADVANTAGES Efficient way of converting primary fuel to useful energy Process Industries benefit viz. commercial + Environmental sectors Targets have been set by Governments and this will depend on: Future gas and electricity prices Development in electricity trading Environmental pressures 10/11/2018 Cogeneration and Distributed Resources

The Future INDUSTRY TODAY: Market Driven energy market Needs specific legislation COGEN CAN BECOME A DRIVING FORCE 10/11/2018 Cogeneration and Distributed Resources

In total contrast to coal, gas can be moved relatively easily and without impacting on the environment. Therefore, the engineering case for gas-fired cogeneration meeting local heat and power needs is very strong. There might well be seen a reversal of the trends of the last 60 years, with the use of the Grid declining and heat and power production being combined close to the point of need. 10/11/2018 Cogeneration and Distributed Resources

WHY COGENERATION NOW? Regardless of the engineering case for cogeneration, it will not "take off" unless it is economically attractive. The two fundamental parameters that dominate commercial viability are:- (a) primary fuel costs; (b) the capital costs of cogeneration schemes. 10/11/2018 Cogeneration and Distributed Resources

Fuel Prices Most cogeneration schemes currently being developed are fuelled by gas. Until comparatively recently the pricing policy, did not encourage the development of gas-fired electricity generation. It was argued that gas was a premium fuel, too valuable for this application. This view has now changed. 10/11/2018 Cogeneration and Distributed Resources

Capital Cost Industrial cogeneration schemes in general utilise either reciprocating engines or, more commonly now for larger installations, gas turbines. Concentration here is on gas turbines because they are generally preferred for schemes of several megawatts. Gas turbine technology has been improving rapidly in recent years producing more efficient machines. The market is developing with more players offering a greater range of machines. 10/11/2018 Cogeneration and Distributed Resources

The "Green" Ticket Cogeneration can genuinely be labelled a "Green" technology. The overall thermodynamic efficiency of cogeneration is very high. Further, when gas fired, no sulphur dioxide is produced and NOx can be effectively controlled either by steam injection or dry NOx control through the design of burners. Finally, the application of cogeneration reduces the production of CO2 compared with the grid/boiler approach. Although it is difficult to put a value on "green" benefits in money terms, it can do no company any harm to be associated with environmentally friendly technology. 10/11/2018 Cogeneration and Distributed Resources

Ageing Boiler Plant In the fifties and sixties falling electricity prices, in real terms, encouraged industry to import electricity and produce steam and hot water in conventional boiler plant. Significant amounts of low cost, efficient package boilers were installed in the 1960's. Much of this plant is now reaching the end of its useful life. 10/11/2018 Cogeneration and Distributed Resources

Security of Supply Security of supply can be of paramount importance in industrial environments. An on-site cogeneration scheme can enhance the security of both heat and electricity supplies. In particular, it is possible to design the electrical connections to ensure continuity of supply for the complete failure of the Grid. Such arrangements can prove most beneficial from both commercial and, in certain situations, safety viewpoints. 10/11/2018 Cogeneration and Distributed Resources

Cogeneration in Australia
VICTORIA (SECV) + State Government – INCENTIVE PACKAGE SOUTH AUSTRALIA (SAGASCO) – Established a COGEN division At the end of 1999, cogeneration and distribution generation represented 8.3% of installed capacity. 10/11/2018 Cogeneration and Distributed Resources

Cogeneration data No authoritative information is available on the extent of non-utility cogeneration and power production. The best available estimate puts cogeneration capacity in Australia at about 2,200MW, made up of the following industries: Alumina industry is the most significant industry, accounting for 23% of operational capacity, 38% of electricity generation and 36% of thermal production 10/11/2018 Cogeneration and Distributed Resources

Industry Capacity(MW) No. of projects Alumina 498.5 6 Sugar 332.1 30 Paper 271 9 Nickel 261 Chemical 215.7 Misc Manufact 189.7 4 Oil Refining 183 Steel 73.8 3 Mineral Process 66.9 Health 60 25 Water 20 Food 13.2 10 Building 7.8 7 Education 7.6 Recreation 2.9 11 TOTAL 2203.2 133 10/11/2018 Cogeneration and Distributed Resources

WA is the greatest user of cogeneration by State/Territory accounting for 35% of operational capacity, 39% of electricity generation capacity and 32% of thermal production State Capacity (MW) No. of projects ACT 0.1 1 NSW 281.9 18 NT 105 QLD 413.5 35 SA 215 25 TAS 15.5 2 VIC 409.7 34 WA 762.5 17 TOTAL 2203.2 133 10/11/2018 Cogeneration and Distributed Resources

Steam turbine projects accounted for 58% of operational capacity by prime mover technology, 57% of electricity generation and 95% of thermal production Type Capacity (MW) No. of projects CCGT 538 4 GT 285.9 19 RCP 77 53 FCELL 0.2 1 ST 1302 56 TOTAL 2203.2 133 10/11/2018 Cogeneration and Distributed Resources

Natural gas projects accounted for 56% of operational capacity by primary fuel, 66% of electricity generation and 38% of thermal production. Renewable generation capacity accounted for 360.3MW of capacity, representing 16.4% of total generation capacity Fuel Type Capacity (MW) No. of projects Natural Gas 1224.5 71 Bagasse 332.1 30 Coal 363.5 8 Waste Gas 144.3 6 Oil 109 2 Digester Gas 19.1 Landfill Gas 7.1 Waste Biomass 1 LPG 1.6 7 TOTAL 2203.2 133 Renewable 360.3 40 Fossil Fuel 1842.9 93 10/11/2018 Cogeneration and Distributed Resources

Non-Cogeneration – State/Territory State Capacity (MW) No. of projects ACT 2 NSW 162.1 8 NT 65.4 3 QLD 501.5 5 SA 74.5 6 TAS 10 1 VIC 75.2 13 WA 569.3 9 TOTAL 1460 47 10/11/2018 Cogeneration and Distributed Resources

Non-Cogeneration – Prime Mover Technology Type Capacity (MW) No. of projects CCGT 415.9 4 GT 553.5 19 RCP 191.2 53 HT 75 1 ST 224.5 3 TOTAL 1460.1 47 10/11/2018 Cogeneration and Distributed Resources

Non-Cogeneration – Primary Fuel Fuel Type Capacity (MW) No. of projects Natural Gas 1123.9 12 Landfill Gas 94.4 21 Water Hydro 75 10 Coal Steam Meth 96.8 2 Waste Gas 60 1 Oil TOTAL 1460.1 47 Renewable 169.4 31 Fossil Fuel 1290.7 16 10/11/2018 Cogeneration and Distributed Resources

1999 – 7 Cogen projects totalling 234MW & 10 non-Cogen, grid connected, distributed generation project totalling 295MW were committed and under construction. Renewable projects amounted to 13% of the overall total Plant Location Type/Fuel MW Capacity COGENERATON FOSSIL FUEL Worsley Alumina Worsley, WA GT/natural gas 120 ST/natural gas 34 Bulwer Island Bulwer Is., QLD CCGT/natural gas 37 QLD Phosphate Mount Isa, QLD 20 Macquarie Uni Nth Ryde, NSW RCP/natural gas 1 212 RENEWABLE Visy Paper Tumut, NSW ST/woodwaste 17 Energy Developments Wollongong, NSW RCP/munic.waste 5 22 TOTAL COGEN 1460.1 47 234 NON-COGENERATON GRID CONNECTED DISTRIBUTED GENERATION Redbank Power Plant Redbank, NSW ST/coal tailings Ladbroke Grove Power Plant Ladbroke Grove, SA 84 East Coast Power Plant Bairnsdale, VIC 42 246 Pacific Power Burrinjuck, NSW HT/water 15 Stanwell Corporation Ravenhoe, QLD WT/wind 12 Blayney, NSW 10 Koomboloomba, QLD 7 Melbourne Water Werribee, VIC RCP/digester gas 2.4 Water Corporation Subiaco, WA RCP/effluent sludge 1.5 Jacks Gully, NSW RCP/landfill gas 48.9 294.9 10/11/2018 Cogeneration and Distributed Resources

Victorian support Within five years, it is conservatively expected that about 500 MW of Victoria's power will be fed into the SEC grid from private and public cogeneration and renewable energy projects, the equivalent to the output from one Loy Yang power station unit. 10/11/2018 Cogeneration and Distributed Resources

COGENERATION COMMERCIAL VIABILITY
It would be irresponsible to give the impression that cogeneration offers a panacea to all energy problems. Commercially viable opportunities are still small in number. The main factors influencing commercial viability are dependant on site's heat to power ratio and equipment utilisation. 10/11/2018 Cogeneration and Distributed Resources

GREENHOUSE EFFECT WORLD ENERGY CONSUMPTION   ELECTRICITY CONSUMPTION IN Vic  FOLD. SIMILAR TRENDS IN OTHER PLACES. NOT POSSIBLE TO SUSTAIN SUCH GROWTH  CONSERVATION REQUIRED 10/11/2018 Cogeneration and Distributed Resources

GREENHOUSE EFFEST IS A SERIOUS PROBLEM
AUSTRALIA  MAJOR CONTRIBUTOR TO GREENHOUSE GASES 6 TIMES MORE THAN THE WORLD AVERAGE RATE GREATER THAN BOTH JAPAN & USA VICTORIA HAS AN EVEN HIGHER PER CAPITA OUTPUT 10/11/2018 Cogeneration and Distributed Resources

GOAL SET FOR 20% REDUCTION IN CO2 EMISSION BY 2010.
IN GLOBAL SENSE: ELECTRICITY CONTRIBUTES 25% OF ALL CO2 EMISSIONS REPRESENTING 14% OF ALL GREENHOUSE GASES GENERATED AND VICTORIA IS RESPONSIBLE FOR 0.1%. 10/11/2018 Cogeneration and Distributed Resources

ALTERNATIVES: COGENERATION & RENEWABLE ENERGY REMOTE AREA POWER SUPPLIES ENERGY AUDITS COGENERATION -- PROVEN REDUCTION OF GREENHOUSE GAS EMISSION REDUCTIONS 10/11/2018 Cogeneration and Distributed Resources

CALCULATIONS OF POTENTIAL EMISSION SAVINGS DEPENDS ON:
 HOW MUCH COGEN IS ASSUMED TO BE POSSIBLE  TYPE OF GENERATION BEING DISPLACED BY COGENERATION  HEAT TO POWER RATION AND CAPACITY FACTOR OF THE COGENERATORS NO AGREED UPON ESTIMATES OF THE TECHNICAL AND ECONOMIC POTENTIAL FOR CONERATION IN AUSTRALIA 10/11/2018 Cogeneration and Distributed Resources

AVERAGE EMISSIONS SAVINGS WILL BE ASSUMED SUCH THAT: * RECIPROCATING ENGINE COGENERATORS DISPLACES 910 gCO2/kWh * & GAS TURBINE COGENERATORS DISPLACES 870 gCO2/kWh 10/11/2018 Cogeneration and Distributed Resources

ASSUME GAS TURBINE COGEN PLANT TO OPERATE AT CAPACTITY FACTOR OF 80% AND RECIPROCATING ENGINE COGEN PLANT TO OPERATE AT CAPACTITY FACTOR OF 40% HEAT TO POWER RATIO = 1.5 10/11/2018 Cogeneration and Distributed Resources

500 MW OF GAS RECIPROCATING COGENERATOR OPERATION AT A CAPACITY FACTOR OF 40%, THE ANNUAL REDUCTION IN CO2 EMISSIONS IS CALCULATED AS FOLLOWS: 500,000 kW X h X 40% X 910 g/kWh = 1,600 kt 10/11/2018 Cogeneration and Distributed Resources

1000 MW OF GAS TURBINE COGENERATOR OPERATING AT A CAPACITY FACTOR OF 80%: ,000,000 kW X 8760 h X 80% X 870 g/kWh = 6,100 kt ONLY CO2 EMISSIONS CONSIDERED! ANALYSIS SHOULD CONSIDER CH4 & NOx . THEREFORE CO2 EMISSION WILL CHANGE BY FEW %. 10/11/2018 Cogeneration and Distributed Resources

Black coal power station Brown coal power station
Species Gas turbine g/kWh Gas engine Gas boiler Black coal power station Brown coal power station CO2 220 1,160-1,400 NOx 4-20 0.26 4-5 CO 0.07 CH4 10/11/2018 Cogeneration and Distributed Resources

CO2 SAVINGS FROM COGENERATION kW GAS TURBINE CO2 SAVINGS DUE TO DISPLACED ELECTRICITY ARE THE DIFFERENCE BETWEEN COAL FIRED POWER STATION EMISSION g/kWh (BLACK COAL) GAS ENGINE EMISSION 530 g/kWh NET g/kWh 10/11/2018 Cogeneration and Distributed Resources

HEAT TO POWER RATIO = 1 (TYPICAL GAS FIRED COGENERATOR) CO2 SAVINGS DUE TO DISPLACED BOILER FUEL ARE FOR 400 X 1.0 = 400 kW (THERMAL) OF HEAT CO2 EMISSIONS FOR GAS FIRED BOILER ARE 220 g/kWh (THERMAL) AND THE COGENERATOR PLANT GENERATES NO ADDITIONAL CO2 IN MEETING THE HEAT REQUIREMENTS THEREFORE TOTAL CO2 SAVING IS THUS ( X 1.0) = 640 g/kWh (ELECTRICAL) 10/11/2018 Cogeneration and Distributed Resources

GAS FIRED COGEN CAPACITY Country Cogen capacity (MW) Generator capacity (MW) Cogen as % of the total Australia 2082 41000 5.1% Japan 180000 6.5% UK 45000 7.0% USA 745600 8.0% Netherlands 15900 29% Spain 28420 10/11/2018 Cogeneration and Distributed Resources

COGENERATION AND DISTRIBUTED RESOURCES

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