Cogeneration

Rangan Banerjee Energy Systems Engineering IIT Bombay

Lecture at NITIE on March 18, 2004

Utility options
Heat Fuel PROCESS Electricity Electricity Heat Cogen Plant Fuel SHP Electricity Power Plant Fuel Cogeneration

BOILER

Heat

Cogeneration Concept
Boiler 90% Power plant 40% Where is the scope for improvement? Cogeneration- Simultaneous generation of heat and power (motive power or electricity) CHP- Total Energy Second Law of Thermodynamics Concept of Exergy

Early 19th century Cogeneration plant

Selection of Cogen Option

Heat/Power Ratio X (Range of values) Fuel Availability Costs
Decreasing X

Steam Turbine Gas Turbine Combined Cycle D.G. Set

5.9 ( 3-7) 1.5 1.2 0.7

Evaluation Criteria
Relative Fuel Savings Rf Fuel savings over separate heat & power generation Rf = ( Fnc Fc) / Fnc Fnc = Fboiler + Fpower plant Fuel Chargeable to Power (FCP) The incremental fuel in cogeneration is charged to the power generation. FCP =( Fc Fboiler)/ W kg of oil/kWh, kJ/kWh, Nm3 gas/kWh, kg of bagasse/kWh

Cogeneration Concept
Process boiler , sat steam at 180 C 90% (1st law eff) Tu= 180+273 =453 K, T0 = 300 K II=Qu(1- T0 / Tu)/ Qin (for fuel 1.0) =0.9(1-300/453) =0.3 (30%) Increase generation temperature to 400 C and pass through an expansion turbine

Back Pressure Steam Turbine System

HP Steam Fuel Air Water LP Steam to Process BOILER Electricity ST

Steam Turbine Cogen

Configuration Boiler BPT with extraction Back Pressure Turbine Condensing Turbine Condensing Power Plant 3 0 X 10
Decreasing X

Steam Turbine Calculations

Specific Enthalpy h1 h2 h2i 1

is = h1-h2 h1-h2i
2 2i Specific Entropy s

Example Problem
A process boiler generates 25T/hour of saturated steam at 10 bar absolute. The fuel used is LSHS. The boiler efficiency is 90%. The power requirement of the industry is 2.5 MW. Evaluate the viability of using a high pressure boiler generating steam at 50 bar 400 C and a back pressure turbine

GAS TURBINE BASED COGEN

Fuel CC GT

Power

C Air

Steam to Process

Suppl Fuel

WHRB Feed water

Stack

Gas Turbine Cogeneration

Unfired Heat Recovery Steam Generator (HRSG) Supplementary Fired (Duct Burners) Fully Fired HRSG Steam Injected Gas Turbines (STIG) Combined Cycle

Cogeneration
Self generated electricity in Chemical 42% of total elec, 86% from cogeneration plants Average price only 57% of grid price Purchased electricity declining (-0.4%), self generated elec increasing at 21.3% per year Evaluate viability of Cogeneration If heat/power loads small-Cogeneration for group of industries

Operating Strategy
Standalone/ Isolated Grid Interconnection
Parallel with Grid Only Buying from grid Buying and Selling to Grid

Thermal Load Following Electrical Load Following Maximum Cogeneration

2 2 a ta 330o C FEED W ATER

5 8 T /h r

F eed w ater

4 .5 T /h r B O IL E R
0 .5 T /h r

2 7 T /h r

2 6 T /h r

PRDS

BA G A SSE 0 .5 T /h r M IL L IN G
PRDS

6 a ta
~ P ro cess

2 .5 M W STEA M T U R B IN E

2 a ta

F la s h e d C o n d e n sa te

P ro cess

S c h e m a tic o f ty p ic a l 2 5 0 0 tc d S u g a r fa c to r y

Options
A- Replace mill turbines by motors + power turbine by efficient motor B- New Boiler 43 ata 480 C + additional TG C- HP Boiler 65 ata 480 C + additional TG D C+ replace mill turbines with TG E similar to D but with condensing extraction turbine

B O IL E R F e e d w a te r

75 TPH , 65 a ta , 4 8 0 O C

STEA M T U R B IN E 13 M W 9 .5 M W P ow er export

BA G A SSE
( A lt e r n a t e f u e l) ~

PR O C ESS 2 a ta 2 a ta

CO NDENSER

Condenser

6 a ta 4 .5 T P H

1 .0 M W M ill d r iv e s

BFP PR O C ESS

2 .5 M W C a p tiv e lo a d

P R O P O S E D P L A N T C O N F IG U R A T IO N : O P T IO N 2

Comparison of Options
Case A B C D E Output 5.4 MW Export 1.9 MW kWh export /tc 18 48 41 69 91

7.5 MW+M 5.0 MW 6.8 MW+M 4.3 MW 10.7 MW 13 MW 7.2 MW 9.5 MW

Optimal Cogeneration Strategy

Decisions
Grid Electricity Bought/Sold Equipment Mass Flow rates Electric/Steam Drive

Constraints
Equipment Characteristics Min/Max Process Steam & Electricity Loads Grid Interconnection

Objective Function
Minimise annual operating cost (Maximise revenue)

Fuel, HSD 5.9 T/h

WHRB-1
G

Stack 136 T/h

Gas turbine -1

20 MW

Supp. Firing LSHS 5.6 T/h WHRB-2 136 T/h Grid 7.52 MW Process Load, 60 MW

Fuel, HSD 5.9 T/h

G

Gas turbine -2

20 MW

Supp. Firing LSHS 5.6 T/h

BUS SHP Steam 100 bar,500o C 117.1 T/h 60.6 T/h Process Load,150 T/h 76.2 T/h ST

131.7 T/h Boiler Fuel, LSHS 9.64 T/h

12.5 MW
G4

Process Load,125 T/h PRDS-1 PRDS-2 HP Steam 41b,400 oC MP Steam 20b, 300 oC

20 T/h

Process Load

40 T/h

49.5 T/h PRDS-3 53.4 T/h

40 T/h

16.2 T/h

LP Steam 5. 5 b, 180 oC

Process Load 40 T/h

Deaerator
Feed water 426.5 T/h

Condenser Make up water,357 T/h

Import Power from Grid with Cogeneration for a Petrochemical Plant

Import power MW

25 20 15 10 5 0

21.6

flat tariff
17.6

TOU tariff
peak period demand 11 MW 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time hours

Export power to the grid with Cogeneration for a Petrochemical Plant

Export Power MW

40 30 20 10 0

flat tariff

TOU tariff

Peak period demand 9.7 MW

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time hours

Summing Up
Even in industries with cogen Retrofits for additional power generation Sugar 2500 tcd plant can generate 9.5 MW surplus by using high pressure boilers Grid Agreement Parallel, Buying/Selling Optimal operating strategy can result in significant savings Significant potential in process industries

Thank You