09/01/2017 COGENERATIONGASENGINE

(COGENERATION)

COGENERATIONGASTURBINE

COGENERATIONGASENGINE

COGENERATION.


COGENERATIONGASENGINE

SmallscaleCogeneration

Introduction

Cogeneration,orcombinedheatandpower(CHP),systemsprovideelectricityandheator,insome
cases,shaftpowerandheatfromasingleunit.Overallefficienciesbetween8090%arenormally
achievedgivingprimaryfuelsavingsofapproximately35%comparedtoseparategeneration.This
directlyreducestheusersfuelcostsandbenefitstheenvironmentthroughreducedcombustionoffossil
fuels.

Typicallyreciprocatingengineconvertsabout3541%oftheirinputfuelenergyintomechanical
power.Another22%isrejectedtothecoolingsystem,34%totheexhaustgasand3%tothe

environment.Alargeportionoftheheatenergyrejectedtothecoolingsystemsandcontainedinthe
exhaustgascanberecoveredbyvariousmeans.

Cogenerationissuitableforawiderangeofapplicationsinbothbuildingsandindustry,provided
thereissubstantialbaseloaddemandforheat.Suchapplicationsincludehospitals,educationcentres,

sportsfacilities,hotels,officebuildings,residentialbuildings,variousindustries,wastewatertreatment
anddistrictheating.


CogenerationSystem

Reciprocatingengineasprimemovercanreadilybetailoredtothecustomersspecific
requirements.Forpowergeneration,typicalelectricalefficiencyisbetween3340%.Upto90%ofthe

engineswasteheatcanberecoveredintheformofhotwaterorlowpressuresteamfromtheengines
jacketcoolingwaterandlubricatingoilsystemsandfromtheexhaustgases.

Thereareseveralalternativestotheconventionaluseofcogenerationsystemsforgenerating
electricityandheat.Forinstance,insteadofproducingelectricity,theshaftpowercanbeusedtodrive
compressorsforairconditioningchillerandindustrialrefrigerationplantortosupplycompressedair.The
recoveredheat,insteadofbeingusedforwaterheating,canbeusedeitherforcoolingpurposesvia
absorptionchillier,orforheatingairtospaceordryerheating.


HeatRecovery

Wasteheatisrecoveredfromtheenginesjacketwatercoolingsystemandlubricatingcircuits.
Connectioncannotbemadedirectlytothesitesheatingmediumbecauseofproblemsassociatedwith
pressure,corrosionandthermalshock.Watertowaterandoiltowaterheatexchangersaretherefore
used.Thesearecommonlyshellandtubetypeor,lessoftenplateheatexchanger.Heatisusually
recoveredashotwaterat8590&degC.

Further,heatisrecoveredfromtheenginesexhaustgasesashotwaterorlowpressuresteam
(100120C)usingashellandtubeheatexchanger.Conventionalheatexchangerreducesthe
temperatureoftheexhaustgastoabout170180C.Temperaturebelowthisfiguremaycause

condensationtotakeplacewhichresultincorrosion.Furtherheatcanberecoveredwithcondensingheat
exchangerstheseareoftenuseformeetinglowtemperatureloads,forexample,preheatingofboiler
feedwater.


SystemPerformance

Cogenerationsystemefficienciesvarywiththetypeofprimemover.Typically,reciprocatingengine

achieveanoverallefficiencyof8090%

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Tobeviable,cogenerationsystemsmustoperatealmostcontinuouslyforextendedperiodsoftime.
Inindustrialapplicationsutilizationisnormallymuchhigher.Unscheduledstoppagesresultinincreased
maintenancecosts,theneedtopurchaseenergyatreliability.

Typically,reciprocatingenginesachieveanavailabilityof9095%.Anumberoffactorscontributeto
theunscheduledoutagesthatreducesystemavailability.Theyincludeovercomplexsystemsorcontrols
andpoordesignormanufacturingquality,inadequateoperatortrainingandpoormaintenance.


SystemDesign

Anydecisiontoimplementcogenerationmustbebasedonadequateknowledgeofthesites
electricalandthermalloadprofiles,boththroughouttheweekandseasonally.Withthisinformationitis
possibletoselectthebesttypeofprimemoveranddetermineanappropriatesystemsize,Maximum
systemefficiencyisachievedwhenaunitisoperatingatfullload.Systemsthatareoversizedwilleither
havetorunforlongperiodsatpartloadoroperateforareducednumberofhoursperyear.

Thecorrectsizingofthecogenerationsysteminvolvesidentifyingthepotentialforenergy
conservationandassessinglikelychangesinthesitesfutureenergydemand.Theresponsetoany
remaininguncertaintyinthelevelofdemandshouldbetoundersizeunitsandensurehighutilization

levels.Unitsshouldnormallybesizedataround50%ofthesitesmaximumthermaldemand,withthe
additionalheatdemandbeingmetbyconventionalboilers.Itmaybeappropriatetoincorporatean
elementofthermalstorageintothedesignortoinstallmorethanonecogenerationunit.

Thereareseveralconfigurationsforconnectingthecogenerationsystemtotheexistingheatingand
electricalsystems.Mostsystemsareconnectedinserieswithexistingheatingsystems,althoughparallel
connectionmaybeselectedfornewinstallations,particularlywhencogenerationsuppliesalarge
proportionoftheheatload.Electricalconnectionisnormallytothelowvoltagesystem,althoughunits

ratedmorethan500ekeandwithhighloadfactormaybelinkeddirectlytothehighvoltagesystemand
exportpowerbacktothegridduringperiodsoflowdemand.Mostcogenerationsystemsuse
synchronousgenerations.There,althoughconnectedtothepublicelectricitysupply,operate
independentlyofthegridandcanthereforecontinuetosupplypowerintheeventofgridfailure.

COGENERATIONGASENGINE




1020kW 7Bar0.75/



8000 10

CONTINUOUS FULLLOAD100%
GASCOGEN110
EXHAUSTBOILERSTEAM
O&MCONTRACT


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401US$




TURNKEYPOWERPLANT

US$/KW (US$)

380 387,600
150 153,000
COGENERATION 100,000
530 640,600

FINANCIALSUMMARY

(US$)
640,600
GAS 2,198,083
O&M 429,559
3,268,242

OPERATION&MAINTENANCECOST

US$/kWh %
FUELCOST 0.0269 83.28
OILCOST 0.0009 2.79
PMCOST 0.0009 2.79
OHCOST 0.0031 9.60
MISCELLANEOUS 0.0005 1.55
0.0323 100
(/kWh) 1.292

CONCLUSION

GASENGINE1.15/ (
kWh) 22kV 2/ (kWh)
0.85/ (kWh) 7Bar2.5/(300/
)


=(0.85x3195x8000)+(0.25x300x8000)
=27,726,000

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