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INTRODUCTION
1.1Definition
By definition, Cogeneration is on-site generation and utilisation of energy in different forms
simultaneously by utilizing fuel energy at optimum efficiency in a cost-effective and environmentally responsible way. Cogeneration systems are of several types and almostall types primarily generate electricity along with making the best practical use of the heat,which is an inevitable by-product. The most prevalent example of cogeneration is the generation of electric power and heat. The heat may be used for generating steam, hot water, or for cooling through absorption chillers. In a broad sense, the system, that produces useful energy in several forms by utilising the energy in the fuel such that overall efficiency of the system is very high, can be classified as Cogeneration System . The concept is verysimple to understand as can be seen from following points
(1) Conventional utility power plants utilise the high potential energy available in thefuels at the end of combustion process to generate electric power. However,substantial portion of the lowend residual energy goes to waste by rejection tocooling tower and in the form of high temperature flue gases. (2)On the other hand, a cogeneration process utilizes first the high-end potentialenergy to generate electric power and then capitalizes on the low-end residualenergy to work for heating process, equipment or such similar use.
1.2 Background
Cogeneration first appearedin late 1880s in Europe and in the U.S.A. during the early parts of the 20th century, when most industrial plants generated their own electricity using coal-fired boilers and steam-turbine generators When central electric power plants and reliable utility grids were constructed andthe costs of electricity decreased, many industrial plants began purchasing electricity andstopped producing their own. Other factors that contributed to the decline of industrialcogeneration were the increasing regulation of electric generation, low energy costswhich represent a small percentage of industrial costs, advances in technology suchas packaged boilers, availability of liquid or gaseous fuels at low prices, and tighteningenvironmental restrictions
The afore mentioned trend in cogeneration started being inverted after the first dramaticrise of fuel costs in 1973. Systems that are efficient and can utilise alternative fuels havebecome more important in the face of price rises and uncertainty of fuel supplies.
In addition to decreased fuel consumption, cogeneration results in a decrease of pollutantemissions. For these reasons, governments in Europe, U.S.A. South East Asia ,INDIA and Japan are taking an active role in the increased use of cogeneration. In India, the policy changes resulting from modernized electricity regulatory rules have induced710MW of new local power generation projects in Sugar Industry. Other core sector industriesare also already moving towards complete self generation of heat and electricity
2. PRINCIPLE OF COGENERATION
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 provides a wide range of technologies for application in various domains of economic activities. The overall efficiency of energy use in cogeneration mode can be up to 85 per cent and above in some cases.
For example in the scheme shown in Figure1 an industry requires 24 units of electrical energy and 34 units of heat energy. Through separate heat and power route the 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.
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Fig2 :Balance in typical coal fired power station(for an input energy of 100GJ )
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Cogeneration uses a single process to generate both electricity and usable heat or cooling. 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. The plant may therefore be set up to supply part or all of the site heat and electricity loads, or an excess of either may be exported if a suitable customer is available. The ratio of heat to power required by a site may vary during different times of the day and seasons of the year. Importing power from the grid can make up a shortfall in electrical output from the cogeneration unit and firing standby boilers can satisfy additional heat demand. Many large cogeneration units utilize supplementary or boost firing of the exhaust gases in order to modify the heat: power ratio of the system to match site loads.
6.4-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.
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8.3.(a) Compact: Their compact and lightweight design makes microturbinesan attractive
option for many light commercial/ industrialapplications.
8.3.(b) Right-sized: Microturbine capacity is right sized for many customerswith relatively
high electric costs.
8.3.(c) Lower noise: Microturbines promise lower noise levels and can belocated adjacent to
occupied areas.
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8.4.(c) Availability
Although field experience is limited, manufacturers claim that availability will be similarto other competing distributed resource technologies, i.e. in the 90->95% range.
8.4.(d) Maintenance
Microturbines have substantially fewer moving parts than engines. The single shaftdesign with air bearings will not require lubricating oil or water, so maintenance costsshould be below conventional gas turbines. Microturbines that use lubricating oil shouldnot require frequent oil changes since the oil is isolated from combustion products. Onlyan annual scheduled maintenance interval is planned for micoturbines. Maintenancecosts are being estimated at 0.006-0.01$/kW.
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8.6 Emissions
NOx emissions are targeted below 9 ppm using lean pre-mix technology without any post combustion treatment.
8.7 Applications
Markets for the microturbine include commercial and light industrial facilities. Sincethese customers often pay more for electricity than larger end-users, microturbines mayoffer these customers a cost effective alternative to the grid. Their relatively modest heatmoutput may be ideally matched to customers with low pressure steam or hot waterrequirements. Manufacturers will target several electric generation applications,including standby power, peak shaving and base loaded operation with and without heatrecovery. One manufacturer is offering a two shaft turbine that can drive refrigeration chillers (100-350 tons), air compressors and other prime movers. The system also includes an optionalheat recovery package for hot water and steam applications.
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9. BENEFITS OF COGENRATION
(a) FUEL ECONOMY : Cogeneration results in substantial economy in consumption of primary fuel .i.e., coal, oil, gas.
The fuel economy results from higher thermodynamic efficiency of cogeneration system ascompare to separate power producing and heat producing systems . Moreover the extra fuelneeded to generate electricity for same quantity of steam produced for process requirement is only about 10%.
(b) LOWER CAPITAL COST
It is seen that an industry needing steam for processing has to invest in boilers . The extra investment needed to upgrade boilers so that electricity can also be generated is pritty small as compared to the cost of boiler. It has been estimated that incremental statement in cogeneration system is only about 50% of the investement needed by an electric utility to supply the same power to industry . Thus cogeneration results in enormous saving in capital cost.
(c) SAVING INDUSTRY FROM POWER CUTS In all developing countries including india the generation capacity is much less than the demand. The electricity supply authorities impose severe power cuts on industry especially when electricity demand for agriculture is high. The power cuts and supply interruption result in huge losses to industry. Many industries install diesel generating sets to keep their process running .The generation cost per KWh of these sets is very high
(d) EFFICIENCY BENIFITS By using waste heat recovery technology to capture a significant proportion of this wasted heat, CHP systems typically achieve total system efficiencies of 60 to 80 percent for producing electricity and thermal energy.Because CHP is more efficient, less fuel is required to produce a given energy output than with separate heat and power. Higher efficiency translates into:
Lower operating costs Reduced emissions of all pollutants Increased reliability and power quality Reduced grid congestion and avoided distribution losses
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Cogeneration technology exists in a wide variety of energy-intensive facility types and sizes nationwide, including:
Industrial manufacturers - chemical, refining, pulp and paper, food processing, glass manufacturing Institutions - colleges and universities, hospitals, prisons, military bases Commercial buildings - hotels and casinos, airports, high-tech campuses, large office buildings, nursing homes Municipal - district energy systems, wastewater treatment facilities Residential - multi-family housing, planned communities
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CONCLUSION
Cogeneration or combined heat power generation is higher in energy efficiency than conventional thermal generation because it reuses heat. Energy that would otherwise be wasted is put to some useful work. Because of its efficient use of energy, cogeneration is more economic and environmentally attractive than conventional fossil fuel power plants. Cogeneration can be located close to electric consumers, thereby reducing transmission line losses. Cogeneration or combined heat power generation is well-suited to facilities with higher thermal loads, consistent electric and thermal energy requirements, and round-the-clock operations. Campus institutions, such as universities and hospitals, often benefit from aggregating energy needs in a district energy combined heat power generation system
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