Cogeneration

Definition and Scope

• Cogeneration also known as CHP (combined heat and power), is on site
generation of electricity using waste heat.
• Cogeneration is defined as simultaneous production of two forms of energy
using single fuel. Two forms of energy may be electrical energy and process
steam.
• In a conventional power plant while generating electricity, only a part of
input is converted into useful output. Remaining part is lost as waste heat.
• In case of cogeneration plant, waste heat is recovered for other applications.
e.g. Process steam, space heating, waste heat recovery boiler etc.
• In other words, we can say that CHP is an efficient process which recovers
the waste energy which leads to increase in efficiency as well as reduction
in climate change and promotes environmental benefits.
Figure 7.1 : Typical Conventional Power Generation Station

Figure 7.2: Typical Cogeneration System

 Types of Cogeneration
A conventional power plant either produces electrical energy or thermal
energy (process steam) but a cogeneration plant produces both types-
electrical as well as thermal energy.
• In-plant heat utilization system
• Reject heat utilization system
In-plant heat utilization system is mainly used in industries and reject heat
utilization system is mainly used at power plants.
 Electric Power
Steam For Manufacturing Process

Turbine

Steam Generator

Condensate

Boiler

Fuel
Water

Figure 7.3 : In-plant heat utilization system

 Electric Power
Exhaust Steam to Adjacent Industry

Turbine

Steam Generator

Condensate

Boiler

Fuel
Water

Figure 7.4 : Reject heat utilization system

 Topping and Bottoming Cycles
• In topping cycle, fuel is burnt in • Fuel burnt in the boiler first
the boiler to produce steam. produces process steam.
• Steam expands in a turbine which • The reject heat from process steam
is mechanically coupled to is used to generate electrical
generator and hence produces energy.
electrical energy. • It means, first heat energy in the
• Electricity is produced first and form of process steam is produced
exhaust steam is used as process first and then electrical energy is
steam. produced.
• Commonly used cycle • Not commonly used cycle
 Benefits of Cogeneration
• Fuel economy
• Lower capital cost
• Lower gestation period
• Reduces emissions
• Energy reform benefits
• Un-interrupted power supply for industries
 APPLICATIONS
• Cogeneration plants are commonly found in district heating systems of big towns, universities,
hospitals, hotels, prisons, oil refineries, paper mills, wastewater treatment plants, thermal enhanced
oil recovery wells and industrial plants with large heating needs.
• The industries that need both power and steam for their working are most suitable for cogeneration.
• Paper, pulp, chemical, petroleum refining, textile, sugar, cement and iron industries are some
examples of cogeneration.
• Cogeneration plants are also found in district heating systems of big towns, universities, hospitals,
hotels, prisons, oil refineries, paper mills, wastewater treatment plants etc.
Cogeneration
Cogeneration Technologies
 Cogeneration Technologies
• Steam turbine cogeneration technology
• Gas turbine cogeneration technology
• Combined cycle cogeneration technology
• Diesel engine cogeneration technology
 Steam Turbine Cogeneration Technology
• Similar to thermal power plant
• Flexibility in fuel selection
• High pressure steam produced by the boiler is used for electricity
production.
• Lower pressure steam is used for manufacturing processes.
• 13% energy saving
• This type of system burns fuel to produce high-pressure steam that then
passes through a steam turbine, which is coupled, to generator. So,
electrical power is generated.
Figure 7.5: Steam turbine cogeneration technology
 Gas Turbine Cogeneration Technology

• In gas turbine power plant, when fuel mixes with compressed air in
combustion chamber, huge amount of heat is produced.
• Exhaust from gas turbine is sent to waste heat recovery boiler.
• Costlier than steam turbine cogeneration technology.
• Energy saving of about 25% is obtained using this cogeneration
technology.
 Fuel Combustion

Compressor Chamber

Generator

Air Gas Turbine

Electricity

Process
Gas Turbine
Steam
Waste Heat Exhaust
recovery
Water Boiler

Figure 7.6 : Gas turbine cogeneration technology

 Combined Cycle Cogeneration Technology
• Combination of gas turbine and steam
turbine cogeneration technologies.
• First, electricity is produced in gas
turbine plant and exhaust from gas
turbine is sent to waste heat recovery
boiler.
• High pressure steam is used to produce
electricity and exhaust from steam
turbine is used as process steam.
• Energy saving of about 35% is possible.
 Fuel Combustion

Chamber
Compressor

Generator

Air Gas Turbine

Electricity

Gas Turbine

Exhaust
Waste Heat
recovery Boiler
Water

Figure 7.7: Combined cycle cogeneration technology

 Diesel Engine Cogeneration Technology
• The heart of the system is diesel engine which drives the generator. The input to diesel
engine is fuel and air.
• Jacket cooling water and engine exhaust are used as input to waste heat recovery
boiler.
• The hot water from the engine jacket cooling system flows to a heat recovery boiler,
where it is converted to process steam and hot water for space heating.
• This system can be used only if excess electricity can be sold because the generation
cost per unit is higher than other systems.
• High electricity to thermal ratio
• Energy saving of about 26% is possible.
 Generator
Air and fuel
Diesel Electrical
Engine Energy

Engine
Jacket exhaust
coolin W.H. Process steam
g Boiler
water

Water

Figure 7.8 : Diesel engine cogeneration technology

 Gas Turbine Combined Cycle Diesel Engine Steam Turbine

Suitable applications Where high pressure steam Where wide fluctuations Where high pressure steam not Where low-cost solid fuel
required in the amount of energy needed available
required

Suitable size for 1 MW to 250 MW Medium to large Up to about 3 MW Low MW upwards

applications
Electrical efficiency Moderate to high High High to Medium Moderate

Initial Cost Moderate High Low because of less pressure High

Maintenance and Moderate Moderate High High

Operating Costs
Advantages Heat recovery steam High efficiency Good operational characteristics Can use most types of fuel
generator can have with small sets including solid fuels such
supplementary firing High electricity to thermal ratio as wood,

Disadvantages Not suitable below about Expensive to make and High purchase cost and Low power-to-heat ratio
3MWe to maintain expensive to maintain and a poor match between
process steam and
electrical requirements
 Cogeneration
Allocation of Costs and Impact of Pricing on Cogeneration
 Allocation of costs

• Includes fixed costs (interest and depreciation on capital cost, salaries of high officials) and
variable costs ( fuel cost, labour wages, operation and maintenance costs etc.).
• As compared to conventional power plants, cogeneration plants are having facilities for
producing electricity as well as process steam.
• The incremental cost is defined as the additional costs incurred for adopting cogeneration.
• The determination of the incremental cost depends upon whether the cogeneration facility is
owned by an industry or power plant.
• In case of an industry, main product is process steam and by product is electricity whereas
in case of power plant, main product is electricity and by product is process steam.
Figure 7.9 : Graphical representation of allocation of cost in cogeneration system
 SALE OF ELECTRICITY TO UTILITY AND
IMPACT ON COGENERATION
• If electricity produced in a cogeneration plant is sold to the utility, the pricing of
generation has great impact on promotion of cogeneration.
• Industrial unit can be encouraged to adopt cogeneration if electric utility purchases
electricity from it at reasonable rate. Too high cost of electricity paid to industries, would
subsidize industries but put a burden on other users of electricity and too low cost of
electricity paid to industries would discourage cogeneration.
• Let the total annual cost of cogeneration system be Rs. C. if system produces ‘a’ units of
electricity and ‘b’ units of steam then a(x) + b(y) =C
Where x = cost of per unit electricity generated
and y = cost of per unit of producing process steam
 Y

Steam
Price
Rs/KCal
a2x+b1y=C

a1x+b1y=C
S

a3x+b1y=C

0 E X2 X X1

Electricity Price Rs. /KWh

Figure 7.10 : Graph showing impact of cogeneration on sale of electricity

• If rate of purchasing is low, industries would have to produce more
electricity to recover the cost. If they are not doing so, then they have to
pay tax indicated by area XYX2.

• They need to produce less electricity. If the unit produces same amount of
electricity then the area XYX1 indicates the amount of subsidy paid to
industries going for cogeneration.
 DRAWBACKS OF COGENERATION

• In some cases, cogeneration can increase emissions of nitrogen oxides and noise.
• CHP is most efficient when the heat can be used on site or very close to it.
• Overall efficiency is reduced when the heat must be transported over longer distances whereas
electricity can be transmitted along a comparatively simple wire, and over much longer distances
for the same energy loss