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Image 1. Process flow diagram with main process parameters of the reference plant.
are possible for this. It must be differentiated In this process flow, the district heating supply ween useful power and total power. Analo-
as to whether the requirement is to provide is provided in two ways. On the one hand by gously, a mean efficiency can be calculated
the highest-possible electricity generation directly using the engine exhaust heat in the over a period of time, which is then described
capacity (application: condensing turbine) or form of cooling water and the residiual engine as degree of utilisation, representing the relati-
to provide low temperature heat with con- exhaust heat, and on the other hand indirectly onship between the target energy output and
current electricity production (application: via the heating condenser. When the engine the energy expended. Since CHP plants are
back-pressure turbine). For the application exhaust heat is used directly, the water retur- operated under different boundary conditions,
considered here, the use of a back-pressure ning from the district heating with a tempera- the time-based evaluation approach is of
turbine similar to the CCPP reference plant ture of 60 C is routed to the heat exchanger great importance, hence why it is used here.
seems promising, since the exhaust steam LT-CW-DH-HE. Here, the water is heated for
can also provide district heating. Figure 2 the first time by using the waste heat in the Fuel utilisation factor
shows the respective process flow diagram low-temperature cooling water. After this, it When evaluating the energy characteristics
of such a module, consisting of a gas engine flows to the HT-CW-DH-HE, where the HT of a CHP plant in the form of an efficiency,
(GCC version) coupled with a downstream cooling water further heats the water (on the i.e. the ratio of useful power output to energy
located water-/steam cycle, composed of a district heating side). A further temperature expenditure, the two qualities of the different
single-stage heat recovery steam generator increase is provided by the residual heat in target energy types, electrical energy W and
(HRSG), a back-pressure extraction turbine the engine exhaust gas. Depending on the heat Q, are considered to be equal. In order to
and two heating condensers. In the following, required temperature level of the district hea- make this distinction, the efficiency of the CHP
this will be referred as engine (GCC)+Hea- ting supply flow, different mass-flow overlays plant is described according to VDI 4608 as
Cosystem. Due to the variable feed tempe- occur, which is why bypasses and additional the fuel utilisation factor ), which is calculated
rature in the district heating, the main process (district heating return) feeds are provided, as per equation 1:
parameters for both limiting cases (district which will not be discussed here further. In Table 1. Parameters for economic assessment.
heating supply flow temperature of + 130 the case of indirect provision, the water from Parameter Unit high price low price
and +80 C) are displayed in the table to give the district heating return is routed back to the scenario scenario
(HPS) (LPS)
an impression of the range of values. heating condenser and is heated up before
Natural gas /MWhth 21 21
First, the engine exhaust gas is routed to a then being added to the water which has price
heat recovery steam generator (HRSG), con- been directly heated. A gas-fired peak load Electricity price /MWhel 60 28
sisting of superheater, evaporator with drum, boiler ensures that the maximum district hea- Heat price /MWhth 50 50
and preheater. As a result of the heat transfer ting supply flow temperature can be met. CHP bonus /MWhel 18 18
electricity
from the engine exhaust gas to the water-/ For both concepts, Engine(CHP) and Engine
CO2 costs /tCO2 7.5 7.5
steam cycle, live steam at 380 C and approx. (GCC)+HeaCo, a modular structure up to the
20 bar is generated. The live steam is then ex- level of a large combined power plant is pos-
(1)
panded in a back-pressure extraction turbine, sible. This means that the supply of district
whereby the extraction serves the supply of heating networks, such as in this example,
Since heat is also partially provided from un-
the deareator (DEA) with bleed steam and the- can be covered in a similar manner as with
coupled generation from the CHP plant, for
reby ensures degassing. The majority of the the CCPP concept. In this context, the follo-
example to cover peak demand loads, this
steam, however, is still fully expanded to the wing section describes an evaluation of the
proportion must be subtracted out of the CHP
level of possible back-pressure depending on reference year carried out with the developed
evaluation. In addition to the simple fuel utili-
the district heating supply flow temperature. calculation models.
sation factor, we therefore introduce the fuel
The turbine exhaust steam condenses in the
utilisation factor of the coupled production of
heating condenser, thereby transferring the Evaluation parameters
electricity and heat in addition to equation 1,
heat released in the process into the district
With regard to the evaluation parameters, it CHP, with the modified values flowing into the
heating network. After this, the condensed
necessary to differentiate between energetic evaluation in each case:
water is fed to the deareators by the conden-
is and exergetic parameters, as well as bet-
sate pump, from where it then returns to the
ween considerations based on specific points (2)
heat recovery steam generator via the feed
in time and time periods. For a specific point
water pump.
in time, the efficiency represents the ratio bet-
Image 2. Process flow diagram with main process parameters of the engine (GCC)+heating condenser system.
CHP coefficient of selecting the mean ambient temperature, - CCPP plant,
The CHP coefficient CHP of a CHP plant in which is summarised in [2]. Within this study, - Engine(CHP) and
equation 3 according to [5] represents the the mean ambient temperature of each heat - Engine (GCC)+HeaCo
relationship between the electrical energy requirement Tamb,i is used for their evaluation,
WCHP provided and the heat QCHP provided: which in line with VDI 4608 Sheet 1. Based on the developed calculation models,
an exemplary assessment was carried out
Cost effectiveness for the supply of the example application with
(3) As well as the investment, the economic effi- district heating and electricity based on the
ciency of a CHP plant is determined by the re- reference year. The plants were all operated
venue situation. For this reason, an estimation in heat-optimised mode. For reasons of com-
Primary Energy Savings PES of the revenue situation is also provided, with parability, the temperature dependence of the
The Primary Energy Saving (PES), defined the assumptions stated in table 1 being taken engine and gas turbine were neglected.
according to [5], represent the percentage as a basis. Due to the variable compensation
fuel saving through the coupling of heat and situation for electricity, two scenarios with high Starting situation of the CCPP plant
power for a CHP application versus separate price scenario (HPS) and low price scenario Figure 3 shows the sorted annual profile line
generation using suitable reference systems. (LPS) were used. The HPS represents roughly for the district heating demand within the
Its calculation is shown in equation 4: the price which a municipal utility can gene- supply area, as well as key performance data
rate for electricity distribution within its own (district heating load, re-cooling power, net
network, whereas the LPS is based on the electrical power and fuel requirements) of the
(4) CHP-index of the EEX electricity exchange. CCPP plant in the reference year.
In order to get the CHP bonus, it is neces- The profile of the district heating demand in
sary to target an annual fuel utilisation factor the reference year shows that the required
For the efficiencies of the reference systems, of more than 80%, as well as a PES of more district heating load lies between 142.7 MWth
the harmonised efficiency figures given in [4] than 10% [5]. and 14 MWth. But demands of more than
for natural gas were used. With the separate 120 MWth only occur on 14 days in the year.
generation of electricity, the harmonised effi- Results of the annual yield simulation Furthermore, the district heating demand pro-
ciency reference value for construction years and evaluation file shows that even in the midsummer, there
2012-2015 is 52.5%, whereas a harmonised is still a baseload demand within the district
efficiency reference value for the separate In the following, an example evaluation for the
heating network.
generation of heat in the form of steam or three technical system configurations:
hot water is reckoned to be 90%.
DH-demand 300
provided DH-power output CCPP
140
Exergetic efficiency provided electrical net power output CCPP
recooled power output CCPP 250
Based on VDI 4608 Sheet 1, the exergetic 120 thermal fuel input CCPP
efficiency for ne year in daily increments is
100 200
defined in equation 5 as:
80
150
(5) 60
100
40
With Ti being the temperature of the district
50
heating supply, and according to equation 6 20
equates to the thermodynamic mean tempe-
0 0
rature of flow and return temperatures: 0 50 100 150 200 250 300 350
days
Image 3. Sorted annual profile line for the district heating demand within the supply area, as well as key performance data (district
(6) heating load, re-cooling power, net electrical power and thermal fuel power) of the CCGT plant in the reference year.
160
DH-demand
For methane, the fuel exergy proportion based
provided DH-power output engine(CHP)
140
on LHV according to [1] is 0.95. In contrast to provided DH-power output engine(GCC)+HeaCo
the energetic efficiency, here only the exer- provided DH-power output CCPP
120
thermal output [MWth]
then the first requirement is to create a com- PES % 21.11 24.15 23.71
plant configuration (see above), the number of Revenue costs HPS Million 45.05 44.87 48.02
engines in a combined power plant provides Revenue costs LPS Million 25.28 25.94 26.70
The provided net electrical power output from systems comparing favourably with the CCPP For the Engine (GCC)+HeaCo system are due
the engine systems also shows a stepped plant. Furthermore, all three systems are abo- to the modular concept, in most cases only a
layout across the sorted annual distribution. ve the evaluation benchmark of 80% stated part of the water-/ steam cycle modules cou-
Furthermore, it should be noted that the hig- in the CHP regulations for the CHP bonus. pled to the engines in operation. Fundamen-
hest electrical net power output is provided by The highest CHP coefficient is offered by the tally, however, the investment amount would
the Engine (GCC)+HeaCo system. The district Engine (GCC)+HeaCo system, at 1.3, follo- be equally high even if they were operated du-
heating supply temperature reduces with in- wed by the Engine(CHP) with 1.12 then the ring the whole year. A higher utilisation period
creasing ambient temperature, which is why CCPP plant with 1.07. As a result, the Engine of the coupled water-/ steam cycles can be
the back-pressure reduces and the net power (GCC)+HeaCo system is especially interesting achieved if not all of the engines are equipped
output increases. As a result of this behaviour, from the point of view of the CHP bonus, since with the waste heat capture. In this case, the
there is no plateau within the steps for Engine it provides a favourable ratio of electrical ener- engines with waste heat capture are used for
(GCC)+HeaCo at supply temperatures above gy to heat. To take into account the different district heating baseload, so that these engi-
80 C. For this reason, the net power output thermodynamic qualities of heat and electrical nes and the downstream processes will have
within one step increases from left to right. energy, an evaluation of the primary energy substantially higher full load hours. Ultimately,
The maximum provided net power output du- saving as well as the exergetic utilisation fac- this results in a better relationship between
ring the annual cycle is 122.6 MWel. To this tor were also used. The Engine(CHP) has the additional revenue and additional investment.
effect, a constant electrical net power output highest primary energy saving with 24.15%, Based on this approach, a sensitivity analysis
is produced in one step with the Engine(CHP) followed by the Engine (GCC)+HeaCo with was carried out for the application being con-
system. During the winter plateau, the net 23.71% and the CCPP plant with 21.11%. sidered here. Starting with a combined power
electrical power output is 116.6 MWel. The lo- Thus all three systems lie above the threshold plant comprising only Engine(CHP) modules,
west maximum electrical net power output is value of 10% required in [5]. Due to its higher the number of modules in the Engine (GC-
provided by the CCPP plant, although there electricity production, the Engine (GCC)+Hea- C)+HeaCo configuration was then increased
is also a small rise to the right (higher ambi- Co system has the highest exergetic utili- step by step until the combined power plant
ent temperature) due to the behaviour of the sation factor of 51.78%. The CCPP plant has was created is consisting only out of Engine
back-pressure turbine and heating conden- the lowest exergetic utilisation factor with (GCC)+HeaCo modules. In the intermediate
ser. The minimum power of the CCPP plant 49.77%. steps, the combined power plant consisted of
is substantially higher than that of the engines, However, all systems must also enable effi- a mixture of Engine(CHP) modules and Engi-
which can be explained by the lower number cient economic operation. The thermodyna- ne (GCC)+HeaCo modules. The results of the
of gas turbines. Overall, there is a power ad- mic evaluation factors for system efficiency sensitivity analysis are shown in Figures 6 and
vantage for the Engine (GCC)+HeaCo system have shown that all plants are eligible under 7.
during the winter plateau, lying at 5.1% com- the auspices of the CHP regulations. Based At the intersection with the Y-axes, the com-
pared to the Engine (GCC)+HeaCo system on the project specific costs and revenues, a bined power plant consists completely out of
and 20.7% compared to the CCPP plant. cost-revenue calculation was carried out. A Engine(CHP) modules (primary Y-axis) and
All three systems provide the required heat positive revenue was shown for all three sys- Engine (GCC)+HeaCo modules (secondary
load of 587.78 GWhth demanded by the tems, with the highest amount shown with the Y-axis). Therefore their values correspond
district heating network, with the highest Engine (GCC)+HeaCo under both scenarios with the values in Table 2. If, starting from the
heat component being delivered in CHP by (HPS and LPS). Engine (CHP), the number of Engine (GCC)+
the CCPP plant with 97.9%, excluding the
re-cooling power. This high component is pri- Eta_FUR_CHP full load operating ratio supplementary fuel income-cost
marily due to the auxiliary firing of the was-
1,00 49,00
supplementary fuel [1e5 MWh]
0,95
engine systems. Furthermore, the maximum
0,90 48,00
CHP heat output of the engine models is al- income-cost [Mio. ]
0,85
ways below that of the CCPP plant, as already 0,80 47,00
shown in Figure 4. During electricity producti- 0,75
on, it can be observed that the entire electri- 0,70 46,00
city production is descended from CHP. The 0,65
greatest quantity of electricity is provided by 0,60 45,00
the Engine (GCC)+HeaCo system at 666.24 0,55
GWhel, which represents an increased yield 0,50 44,00
of 7.8% compared with the CCPP plant, and 0 2 4 6 8 10
number of gas engines with heating condenser
12.6% compared with the Engine (CHP) sys-
tem. The picture for fuel consumption is very
Image 6. Profile of fuel utilisation factor, fuel load amount, additional fuel requirements and revenue costs of the combined power plant
similar to that for electricity production. In this consisting of 11 engines and variable number of engine (CHP) and engine (GCC)+heating condenser modules in the reference year.
case, the highest demand also lies with En-
gine (GCC)+HeaCo, followed by CCPP plant In conclusion, it should therefore be noted that HeaCo modules in the combination power
and then the Engine(CHP). the engine combination systems reviewed in plant increases, the full load operating pro-
the chosen application may have advantages portion as well as the revenues also increase,
In order to carry out a comprehensive evalua- in terms of energy efficiency and economic whereas the CHP fuel utilisation factor drops.
tion of the systems based on the yield values efficiency compared with the CCPP reference The fuel demand can initially be slightly re-
stated, the evaluation parameters introduced plant. duced, being at its minimum with 2 Engine
previously were used. The highest CHP fuel (GCC)+HeaCo modules, before it increases
utilisation factor is shown by the Engine (CHP) Economically optimised application of the again with the increasing number of Engine
system with 86.16%, but with both engine heating condenser module (GCC)+HeaCo modules. For the investment
decision however, the key factor is the pos- heating load several days in advance, the cally attractive. When considering the future
sible advantage from the heating condenser number of modules of the combined power changes in the German energy supply sys-
application in the cost-revenue calculation plant which would be available for residual tem, it must also be pointed out that, due to
based on the installed capacity of the steam load management can always be identified. their modular operation in CHP applications,
turbine (ST), as well as the pricing basis for The gas engine used for this study, enables these highly efficient gas engines will be due
the steam turbine of the applicable power from standstill a fast start-up to full load within to their high specific load gradients in a positi-
class. Both of these parameters are therefore 180 s [6], which represents a load gradient of on to participate also in the balancing energy
shown additionally in Figure 7. 3.5 MWel/min. Based on the installed power, market.
Due to the modular illustration selected, the this means 33% MWel,inst/Min.
installed ST power increases linearly with the In comparison, modern CCPP plants such Acknowledgements
number of Engine (GCC)+HeaCo modules in as the Siemens H-class currently offer hig- The investigations were carried out under the
the combined power plant. It is possbile to her load gradients of up to 16.6 MWel/min [7]. auspices of the joint project TURIKON, which
draw from the installed ST capacity conclusi- Based on the installed power, however, this was financially supported by the federal state
ons regarding the investment needs. Funda- only equates to 3% MWel,inst/Min. As a result, of North Rhine-Westphalia as well as the
mentally, the specific investment for a steam a combined engine power plant has a clear European Fund For Regional Development
turbine decreases with increasing ST capa- advantage in this respect. Furthermore, it within the progress. NRW and the Ziel 2 pro-
city. According to this, it would be advanta- must be pointed out that for engines there is gramme 2007-2013, Phase VI (funding code:
geous to connect multiple engine modules to no lifetime consumption related with starting 64.65.69-EN-2019).
one larger steam turbine of a higher power cycles and have even lower starting costs. For
This text was first published in German lan-
class. For exact analysis of the ST invest- this reason, from the point of view of flexibility,
guage in VGB PowerTech Journal, edition
ment, manufacturer-specific information need as well as for example stated in [8], gas engi-
03/2016.
to be used, which was not done in this study nes are a suitable element in a future German
for reasons of comparability. energy supply system.
List of abbreviations
installed ST-power output spec. income-cost
Amb Ambient
5,00 1,80
installed ST-power output [MWel]
References
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All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the sub-
sequent specific individual projects, the relevant data may be subject to changes
and will be assessed and determined individually for each project. This will depend
on the particular characteristics of each individual project, especially specific site
and operational conditions. CopyrightMAN Diesel & Turbo.