COGENERATION (CHP=Combined Heat Power Generation)

- Some industries (such as chemical, paper, oil production, steel making, food
processing, textile etc.) reguire energy input in the form of heat, called
process heat.
- Process heat in these industries usually supplied by steam at 5 to 7 Bar and
150-200
0
C.
- Energy is transferred to the steam by burning coal, oil, natural gas, etc. in a
furnace.
If the heat losses are neglected in the piping,
all the heat transferred to the steam is used in
the process heaters (q ~ 100 %).
This operation seems to be perfect. Is it ?
T
furnace
=1300
0
C = Quality of the energy is
very high
This high-qaulity energy is transferred to
water to produce steam at about 200
0
C =
irreversibility is very high (AT 7)
~200
0
C
1300
0
C
It is not wise to use high-quality energy to accomplish a task that can be
accomplished with low-quality energy.
Why use Cogeneration ?
IDEAL
ACTUAL
- Industries that use large amounts of process heat also consume a large
amount of electric power.
- Therefore, it is economic to use already existing work potential (because of
high-quality energy at furnace) to produce power, instead of wasting it.
- The result is a cogeneration plant which produces both electricity and process
heat requirements of certain industrial plants from the same energy source.
- The following power cycles can be used in a cogeneration plant :
+ Steam turbine (Rankine cycle)
+ Gas turbine (Brayton cycle)
+ Combined cycle (Rankine+Brayton)
+ Diesel cycle
+ Otto cycle
AIR INLET
FILTER
AIR INLET
FILTER
GAS
TURBINE
GAS
TURBINE
EXHAUST
BYPASS
SILENCER
EXHAUST
BYPASS
SILENCER
GENERATOR GENERATOR
DIVERTER
VALVE
DIVERTER
VALVE
SUPPLE-
MENTARY
BURNER
SUPPLE-
MENTARY
BURNER
HEAT
RECOVERY
STEAM
GENERATOR
(HRSG)
HEAT
RECOVERY
STEAM
GENERATOR
(HRSG)
EXHAUST
SILENCER
EXHAUST
SILENCER
PROCESS
STEAM
PROCESS
STEAM
Gas Turbine Cogeneration Plant
Gas Turbine Cogeneration Plant
Pulp and Paper
Pulp and Paper
Pulp and Paper
Pulp and Paper
Hospitals
Hospitals
Hospitals
Hospitals
Gas Turbine Cogeneration Plant
Pharmaceutical
Pharmaceutical
Pharmaceutical
Pharmaceutical
Gas Turbine Cogeneration Plant
Combined Cycle (Brayton & Rankine Cycles)
GAS TURBINE STEAM TURBINE
Ideal Steam-Turbine Cogeneration Plant

- This system has no condenser, which
means there is no waste heat rejection.
- All the energy transferred to the steam in
the boiler is utilized as either process heat
or electricity.
in
.
out
.
in
.
P
.
net
.
u
Q
Q
1
Q
Q W
factor n Utilizatio =
+
= c =
c
u,ideal
= 100 %, c
u,actual
= 70 %,
- The heat and electricity demand (in a day, or in a week) of the plant is not
constant for most industries.
- Therefore, a cogeneration plant that can adopt to variable loads is more
practical in real life.
( )
( )
( ) ( )
7 6
7
.
6 4
5
.
4
.
turb
.
8
8
.
6
6
.
5
5
.
P
.
1 7
7
.
out
.
3 4
3
.
in
.
h h m h h m m W
h m h m h m Q
h h m Q
h h m Q
+
|
.
|

\
|
=
+ =
=
=
Cogeneration plants have proved to be economically very
attractive. Therefore, more and more cogeneration plants are
being installed in recent years.

Otoprodktr santrallar kendinin ve ortaklarnn enerji
ihtiyacn karladktan sonra kalan fazla enerjilerini
fiziki balant yaptklar kurulua, tketiciye uygulanan
ortalama net sat fiyatnn %85'ini amayacak bir fiyatla
satarlar.
-95 MW steam turbine generator facility provides electricity and process
steam to Ispat Inland's steel-making operation.
-16 heat recovery boilers produce steam from waste heat given off by the
metallurgical coke-making facility.
-The cogeneration facility supplies 25% of the Ispat Inland's total
electrical requirements and 85% of the plant's process steam needs.
COGENERATION PROJECTS (1)

Ispat Inland Inc.
Steel Making Company
East Chicago, Indiana, USA
October 1998
-161 MW cogeneration facility provides electricity and process steam to
U.S. Steel's Gary Works.
-This facility uses an ABB condensing-extraction steam turbine generator
with steam produced from blast furnace gas.
-The cogeneration facility provides more than 40% of the total electrical
requirements of the steel-making complex.
COGENERATION PROJECTS (2)

United States Steel Corporation
Gary, Indiana, USA
April 1997
-63 MW GE natural gas-fueled, trigeneration facility supplies process
steam, hot softened water and electricity to U.S. Steel's Midwest
Operations.
-The trigeneration plant supplies 100% of the thermal energy needs and
can provide 100% of the electric requirements of U.S. Steel's facility
COGENERATION PROJECTS (3)

United States Steel Corporation
Portage, Indiana
September 1997
-120 MW elektrik
-Kojenerasyon + Kombine evrim
-Santraldan SASAya direkt balant ile elektrik ve buhar verilmektedir.
-Elektrik retiminin kalan ksm dier mterilere nakledilmektedir.
-Ana yakt : nafta, Yardmc yakt : motorin, leride : doal gaz
-Santralda 40ar MW kapasiteye sahip iki adet gaz trbini ve 1 adet buhar
trbini bulunmaktadr.
-SASAya buhar temini iin ayrca iki adet konvansiyonel kazan
ENERJSA
Adana
SASA fabrikasnn yanndadr.
SASA, tekstil sektrne ynelik
polyester elyaf, iplik ve benzeri
rnler, ie retimi iin resin
pet ie ve polyesterin ana
hammaddelerinden biri olan
DMT retmektedir.
COGENERATION PROJECTS (4)






- 1 Gas turbine
- 4.736 MW electricity
- The exhaust gases leaving the turbine are used for steam
production and drying.



COGENERATION PROJECTS (5)

TOROS GBRE
Mersin + Ceyhan
Small, high-speed generator power plants, 25 200 kWe
One moving part
Primarily fuelled with natural gas; major biogas potential
Relatively low capital, O&M costs
Lower emissions than conventional reciprocating engines
Several applications
Traditional cogeneration, hospitals etc
Generation using waste and biofuels
Backup power
Remote Power for those with Black Start capability
Peak Shaving.


MICROTURBINES
5/1/2012 9:41 PM sila\Roadshow\dry-run.ppt 18
30-60 kW power output
Multi-fuel capability
High cogen efficiency
Low maintenance
Low emissions
2-to-100 unit multipacking
<30 kW to 6 MW
>2,500 sold worldwide
>5 million operating hours
MICROTURBINES THE CAPSTONE SYSTEM
Digital power
controller
MicroTurbine
Air inlets
Exhaust
Control panel
User connection
bay
0-30; 0-60 kW
400-480
VAC/DC
Fuel supply
Inside the Microturbine
MICROTURBINES THE CAPSTONE SYSTEM
5/1/2012 9:41 PM capstone\Roadshow\Roadshow_WIP
_429-3.ppt
20
Combustion
chamber
Exhaust output
Recuperator
Fuel injector
Air bearings
Compressor
Generator
Air intake
Cooling fins
Turbine
One moving part

No coolants or lubricants

Compact and lightweight
Deep Inside the Microturbine
MICROTURBINES THE CAPSTONE SYSTEM
CoGen MicroSystems
- Small Rankine cycle
- 2.5kW electrical
- 11kW heating
- 90% overall efficiency*
- 17% electrical efficiency*
- Modulates down to 3kW heat
- Integrated boost heating to
22kW possible
- Good electrical efficiency at
part load
MICRO COGENERATION SYSTEM
Example 9-8: Consider a cogeneration plant. Steam enters the turbine at
7MPa and 500 C. Some steam is extracted from the turbine at 500 kPa for
process heating. The remaining steam continuous to expand to 5 kPa. Steam is
then condensed at constant pressure and pumped to the boiler pressure of 7MPa.
At times of high demand for process heat, some steam leaving the boiler is
throttled to 500kPa and is routed to the process heater. The extraction fractions
are adjusted so that steam leaves the process heater as a saturated liquid at
500kPa. It is subsequently pumped to 7MPa. The mass flow rate of steam
through the boiler is 15 kg/s. Disregarding any pressure drops and heat losses in
the piping and assuming the turbine and the pump to be isentrpic, determine
a) the maximum rate at the which process heat can be supplied
b) the power produced and the utilization factor when no process heat is supplied
c) the rate of process heat supply when 10 percent of the steam is extracted before
it enters the turbine and 70 percent of the steam is extracted from the turbine at
500kPa for the process heating.

kW 105
W
kW 20.076 W
m and kg/s m
kW 41.551 Q
m and kg/s m
in pump,
out turb,
2 3
max p,
3 4
= =
= + =
= = =
= = = = =
= = =
= = = = = =
) 03 . 7 ( 15
) 9 . 2071 3 . 3410 .( 15 ) (
0 15
) 23 . 640 3 . 3410 .( 15 ) (
0 15
1 1 2 1
6 3 1
5 1 6
4 7 1
6 5 1 7
,in pump, ,in pump, ,in pump,
w m W W
h h m
m m m
h h m
m m m m

W
pump ,in
=v
8
(P
9
-P
8
)=0.001005 (7000-5) = 7.03 kJ/kg
W
pump u,in
=v
7
(P
10
-P
7
)=0.001095 (7000-500) = 7.12 kJ/kg
h
1
=h
2
=h
3
=h
4
= 3410.3 kJ/kg
h
5
=2738.2 kJ/kg (x
5
=0.995)
h
6
=2071.9 kJ/kg (x
6
=0.798)
h
7
=h
f@500 kPa
= 640.23 kJ/kg
h
8
=h
f@5 kPa
=137.82 kJ/kg
h
9
=h
8
+W
pump ,in
=137.82+7.03 = 144.85 kJ/kg
h
10
=h
7
+W
pump u,in
=640.23+7.12 = 647.35 kJ/kg
b)
a)
0
kW 26.184 Q
kW -26.184 2 10.5x2738. - 1.5x3410.3 - 12x640.23 Q
kg/s 12 10.5 1.5 m m m
kg/s 10.5 15 7 . 0 m
kg/s 5 . 1 15 1 . 0 m
m Q
m W - Q
%) 40.8 (or 408 . 0
982 . 48
0 971 . 19

kW 48.982 144.85) - 3410.3 ( 15 ) ( Q
kW 19.971 105 076 . 20
p
5 4 7
5
4
5 5 4 4 7 7
e
u
11 1 1 in
, , ,
=
= =
= + = + =
= =
= =
=
=
=
+
=
+
=
= = =
= = =

x
x
h m h m h
h m h
Q
Q W
x h h m
W W W
i i e
in
P net
in pump out turb out net
c
c)
0
BINARY VAPOR CYCLES

-With a few exception, almost all steam power plants use water as working
fluid.
-Water is the best available working fluid today.
-But is it the ideal working fluid ?
-To be able to answer this question, lets have a look at characteristics of an
ideal working fluid ?
1. A high critical point temperature. The pressure at the maximum
allowable temp. (620
0
C) should not be too high.
2. Low triple-point temp.
3. A condenser pressure which is not too low.
4. A high enthalpy of vaporization (h
fg
)
5. A saturation dome that resembles an inverted U.
6. Good heat transfer characteristics.
7. Inert, inexpensive, nontoxic, readily available, etc.
-No fluid possesses all these characteristics.
-Water comes the closest. But it fails in C, C, C.
CFor water Tc=374
0
C < 620
0
C
CAt T
cond
=30
0
C P
cond
=4.246 kPa < P
atm
CV-shaped saturation dome
-To overcome these problems ralated with working fluid, binary vapor cycle
can be designed:
-The working fluids that can be used for the high-temp. cycle are : Mercury,
Sodium, Potasium, and Sodium-Potasium mixtures
-Mercury is the most-commonly used fluid. Because :
- T
c
=898
0
C > 620
0
C P
c
=18 Mpa (Not too high)
Mercury cannot be used alone in a Rankine cycle. Because :
- T
c
=32
0
C P
c
=0.07 Pa<P
atm
P
c
=7 kPa T
c
=237
0
C (T
L
7)
Mercury is toxic and high cost.
COMBINED GAS-VAPOR POWER CYCLES

-Combined Gas-Vapor Cycle (Combined Cycle): Gas power cycle + Vapor cycle
(Brayton) (Rankine)
-q
combined
> q
Brayton

-q
combined
> q
Rankine

Brayton cycle has a potential for higher q
th
, because of high T
H
(~1200
0
C)
Disadvantage of Brayton cycle is the high exhaust gas temp, T
L
(>500
0
C)
Rankine cycle has a potential for higher q
th
, because of low T
L
(~30
0
C)
Disadvantage of Rankine cycle is the low T
H
(<620
0
C)
Because T
H
7, and T
L
N
Combined Gas-Vapor Cycle
Bursa Organize San. Blg.
Natural Gas
90 MWe Electricity
UNIT 1
26 MWe gas turbine (GE, LM 2500+)
+
9 MWe steam turbine
UNIT 2
43 MWe gas turbine (GE, LM 6000 Pc)
+
12 MWe steam turbine
35 MWe 55 MWe
COMBINED GAS-VAPOR POWER CYCLE APPLICATIONS (ZORLU ENERJ)

Combined Gas-Vapor Cycle with Cogeneration
Lleburgaz
Natural Gas
66 MW Electricity
UNIT 1
14 MWe gas turbine
+
150 ton/h Steam
UNIT 2
43 MWe gas turbine
+
9 MWe steam turbine
14 MWe
+
150 ton/h Steam
52 MWe
COMBINED GAS-VAPOR POWER CYCLE APPLICATIONS (ZORLU ENERJ)

COMBINED GAS-VAPOR POWER CYCLE APPLICATIONS (TEK-HEA)

Combined Gas-Vapor Cycle
Trakya (Hamitabat)
Natural Gas
1200 MW Electricity
UNIT
2x100 MWe Gas turbine
+
100 MWe Steam turbine
300 MWe
4 x
4 x
Example 9-9: Consider the combined gas -stream power cycle. The topping
cycle is a gas-turbine cycle which has a pressure ratio of 8. Air enters the
compressor at 300 K and the turbine at 1300 K. The adiabatic efficiency of the
compressor is 80 percent, and that of the gas turbine is 85 percent.
The bottoming cycle is a simple ideal Rankine cycle operating between
the pressure limits of 7 Mpa and 5 kPa. Steam is heated in a heat exchanger by
the exhaust gases to a temperature of 500 C. The exhaust gases leave the heat
exchanger at 450 K.
Determine :
a) the ratio of the mass flow rates of the steam and the combustion gases and
b) the thermal efficiency of the combined cycle.
h
1
300.19 kJ/kg
h
2
605.39 kJ/kg
h
3
1395.97 kJ/kg
h
5
451.8 kJ/kg
h
4
880.14 kJ/kg
w
comp,in
305.20 kJ/kg
w
turb,out
515.83 kJ/kg
w
net
210.63 kJ/kg
q
in
790.58 kJ/kg
q
th
0.266
r
bw
0.592
(Example 8-6)
2
4
1
3
5
h
1
137.82 kJ/kg
h
2
144.85 kJ/kg
h
3
3410.3 kJ/kg
h
4
2071.9 kJ/kg
w
pum,in
7.03 kJ/kg
w
turb,ou
t
1338.4 kJ/kg
w
net
1331.4 kJ/kg
q
in
3265.45 kJ/kg
q
th
0.408
r
bw
0,005
a)
0 0
? y
m
m
steam of rate flow Mass
steam of rate flow Mass
g
s
= = =

1
st
law for the heat exchanger
4
5
3 2
1

=
i i e e
h m h m W - Q


2 s 4 g 3 s 5 g
h m h m h m h m

+
'
= +
'
) h h ( m ) h h ( m
5 4 g 2 3 s
'

'
=

) 80 . 451 14 . 880 ( m ) 85 . 144 3 . 3410 ( m
g s
=

131 . 0 y
m
m
g
s
= =

b)
q
th
=?
gas) kJ/(kg 385.04
.4 0.131x1331 210.63
yw w w
steam , net gas , net net
=
+ =
+ =
%) 48.7 (or 487 . 0
58 . 790
04 . 385
q
w
in
net
th
= = = q
q
th,gas
=0,266 q
th,steam
=0,408
q
th,combined
=0,487