09/01/2017 COGENERATIONGASTURBINE

(COGENERATION)

COGENERATIONGASTURBINE

COGENERATIONGASENGINE

COGENERATION.


COGENERATIONGASTURBINE

IntroductiontoCogenerationSystems
IntroductiontoTRIgenerationSystems
StudyforTRIGENERATIONsystemcomparedtoconventionalsolution
EconomicalevaluationofTRIgenerationversusconventionalsystem

IntroductiontoCogenerationSystems

Thepriceofenergyisveryoftenoneofthemajorcomponentsoftheproductioncostsofindustrial
products.Anyimprovementintheenergyefficiencyofanindustrialprocesswillreducetheoperating
costsandwillthereforehaveapositiveimpactontheprofitabilityorthecompetitivepositionofthe
company.

Cogenerationsystems(alsonamedCHPCombinedHeatandPowerorTotalEnergySystems)is
thesimultaneousproduction,byasingleenergyconversionsystem,ofelectricityormechanicalpower
andusablethermalenergy(steamorheat).

Cogenerationsystemsusefarlessprimaryenergy(fuel)toproducethesameamountsofpower
andheatthanseparateenergysystems.

Themainadvantagesofcogenerationsystems,comparestoconventionalenergysystems,are:

highthermalefficiency:upto90%fuelutilization,
loweremissions:lessemissionareproducedbecauseofthereducedfuel
usageandthereforetheenvironmentalimpactoftheprocessisminimized
improvedenergyeconomics:lowerfuelexpensesreducetheproduction
costsoftheprocessandimprovetheprofitabilityoftheindustrial.

Acogenerationsystemcanbeoperatedatornearitspeakefficiencyatalltimes,anditsabilityto
operateinparallelwiththeutilityhasgeneratedareevaluationofindustrialplantenergyneeds.

Withanintertiewiththepublicutilityforbackupandthepossibilitytosellexcesspowertotheutility,
cogenerationsystemsbasedongasturbineprimemovershavedevelopedintoaflexibleandreliable
sourceofelectricalpowerandthermalenergygenerationtosatisfytheenergyneedsofindustrialplants.

Withtechniquessuchassupplementaryfiring,thermalloadfollowing,andcombinedcyclesystems,
gasturbinescanbeusedinalmostanyindustrialapplicationregardlessoftheratioofelectricaltothermal
energy.

Gasturbinebasedcogeneration.

Theconventionalapproachtotheenergysupplyofanindustrialprocessistopurchasethe
electricalenergyfromthepublicutilitygridortogenerateelectricityattheplantsitebysmallgenerator
sets(Dieselengines,steamturbineorgasturbine)andtoproducetheprocesssteambymeansof
packagedboilersfueledwithnaturalgas,lightDieseloil,heavyoilorcoal.

Inacogenerationsystemsthegasturbinegeneratorsetwillproducetheelectricalpower,andthe
processsteamwillbegeneratedinawasteheatrecoveryboilerwhichrecoversthethermalenergy
containedintheexhaustgasofthegasturbine.

Efficiencycomparison.

1.Conventionalsystem:separateproductionofheatandpower

electricityproduction:

a .smallindustrialelectricitygeneratingpowerplants,suchasDieselgeneratorset,gasturbinesor

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 1/7
09/01/2017 COGENERATIONGASTURBINE
steamturbinesproduceelectricitytypicallywithanefficiencyof30to40%

b.largeutilitytypepowerplantsgenerateelectricitywithafueltoenergyefficiencyrangingfrom

37to42%forconventionalsteampowerplantstoamaximumof52%formoderncombinedcycle
powerplantstakingintoaccountthelossesinthetransmissionanddistributionsystem,53to67%
oftheenergycontentofthefueliswastedintheelectricitygeneratingprocess

steamgenerator:


theefficiencyofthesteamproductionprocessinconventionalboilersusuallyrangesfrom80to
92%,dependingonthetypeoffuelusedandtherequiredsteamconditions

assumingatypicalindustrialprocessrequiring1.7unitsofheatforeach1unitofelectricity
(electricitytoheatratioof1:1.7),thecombinedfueltoenergyefficiencywillrangefrom48%fora
smallenergysystemattheplantsite,toamaximumof65%whenelectricityispurchased
fromthepublicutility

2.Cogenerationsystem:gasturbineandwasteheatrecoveryboiler

withthesameassumptionofanelectricitytoheatratioof1:1.7,theoverallfueltoenergyefficiency
willtypicallybeinexcessof75%.

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 2/7
09/01/2017 COGENERATIONGASTURBINE

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 3/7
09/01/2017 COGENERATIONGASTURBINE

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 4/7
09/01/2017 COGENERATIONGASTURBINE

IntroductiontoTRIgenerationSystems

Amongvariousalternativestoservetheenergyrequirementsofairportsandpublicbuildings,as
wellasrailwaystations,computercentersandhightechindustries,thegasturbineTRIgeneration
concept,istodaythemostselectedsolution

KualaLumpurInternationalAirport
ShanghaiPudongIntlairport
Malpensa2000IntlAirportItaly
AirportdeParis

arejustfewoftheairportswhicharetodayutilizingagasturbineTrigenconceptfortheproductionof
electricity,heatandchilledwaterfortheairconditioningsystem.Mostofnewhighrisetower(KLCC)and
shoppingcenterdoalsooptforTrigenconceptmainlydrivenbythefollowingadvantages:

highthermalefficiency:upto90%fuelutilization,
Higherreliabilityandavailability,
Lowermaintenanceandoperationalcost,
Compactandsimpledesignlessspaceconsuming,
LowerNOxandCOemission

TRIgenerationsystemsusefarlessprimaryenergy(fuel)toproducethesameamountsofpowerandheatthan
separateenergysystems.Itisthesimultaneousproduction,byasingleenergyconversionsystem,ofelectricity,usable
thermalenergy(steamorhotwater),andchilledwaterforthecentralizedairconditioningsystem.

Pleaserefertotheattachedflowdiagram

Thegasturbine,fuelledbynaturalgas,producesmechanicalpowerandthermalenergy.Dieseloil,
LPG,Naphtha,lowBtugasetc.canbeusedinthegasturbineasalternativeorbackupfuels.Dualor
TRIfuelledmachinesareavailable,howeversimultaneousoperationondifferentfuelsisnotpossible.

Theelectricgeneratorconvertsthemechanicalenergyintoelectricityatpreselectedvoltageinthe
rangebetween3to12kV.Ifhigherorlowervoltageisrequired,stepuporstepdowntransformerswillbe
used.Thegeneratorsetisdesigntoruninparalleltothepublicgridand/orothergenerators,aswellas
onislandmode.Whenoperatingsynchronizedinparallelmode,100%backuppowercanbeprovidedby
thepublicgridorothergenerators,withoutinterruption.

Theexhaustgasesareleavingtheturbineatapprox.500Candarepassingtroughaheatrecovery
(HR)unit(productionofsteamand/orhotwater)beforebeingdischargedtotheatmospherewithavery
littleenergyleft(approx.100C).Theexhaustgasmassflowandtemperaturedoesnotchange
significantlyduringbaseloadoperation,thereforthesteamorhotwaterproductionremainsstable.By
burningadditionalfuelintheInductburner,anyhighersteamflow,pressureandtemperatureaswellas
higherhotwaterflowcanbeachievedveryefficiently.15%ofO2intheexhaustgasses,allowsefficient
postcombustion.Withanadditionalfanupstreamtheinductburner(freshair),theHRunitcanbe
convertedtoanormalpackageboiler.Steamproductionisthensecuredevenwhenthegasturbineisnot
inoperation.

Thesteamand/orhotwaterproducedintheHRunitisnowusedinasteam/hotwaterabsorption
chiller,andreturntotheHRunitinwater(condensate)form.Nowaterisconsumedintheprocess.

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 5/7
09/01/2017 COGENERATIONGASTURBINE
Theabsorptiontechnologyhasbeenfirstintroducedinthelate50s.Itisnowwidelyusedinthe
absorptionchillerfortheproductionofchilledwater(712C)whichisusedforcentralizedairconditioning
system.Basicallythismachineisacombinationofheatexchangersworkingatdifferenttechnical
condition(pressureandtemperature)ItusesLithiumbromideasabsorbentinsteadoftheenvironmentally
unfriendlyCFC/HCFCusedinthecompressortechnology.CFCisresponsiblefortheozonelayer
degradation,andwillbereplacedinthecomingyearsbymorefriendlyproducts.

AdvantagesofAbsorptionmachineversusconventionalsystem

Staticmachinenomovingparts,

negligiblenoiselevel
highreliabilityandavailability
vibrationfree
HighefficientmachineC.O.P.1,14
Compactandlightreducespacerequired
Negligiblemaintenancecost

Theconventionalapproachtotheenergysupply,istopurchasetheelectricalenergyfromthe
publicutilitygrid,andtogeneratetheemergencyelectricityattheplantsitebydieselgeneratorsets.
Steamand/orhotwaterisproducedbymeansofpackagedboilersfueledwithnaturalgas,lightDieseloil,
orelectricity,andchilledwaterfortheairconditioningisproducedalsofromanelectricalconversion
process(electricalchiller).

InaTRIgenerationsystemthegasturbinegeneratorsetwillproducetheelectricalpower.Thehot
waterorsteamgeneratedinaboiler,whichrecoversthethermalenergycontainedintheexhaustgasof
thegasturbine,willbepartlyusedfortheprocessuseandtogeneratechilledwaterfortheair
conditioning.

StudyforTRIGENERATIONsystemcomparedtoconventionalsolution

Assumption

InordertoillustratethetechnicalandeconomicalbenefitsofaTRIgenerationsystemfollowing
loadprofileareevaluated.

Loadprofile:Electricaldemand1MWe

Heatdemand1t/hofsteamorhotwater(8barsaturated)
ChilledWaterDemand1000RT(3516kW)

Loadprofile:Electricaldemand4.5MWe

Heatdemand2t/hofsteamorhotwater(8barsaturated)

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 6/7
09/01/2017 COGENERATIONGASTURBINE
ChilledWaterDemand3000RT(10548kW)

Anyotherloadprofilewillofferthesamebenefitsasherebelowmentioned.

1.OperationCost

TheattachedanalysisshowsasignificantlyloweroperationcostforaTRIGenerationsystem
versusaconventionalsolution.Herebelowaretheoperationcostresultsforbothconfigurations

a)MioB/y b)MioB/y
Conventionalsolution 49.04 176.13
TRIGeneration 17.87 65.52

2.Backuporemergency(electricitysteamchilledwater)

Electricity:ThegasturbineoperatesinparallelwithPEA/MEA.Uninterruptedpowersupplyis
guaranteedwhenswitchingfromonetotheother.Thegridwillactasemergencywhenthegas
turbineisnotinoperation.Industrialgasturbinesaredesignedtooperate24hour/dayand7daysa
week.FurtherDieselgeneratorasbackupcanbeinstalled

Conventionalsolution:Dieselgeneratorhastobeinstalled.Investmentcostwillbeincreased(DG,
fuelstoragetank,fuelforwardingstationetc.).ReactiontimeofaDGisapprox.30sec.

Steam:Whenthegasturbineisnotinoperation,theHRunit(HeatRecoveryunit)willworkasa
packageboilerthankstothefreshairfiringsystemandtheinductburner.Additionalemergency
packageboilercanbeinstalled.

Conventionalsolution:Packageboilerhastobeinstalled

ChilledWater:Standbymachineforbothconfigurationhastobeconsidered

TRIgenerationplantsofferamoreflexibleandeconomicalsolutiontoguaranteeuninterrupted
supplyofelectricity,steamandchilledwater.

EconomicalevaluationofTRIgenerationversusconventionalsystem

Electricityprice 2.5B/unit
Naturalgaspriceforcogen 109.63B/MBtu
0.104B/MJ
Naturalgaspriceforboiler 148B/MBtu
0.140B/MJ
Operatinghours 8760h/y
Exchangerate 37B/USD

ConventionalSolutionOperatingCost 1MWe 4.5MWe

PEAelectricitycost 45.22MioB/y 168.54MioB/y
FuelcostforBoiler 3.70MioB/y 7.41MioB/y
Maintenancecostforchillerandboiler 0.12MioB/y 0.18MioB/y

Totaloperationcost 49.04MioB/y 176.13MioB/y


TRIGenerationOperatingCost

Fuelcost 16.25MioB/y 58.22MioB/y
Maintenancecostincludingoverhaul0.005USD/kWh 1.62MioB/y 7.29MioB/y

Totaloperationcost 17.87MioB/y 65.52MioB/y

SavingusingTRIGeneration 31.17MioB/y 110.61MioB/y
0.84MioUSD/y 2.99MioUSD/y


Investmentcostturnkeybasis

Conventionalsolution estimated 0.5MioUSD 0.9MioUSD
Trigen estimated 2.5MioUSD 4.5MioUSD
Investmentcostdifference 2MioUSD 3.6MioUSD


Expectedpaybacktime 2.37years 1.20Years

http://pttinternet.pttplc.com/csc_gas/csc_ind/utilization/cogeneration_gasturbine.asp 7/7