CogenerationLounge

Nishkam Dhiman
Asst Prof : Electrical and Electronics Engineering
Chitkara University, Punjab

Introduction
Cogeneration means sequential conversion of energy contained in fuel into
two or more usable forms.
1. Energy from coal is converted to heat in boiler to produce steam, this
steam produces electricity, in addition provides heat for manufacturing
process.
2. Gas is used in gas turbine to generate electrical energy, the remaining
heat is used to produce steam in a heat recovery boiler which can be used
for manufacturing process.
Thus a conventional system produces either Electrical or thermal energy.
But a cogeneration system produces both the energies.
A cogeneration system can either be an inplant power generation system or
a reject heat utilization system.

Inplant power generation system

The industry needs both process
steam and electricity.
In conventional system, steam is
produced by a boiler, electricity is
either purchased or produced by
diesel engine.
In cogeneration: the boiler is made
to produce steam at higher
temperature and pressure than
needed for manufacturing process,
this steam is used in a turbine
generator set to produce electricity.
The exhaust steam is used for
manufacturing process.

Reject heat utilization system.

The reject heat utilization system is used in power plants.
Some steam is extracted from the turbine(at suitable temp. and
pressure) and supplied to an adjacent industry for
manufacturing purposes.

Topping and Bottoming Cycles

Topping Cycle:
Fuel is burnt in the boiler to produce
high temperature steam. This steam is
expanded in a turbine coupled to a
generator to give electric power. The
reject heat from the turbine is used for
manufacturing process.
Electrical energy is produced first.
Since steam required for
manufacturing process need low temp
therefore topping cycle is mostly used.
Efficiency: 75%
Efficiency of separate systems: 55%

Bottoming Cycle:
Fuel burnt in the boiler to
produce steam. The steam
is used for manufacturing
process. The reject heat
from process is used to
generate power.
Heat energy is produced
first.

Benefits

(a)Fuel Economy: Less consumption of primary fuel.

Fuel economy results from higher thermodynamic efficiency of a
cogeneration system as compared to separate power producing and heat
producing systems.
(b) Lower capital cost: Industry needing steam has to invest on boilers,
the extra investment needed to upgrade boiler so that electricity can also
be generated is pretty small as compared to the cost of boiler. Thus
cogeneration results in enormous savings in capital costs.
(C) Low gestation period: A utility needs 6yrs to add a thermal
generation system. Whereas, installation of a cogeneration system by and
industry needs only 3yrs. The lower gestation period results in saving in
interest, early utilisation of facility, early return on investment.
(D) Saving to industry from power cuts and power supply interruptions.

Cogeneration Technologies

The cogeneration technologies used for

topping cycles are:
Steam Turbine System
Gas Turbine System
Combined Cycle system
Diesel Engine System

Steam Turbine System

Uses system similar to thermal plant.

Fuel may be oil, coal or wood.
The higher pressure steam produced by the boiler drives turbine and then generate
electricity.
The lower pressure exhaust form steam turbine is used for industrial process application.
Back pressure steam turbines are used as they exhaust low pressure steam and are more
efficient.
13% energy saving . If steam-turbine cogeneration is used.
Fuel flexibility

Gas Turbine System

The exhaust from the
combustion chamber is used as
process heat. If necessary the hot
gases can be used to raise steam
in waste heat recovery boiler
where the heat of gasses is
transferred to water.
Due to less availability and high
cost of petroleum products, the
cost of electricity produced is
high.
Gas turbines need more
maintenance than steam turbines.

Energy Savings of about 25%

is obtained using cogeneration.

Combined Cycle System

It is a combination of gas turbine
and steam turbine system.
The gas turbine exhaust is used in
waste heat boiler to raise steam.
The steam from the boiler is used
in a back pressure turbine which
drives another alternator to
produce electricity.
The low pressure exhaust from
steam turbine is used as process
steam.
This system has greater flexibility
for topping process steam.

Energy saving of about 35% is

done by combined cycle
cogeneration system.

Diesel Engine System

This system uses a diesel
engine which drives the electric
generator. The engine exhaust
and jacket cooling are used as
heat sources for the waste heat
boiler which converts water
into process steam.
This system has higher
electricity to thermal ratio than
that
required
by
most
industries,
used
when
electricity can be sold.

Energy saving is about 26%

with diesel engine
cogeneration.