Overview of Cogeneration Technologies and Applications

Transcription

1 Overview of Cogeneration Technologies and Applications 2004 Cogeneration Week in the Philippines June 2004 Mandarin Oriental Hotel, Manila 24 June 2004 Queen Jennifer Hotel, Isabela Arul Joe Mathias Biomass and CDM Advisor

2 Outline 1. Cogeneration 2. Steam Turbine Cogeneration 3. Gas Turbine Cogeneration 4. Combined Cycle Cogeneration 5. Gas Engine Cogeneration 6. Steam Engine Cogeneration 7. Cogeneration Case Studies

3 Cogeneration or Combined Heat and Power (CHP) Sequential generation of two different forms of useful energy using a single primary energy source Most usual: electrical (or mechanical) thermal: heating or cooling

4 What is Cogeneration? Export or Import Electricity Fuel Central power plant Transmission Transformer Fuel Fuel Standby generator Boiler Power Demand FACILITY Heat Demand COGENERATION PLANT Fuel Export Heat/steam

5 Conventional Power Generation vs Cogeneration Conventional system Cogeneration system

6 Benefits of Cogeneration Lower primary energy consumption Reduced energy bills No transmission and distribution losses Less burden on national government for power generation Less environmental pollution

7 Clean Efficient Biomass, Coal, Gas Cogeneration Typical Cogeneration Performance Parameters Prime Mover in Cogeneration Package Nominal Range (Electrical) Electrical Conversion Efficiencies % Overall Cogeneration Steam Turbines MW Up to 80* Smaller Gas Turbines ,000 kw Larger Gas Turbines MW Smaller Reciprocating Gas Engines kw Larger Reciprocating Gas Engines 500 3,000 kw NOTE: Adapted from Cogeneration Handbook California Energy Commission, 1982 * taken from Cogeneration Guide Cogen Europe

8 Typical Cogeneration Applications Industrial cogeneration wood and agro-industries, food processing, pharmaceutical, pulp and paper, oil refinery, textile industry, steel industry, cement industry, glass industry, ceramic industry Residential/commercial/institutional cogeneration hospitals, schools & universities, hotels, houses & apartments, stores & supermarkets, office buildings

9 Steam Turbine Cogeneration Principle

10 Steam Turbine Cogeneration Main Elements Boiler Turbine Fixed grate boiler Inclined grate boiler Travelling grate boiler Vibrating grate boiler Fluidised bed boiler Circulated fluidised bed boiler Back pressure turbine Extraction condensing turbine Generator Condenser Feed water pump

11 Steam Turbine Cogeneration Application Appropriate for sites where Electrical base load is over 250 kw e High pressure process steam is required Cheap, low-premium fuel is available High grade process waste heat is available Existing boiler plant is in need of replacement

12 Steam Turbine Cogeneration Possible Fuels Biomass, solid waste Coal Natural gas Petroleum Others: basically every fuel that can be burnt in a boiler

13 Steam Turbine Cogeneration Advantages Versatility of fuel Well-established technology Flexibility in the size of plants Disadvantages Low electrical plant efficiency Low part load performance High operating cost

14 Gas Turbine Cogeneration Basics Fuel is burnt in a pressurised combustion chamber using combustion air supplied by a compressor Conversion of mechanical energy (turbine) into electrical energy with the help of the generator. Utilisation of gases escaping from the turbine for heat supply.

15 Clean Efficient Biomass, Coal, Gas Cogeneration Gas Turbine Cogeneration Principle

16 Suitable if Gas Turbine Cogeneration Application Power demand is continuous and over 1 MW e Natural gas is available (though not a limiting factor) There is high demand for medium/high pressure steam or hot water, particularly at temperature higher than 140 C

17 Gas Turbine Cogeneration Possible Fuels Gas Petroleum Kerosene Light oil Diesel oil Gasification of coal

18 Gas Turbine Cogeneration Advantages High reliability Wide fuel range capability Relatively low investment cost per kw electrical output Low emission Disadvantages Poor efficiency at low loading (but can operate continuously at low loads) High maintenance cost High fuel cost

19 Clean Efficient Biomass, Coal, Gas Cogeneration Combined Steam-and-Gas Cycle Cogeneration Principle

20 Combined Steam-and-Gas Cycle Cogeneration Possible Fuels Gas Petroleum Fuels obtained through gasification of biomass or coal

21 Combined Steam-and-Gas Cycle Cogeneration Advantages High electrical efficiency Disadvantages Only suitable for high electrical output High operating cost

22 Gas Engine Cogeneration Basics

23 Gas Engine Cogeneration Application Suitable for sites where Power or processes are cyclical or not continuous Low pressure steam or medium or low temperature hot water are required Low heat to power demand ratio

24 Gas Engine Cogeneration Main types 1. Compression-ignition (diesel) engines [100 kw e to 20 MW e ] 2. Spark-ignition engines [3 kw e to 10 MW e ]

25 Gas Engine Cogeneration Possible Fuels Biogas Natural gas Gas oil Heavy fuel oil

26 Gas Engine Cogeneration Advantages High power efficiency over a wide load range Relatively low investment cost per kw e electrical output Multi-fuel capability Low exhaust emission Disadvantages High levels of low frequency noise High maintenance cost

27 Steam Engine Cogeneration Basics

28 Steam Engine Cogeneration Steam throughput rates up to 40 tph Power outputs up to 1,500 kw Intake pressures from 6 to 60 bars Steam temperatures from saturated steam to 450 C Back pressures up to 25 bars

29 Steam Engine Cogeneration Possible Fuels Coal Petroleum Biomass, garbage Others: basically every fuel is possible Efficiency Electrical efficiency : 6 20% Overall efficiency : %

30 Steam Engine Cogeneration Advantages Long service life Very good part-load performance Mature technology Disadvantages Low electrical plant efficiency Requires much maintenance work Noise intensive

31 Cogeneration Case Studies

32 A Rice Husk Fired Plant in Thailand 2.5 MW Cogeneration Plant Steam boiler : Reciprocating inclined grate type Capacity: 17 tph, 35 bar, 420 o C Turbine : 2.5 MW gross Cost : 3.60 M (1997) Customer : Chia Meng Co., Ltd., Thailand

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37 Wood complex in Malaysia 1.5 MW steam turbine Condensing 900 kw Back pressure 600 kw Boiler: Capacity 16 tph, 22 bar, 280 o C In operation since 1995 COGEN phase 2 Full Scale Demonstration Project Steam is used for timber drying

38 Rice Mill in Malaysia 450 KW Cogeneration Plant steam boiler : 8 tph, 32 bar Cost : ~ 1.0 million Pay back period : 3 years Main suppliers from Belgium Customer : Ban Heng Bee Rice Mill (1952) Sdn. Bhd.

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42 Sawmill in Malaysia Steam Generation Plant steam boiler: 5 tph, 12.3 bar, 193oC Cost : 274,800 US$ Pay back period : 2.9 years Main supplier from Denmark Customer : Bekok Kiln Drying & Moulding Sdn. Bhd.

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47 Palm Oil Mill in Malaysia 1.2 MW Cogeneration Plant steam boiler : 35 tph, 23 bar, saturated turbine type : back pressure (4.1 bar) Cost : 693,300 US$ (580 US$/kW) Pay back period : 3.7 years Main supplier from U.K., Germany Customer : Kilang Sawit Sdn. Bhd.

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51 MDF Factory in Malaysia Steam Generation Plant boilers: - thermal oil with steam generation (22 Gcal/hr) - steam boiler: 5 tph, 12.3 bar, 193oC Cost : 5,630,000 US$ Pay back period : 3.5 years Main supplier from Sweden, Denmark Customer : Kumpulan Guthrie Bhd.

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54 Rubber Factory in Malaysia Waste Water Treatment Plant anaerobic digester Cost : 1,507,000 US$ Pay back period : 4.1 years Main supplier from Belgium Customer : Heveafil Sdn. Bhd.

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57 Hybrid Cogeneration Plant in Thailand Uses 6 x 35 MW gas turbine generators 2 x 152 MW steam turbine generators 2 x Circulating Fluidised Bed Boilers 4 x Heat Recovery Units Primary fuels: Natural gas Indonesian bituminous coal Back-up fuel: Diesel oil

58 Hybrid Cogeneration Plant in Thailand Cost: approx. 600 M Product 514 MW electricity 200 tph steam (medium pressure) 150 m 3 /h demineralised water

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62 For more information, please visit COGEN 3 Web Site at:-