Cogeneration Class PDF

Cogeneration
Cogeneration Definition
Thermodynamics background
Cogeneration Parameters
National Legislation
Cogeneration Systems & Technologies
Cogeneration in Portugal
Cogeneration Facilities (examples)
Industrial Sector
Building Sector
Equipamentos Trmicos
What is cogeneration
Cogeneration: simultaneous production of power and heat,
with a view to the practical application of both products
What is cogeneration
Integrated system
Located at or near a building/facility
A way of local energy production
Uses heat that is lost otherwise (cooling, heating,
dehumidification and process heat)
Way to use energy more efficient
Different areas of application
Different technologies
Cogeneration Synonyms
Cogeneration
Combined Heat and Power (CHP)
Cooling, Heating and Power (CHP)

Trigeneration (Trigen)
Integrated Energy Systems (IES)
Building Cooling, Heating, and Power (BCHP)
Benefits of Cogeneration
Improves energy efficiency

Conserves natural resources (fossil fuels)
Lower emissions (including CO2)
Lower energy costs
If heat fits demand, cheapest way of electricity production
Improves security of supply
Reduces transmission and distribution losses
Enhances competition
Thermodynamics and Cogeneration

Thermodynamics:
To produce work from heat is necessary a thermal cycle and part
of the energy (heat) obtained from the hot reservoir is release to
the could reservoir.
Carnot Cycle Efficiency
TB - Cold reservoir temperature

TA - Hot reservoir temperature
Cogeneration:
Is necessary produce heat at an appropriate temperature (Qu
useful Heat).
Combined Gas Turbine Cycle

The combine Gas turbine cycle can be used as a cogeneration
system.
Even when useful heat are not produced, there are a recover of
heat of the gas turbine in the recover boiler. The generated steam
is used tor produce electricity by a Rankine Cycle.
The efficiency of the combined cycle is the sum of the efficiency of
both Cycles
Cogeneration Parameters I
Electrical/Mechanical Efficiency / Rendimento Mecnico/Electico
Global Efficiency / Rendimento global ou Factor de utilizao de

Energia
Heat/Power ratio / Razo Calor/Electricidade
Cogeneration Parameters II
FESR-Fuel Energy Saving ratio / PEP Poupana de Energia
Primria
EEE-Equivalente electrical efficiency / REE - Rendimento Eltrico

Equivalente
specific consumption (inverse)
Equivalent Electrical Efficiency

Rendimento Elctrico equivalente
DL 538/99 EEE = 55 % (from 1999)
-EEE = 45 % (1995-1999)
DL 313/01 from 2001 defines the EEE was a function of the Fuel used in the
Combined heat and Power Plant
55 % Natural Gs, LPG-liquefied petroleum gas, liquid fuel (not fuel oil)
50 % Fuel oil, heavy fuel oil
45 % Biomass or residual fuels with support
Reference boiler efficiency

90 % - Fossil Fuel
70 % - Renewable Fuel
CR - Energy from Renewable Fuel
The FESR depends on the Country Electric Systems
Conventional Generation Versus

Cogeneration
Fuel input
92
53
Separate
generation
Power plant
h = 38%
Boiler
h = 95%
Cogeneration
Electricity
35
Heat
50
Electricity
h = 35%
Heat
h = 50%
Fuel input
100
Total
Total
145
100
Energy conservation = (145-100)/145 = 31%

Cogeneration
Fuel input
81
53
Separate
generation
Power plant
h = 43%
Boiler
h = 95%
Cogeneration
Electricity
35
Heat
50
Electricity
h = 35%
Heat
h = 50%
Fuel input
100
Total
Total
134
100

Cogeneration
Fuel input
64
53
Separate
generation
Power plant
h = 55%
Boiler
h = 95%
Cogeneration
Electricity
35
Heat
50
Electricity
h = 35%
Heat
h = 50%
Fuel input
100
Total
Total
117
100
Parameters analyze
Thermal
Power Plant
Boiler
Heat
Influence of increase the heat production

with a low efficiency equipment
The demand
of heat
increase
The demand of
Heat/Electricity
change over the
year but the
legislation is based
on the annual
value
FESR
Influence of the electric and thermal efficiency on FESR for
different values of Heat/Electricity ratio
FESR/Global Efficiency Specific

technologies
Heat/Electricity ratio
typical values:
TG Gas Turbine: 0,5-1,5
TV Stream Turbines: 1-4
(back pressure)
Source: Pita, 1995
How cogeneration Saves Energy?
Thermodynamic Cycles Classification

Depending on the temperatures at the thermal energy is used
-Bottom Cycles (Heat Power/Work)
-Top Cycles (Power/WorkHeat)
Depending on the Technologies
Gas Cycles Gas turbines, Diesel/SI Engines with recovery boiler to produce
steam or with the use of flue gases direct on a process (greenhouses, drying
processes)
Steam Cycles (Rankine cycles) Water/steam is the work fluid. The hot
water/steam could be used directly on a process or as a energy transport fluid.
Back Pressure Turbines/ Turbinas de Contrapresso (process that need
steam at an elevate temperature or at high pressure)
Extraction Condensing Turbines/ Turbinas de Extraco/Condensao to
maximize the Electric generation
Gas turbine combined cycle Gas turbine cycle with a recover boiler to
generate steam used in a Rankine Cycle
Others: Heat Pumps, Fuel Cells
Technologies Main Properties
Technology
Extraction/Condensing Steam Turbine
Back Pressure Stream Turbines
Gas Turbines Cycles

Internal Combustion Engines
Fuel Cells
Power (MW)
Electric
Efficiency
30-300
0.25-0.3
1-200
0.2-0.25
(0.15) 1-150
0.18-0.35
0.05 25
0.35-0.4
0.005 0.2
0.37-0.4
The efficiency of a Rakine cycle can reach 40 % and the gas turbine combined
cycle 55 %
For all cases the global efficiency is near 80 % in CHP
CHP whit heat pumps have normally a Global Efficiency greater than 100 %
Turbine Cycles used on Electric Power

Generation
Cycle
Q The electric efficiency increase

Gas Turbine
Steam Turbine
Combined Gas Turbine
The cycle with the lower

electric efficiency allows the
use of heat at a higher
temperatures
In the steam turbine and

combined gas turbine cycle
to maximize the electric
efficiency the heat should be
reject at the lower possible
temperature
Source: Horlock, 1987
Cycle
Sigel Turbine Cycles for Combined Heat

and Power Plats
In the steam turbines plant an
increase in the useful Heat Qu
decrease the electric efficiency
Its normal have several levels

of temperature to use the Qu
In the steam turbine and

combined gas turbine cycle
the thermal energy is used to
generate steam in the recover
boiler, In the stream turbine
cycle the steam is expand in a
turbine to produce electricity
Cogeneration Parameters for Single

Turbines Cycles
Cycle
Qu
FESR
QU/E
Extraction/Condensing Steam Turbine
0.38
0.10
0.48
0.057
0.26
Back Pressure Stream Turbines
0.25
0.60
0.85
0.235
2.4
Gas Turbines Cycles with recuperator
0.30
0.55
0.85
0.265
1.83
Combined gas turbines (Gas/back pressure

Steam Turbines)
0.40
0.42
0.82
0.318
1.05
Source: Horlock, 1987 (reference values considered T=0.9 and E=0.4)
In the gas turbine cycle the injection of steam (generated in the recover
boiler) in the turbine increase the electric capacity and the electric efficiency
(STIG).
CHP Applications
Main Cogeneration Technologies
Typical Cogeneration Performance

Parameters
* taken from Cogeneration Guide, Cogen Europe
DL 23/2010 de 25 de Maro de 2012

Adaptation of the European directive 2004/8/CE
Defines benefits/premium to the cogenerations sector based on:

1) Reduction of the primary energy consumption and CO2 emissions
2) Promote the high efficiency cogeneration plants and renewable
cogeneration based on renewable sources of energy
3) Promote the integration of Cogeneration in the electricity market
Define two exploration regimes
General regime (all capacity): The market define the energy price
(temporary-benefit/premium for Plant with Electric capacity < 100 MW)
Special regime (Electric capacity < 100 MW):
The market define the Heat price
The tariff of the electricity have benefit/premium based on the efficiency
Portaria 140/2012 de 14 de Maio de 2012

Review of the Cogeneration Electric Tariff
Reference tariff for the Natural Gas, LPG or liquid Fuel (except Fueloil)
Cogeneration Plants:
89.89 /MWh for Electric capacity < 10 MW
80.44 /MWh for Electric capacity between 10 MW and 20 MW
Reference tariff for the Cogeneration from renewable sources:
Reference tariff for the Fueloil Cogeneration Plants:
Hora ponta/hours with high electricity demand + 10%
Vazio e supervazio/ hours with low electricity demand -13 %
Prmios de eficincia / Efficiency

premium
a) PEm Efficiency premium value in month m

b) PC Reference costs for the valorization of Primary Energy saving 28.71 /MWh
c) PEP Primary energy savings (certified)
d) EEPlm Net electric energy generated by the cogeneration plant in month m
(total electric energy generated electric energy consumed by the Cogeneration Plant)
e) K Primary energy saved differentiates factor

(0.5 to high efficient cogeneration plant and 0.3 efficient plant)
f) EP/EE Ratio between the Primary Energy consumed by the Cogeneration Plant
and the Electric energy generated (typical values)
Ratio EP/EE
i)
Natural gas Internal combustion engines: 2.86
ii) Gas Turbines (Natural Gas) eclectic capacity < 20 MWe: 3.70
iii) Gas Turbines (Natural Gas) eclectic capacity > 20 MWe: 3.12
iv) Fueloil Internal combustion engines: 2.60
v) Steam turbines: 5
vi) Combined gas turbines: 2.5
vii) Renewable cogenerations plats: 5

Transition Regime:
Plants with electric capacity > 20 MW
The transition to the new remuneration regime occurs at the beginning of
the month following the EEGO audit (EEGO - entity that certifies the
primary energy savings)
For all other cases the transition occurs in the following quarter
During the extension period, the reference tariff for no renewable

installations is depreciated annually by one percent, for installation with a
capacity of 20 MW or less

Cogeneration Classification:
According to capacity
-< 1 MW Small Cogeneration
-< 50 kW Micro Cogeneration (Biomass Plant Electric capacity < 3.68 kWe
have a subsidized regime DL 363/2007)
introduces efficiency levels :
-high efficient cogeneration plant:
-Efficiency: Other cases
Electric Energy Certification

The electricity produced in cogeneration plant with high efficiency is certified
based on a series of data (fuel, amount of heat used, PEP, CO2 emissions)
EEGO Is the entity responsible for certificates the Cogenerations electrical

energy (and control the CO2 emissions)
DGEG Is the entity that identify the high efficiency Cogenerations Plants.
For the installations type a) and c) the annual global efficiency as to be > 80 %
For the installations type b), d), e), f), and g) as to be > 75 %
When the annual global efficiency are lower, the C implicit value is used to
calculate the:
ECHP = HCHP/C
Cogenerations Installations Types

Implicit ratio
C = E/H
a) Combined gas turbine cycle with heat recover

0.95
b) Back pressure steam turbines
0.45
c) Extraction/condensing steam turbine
0.45
d) Gas turbine wit heat recovery
0.55
e) Internal combustion Engines
0.75
f) Microturbines
g) Stirling Engines
h) FuelCells
Technologies for small plants
i) Steam Engines
j) Rankine Organic Cycles
l) Other technologies
Cogeneration Economics Analysis

Economics
Costs:
Capital
Operation and maintenance
Fuel
Benefits:
Heat
Electricity
less purchase
sell to grid
Economic value of cogeneration

Depends very much on tariff system
Heat: avoided cost of separate heat production
Electricity: less purchase (kWh); sale of surplus electricity and peak
shaving (kWe)
Carbon credits
Economic Analysis
PT-Payback Time \ Tempo de retorno do investimento
NPV - Net Present Value \ VAL Valor Atual lquido
IRR - Internal Rate of Return \ TIR Taxa interna de Rentabilidade
The Payback time in a first approach is determine by:
PT = Initial Investment / Annual Cash flow
Cash flow= (Revenues - Expenses)
NPV/VAL:
CFi Cash Flow in year i

Ii Investment value in year i
ai Discount Rate (the rate of return that could be earned on an investment in
the financial markets with similar risk.); the opportunity cost of capital
i time period
TIR/IRR- The discount rate that makes the net present value of all cash flows from a
particular project equal to zero. Generally speaking, the higher a project's internal rate of
return, the more desirable it is to undertake the project.
Economic Analysis
IRR - Example
Year (i)
Cash flow (i)
-123400
36200
54800
48100
In this case r = 5.96%
Economical Parameters
The Fuel price/cost
The Electricity price/cost
The useful heat price/cost
The cost of the useful heat depends of the temperature level at the
heat is used.
Price-weighted Global Efficiency / Factor de utilizao de energia
ponderado pelo preo
Heat approximate costs (Investment costs not included)

Heat /kWh(T = 90 %)
Fuel
Propane/Butane Gas LGP
0.09
Natural Gas
0.05
Diesel for heat
0.05
*Heat pump (Cop = 4)
0.03
*Heat pump produce heat by a compressor cycle (using electricity) PE = 0.1
Cogeneration Economics
Cogeneration Economics
Cogeneration System Design Options
Reference Efficiency Values
Source: Manual de Procedimentos da EEGO Entidade Emissora de Garantias de Oringem

Available: www.dgeg.pt (areas sectoriais-energia electrica-produo em regime especial



Source: Cogen Portugal
Example
Otto Natural gas Engine
Gas engine
Nominal Electrical Power
Fuel
Electrical Grid Connection Tension
Construction year
2006
8 000 h
Fuel consumption (LHV based)
25 150 MWh
Useful Heat
10 560 MWh
Electrical Energy Consumptions

Global Efficiency
Fraction of Electric Energy Exported to the National Electric System
0.380 kV
19 C
Electrical Energy Generated
Correction factors
Natural Gas
Annual Average Temperature

Annual operating hours
Reference Electrical efficiency corrected by the average temperature
1100 kW
FESR-Fuel Energy Saving Ratio
8 800 MWh
176 MWh
CO2 Emission- EEGO Proceedings

Manual
CO2 emissions from CHP
Avoid CO2 emissions
The CO2 emissions factor are defined by the IPCC, intergovernmental Panel on Climate
Change, publish in Despacho 17313/2008 (June 26).
Despacho 17313/2008 (June 26)
Demand Heat Curve
Cogeneration in Portugal
The installation of Cogeneration Plants in Portugal occurred in three phases:
-1st Large industries
-2nd The possibility of sold electricity to the National Electric System
-3rd The introduction of Natural Gas in Portugal (Otto, GT and CC)
Cogeneration Install Capacity in Portugal
New CHP Plants:

Combined gas turbine
cycles in Sines and
Matosinhos Petroleum
Refinery
Natural gas
Engines
Natural gas
Turbines
Heavy
Fueloil
Engines
Back
pressure
Turbines
Propane
Engines
Biogas
Engines
Micro
Turbines
Sector by Technologies
Cogeneration Install Capacity by Technologies

The back pressure Steam turbine are installed
mainly in the Pulp paper and chemical Industries
Biogas
Engines
Natural gas
Engines
Chemical and
Petroleum Industry
Pulp Paper Industry
Natural gas
Turbines
Heavy Fueloil
Engines
Propane
Engines
Micro
Turbines
Food Industry
Textile Industry
Others Industry
Actually the Combined Gas Turbines and the Gas

turbines are present in some of this sectors
Back pressure
Turbines
Total capacity at the end of 2005 1200 MW
Sector by Fuel
Fueoil Cogeneration Install Capacity by Sector
Others
Natural Gas Cogeneration Install Capacity by Sector
Textile
Wood
Textile
Tertiary
Food
Others
Chemical
Tertiary
Glass an Ceramics
Chemical
Pulp paper
Wood
Food
Glass an Ceramics
Pulp paper
Total Natural Gas Capacity at the end 2005 322 MW
Other include the building Sector

Fueloil Engines
limitations
have
environmental
Some Fueloil Engines can be converted

to Natural Gas
Pulp Paper Industry Cogeneration Plant

The biomass boiler burn wood residues
rejected by the pulp paper process
The recover boiler burn black liquor
Two steam boiler produce steam for one

circuit
The steam circuit have different pressures
levels
Internal Combustion Engines
Capacity
MW
Input Energy
Fraction
Electricity
7.5
40 %
Heat
6.7
35 %
Capacity MW
Economizer
1.0
Recover Boiler
3.0
Jacket
2.7
Commercial Center Colombo

Cogeneration Plant
Diesel /Fueliol Engines

Convertibles to
Natural gas
Electric Capacity
37 MW
Shops
11.2 MW
Hyper Market
4 MW
Commons Spaces
21.7 MW
Cooling Capacity
14.8 MW
3 Compressor Chillers
2 Absorptions Chillers
g = 86 %
EEE = 37 %
Combined Gas Turbine Plants
GALP - Oil Refining Plants - combined gas cycle
Electric Capacity
[MW]
Exported
Eclectic
Energy (MW)
Steam
Production
(t/h; bar)
EEE/REE
(%)
Matosinhos
80
60-80
200; 67
65
Sines
2 X 80
100-140
415; 82
Fuel: Natural Gas and Refinery Gas
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 and universities, hotels, houses and apartments,
stores and supermarkets, office buildings
Trigeneration Plant Climaespao
Gas turbine
Heat exchanger inside

the buildings
absorption chiller
Trigeneration Plant Climaespao
Fuelcell IST
Cogeneration as a Share of National

Power Production in EU
Main Steps to Realize The Cogeneration

Project
1) Obtain the representative annual diagram of useful/economical Heat/Cooling based on
demand.
1)
2)
2)
Based on the dally diagram for different month of the year

Careful with the temperature/condition necessary to use the heat
Research /define the technology appropriate to the Energy demand

1)
2)
3)
4)
5)
6)
7)
8)
9)
Electrical capacity
Economical Useful Heat capacity
Turn down ratio
Availability Factor
Type of Fuel and efficiency of the equipments
Energy needed to operate (peripherals equipments)
Energy Storage Systems
Startup time
Live time of the equipments
3) Define the business model and the Operation Conditions

1)
2)
3)
4)
5)
Useful heat price Based on Market values

Electricity Energy Price Based on Market values
Investment
Maintenance/Operational Cost Based on Technical information
Other cost (environmental tariffs, eventual financial penalties when the cogeneration plant have
to stop, other cost associate to the project, taxis,)
Main Steps to Realize The Cogeneration

Project
4) Verify The Legislation/Regulation
Check if the defined operating conditions are according to the legislation / regulation
5) Economical Analisys
Sensitivity analysis of the main project variables
The Final Report:

A descriptions of the heat useful demand and the conditions of the heat client
A descriptions of the CHP and the technology
(technical/economical justification of the option)
Economic analysis of the project

(with a justification of the values used)
Technique analysis that proves the cogeneration benefits:

Reduction of the primary energy consumption
Increasing the efficiency
Reduction of the green gas emissions
Useful Documentation
Available Online
Decreto Lei n. 23/2010 de 25 de Maro
Lei n. 19/2010 de 23 Agosto
Portaria n. 140/2012 de 14 de Maio
Portarian. 325-A/2012 de 16 de Outubro
Despacho 17313/2008 de 26 de Junho
Manual de Procedimentos da Entidade Emossora da Garantias de Origem

www.dgeg.pt (areas sectoriais-energia electrica-produo em regime especial
Cogen Portugal- Cogerao

http://www.cogenportugal.com/ficheirosupload/Brochura%20Cogera%C3%A7%C3%A3o.pdf
Estudo do Potencial de Cogerao de Elevada Eficincia em Portugal

(Direco Geral de Energia e Geologia)

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Cogeneration

Cooling, Heating and Power (CHP)

Improves energy efficiency

Thermodynamics and Cogeneration

TB - Cold reservoir temperature

Combined Gas Turbine Cycle

Global Efficiency / Rendimento global ou Factor de utilizao de

Heat/Power ratio / Razo Calor/Electricidade

EEE-Equivalente electrical efficiency / REE - Rendimento Eltrico

specific consumption (inverse)

Equivalent Electrical Efficiency

Reference boiler efficiency

The FESR depends on the Country Electric Systems

Conventional Generation Versus

Energy conservation = (145-100)/145 = 31%

Conventional Generation Versus

Energy conservation = (134-100)/134 = 25%

Conventional Generation Versus

Energy conservation = (117-100)/117 = 15%

Influence of increase the heat production

FESR/Global Efficiency Specific

Source: Pita, 1995

How cogeneration Saves Energy?

Thermodynamic Cycles Classification

Technologies Main Properties

Gas Turbines Cycles

Turbine Cycles used on Electric Power

Q The electric efficiency increase

The cycle with the lower

In the steam turbine and

Sigel Turbine Cycles for Combined Heat

Its normal have several levels

In the steam turbine and

Source: Horlock, 1987

Cogeneration Parameters for Single

Extraction/Condensing Steam Turbine

Back Pressure Stream Turbines

Gas Turbines Cycles with recuperator

Combined gas turbines (Gas/back pressure

Source: Horlock, 1987 (reference values considered T=0.9 and E=0.4)

Main Cogeneration Technologies

Source: Horlock, 1987

Typical Cogeneration Performance

* taken from Cogeneration Guide, Cogen Europe

DL 23/2010 de 25 de Maro de 2012

Defines benefits/premium to the cogenerations sector based on:

Portaria 140/2012 de 14 de Maio de 2012

Prmios de eficincia / Efficiency

a) PEm Efficiency premium value in month m

e) K Primary energy saved differentiates factor

Natural gas Internal combustion engines: 2.86

Portaria 140/2012 de 14 de Maio de 2012

During the extension period, the reference tariff for no renewable

Portaria 140/2012 de 14 de Maio de 2012

-Efficiency: Other cases

Electric Energy Certification

EEGO Is the entity responsible for certificates the Cogenerations electrical

Cogenerations Installations Types

a) Combined gas turbine cycle with heat recover

Cogeneration Economics Analysis

Economic value of cogeneration

CFi Cash Flow in year i

Cash flow (i)