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siemens.com/answersRestricted © Siemens AG 2014 All rights reserved.
Cogeneration: Energy Production maximising Efficiency and
minimising Environmental Impact at all scales
Dr. Ing. Petru Ruset, Siemens srl, Romania
20th – 22nd of November 2014
Restricted © Siemens AG 20XX All rights reserved.
2014-11-20 Dr. Ing. Petru Ruset/Energy Management DivisionPage 2
• What is Cogeneration ? 3
• Utilizing Natural Gas 5
• Cogeneration Applications 7
• Cogeneration Technologies 8
• Choosing a Technology 9
• Alternative Fuel Options 16
• Conclusions 17
Cogeneration
Table of content
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2014-11-20Page 3
What is Cogeneration ?
Definition
‘The simultaneous production of both heat
and power from a single source’
• Cogeneration can be:
• Topping Cycle
• Focused on electricity production with wasted
energy used to provide heat
• Bottoming Cycle
• Focused on heat production, with surplus energy
used to produce electricity
Dr. Ing. Petru/Ruset/Energy Management Division
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2014-11-20Page 4
What is Cogeneration ?
A properly designed Cogeneration plant is the most efficient way to meet site energy demands
Fuel
100%
25 -
55%
75 -
85%
Electricity
Remote
Power
Plant
On-site
Boiler
Steam
Losses 10 -
20%
T&D losses
circa 5%
Steam
distribution losses
Fuel
100%
Overall Energy Efficiency = 50 – 70%
Losses 40 - 70%
On-site
Cogeneration
Plant
Fuel
100%
> 30%
Electricity
Steam
Losses < 25%
Steam distribution
losses
> 45%
Overall Energy Efficiency: > 75%
Dr. Ing. Petru Ruset/Energy Management
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Utilizing Natural Gas
Why use Natural Gas ?
• Widespread availability
• Reserves for > 150 years consumption
• Transportable
• Pipeline
• LNG
• CNG
• Can be stored to provide strategic reserve
• Underground Gas Storage (UGS)
• LNG
• Competitively priced
Dr. Ing. Petru Ruset/Energy Management Division
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2014-11-20Page 6
Utilizing Natural Gas
Why use Natural Gas ?
• ‘Clean’ fossil fuel
• Low carbon content = low CO2 emissions
• Clean burning, low pollutants
• No SOx
• No particulate
• Clean Combustion Technologies
• Low NOx
• Low CO
• Low Unburned Hydrocarbons• Caution: Methane Slip on Gas and Dual Fuel Engines
• Saves money and protects the Environment !0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
Natural
Gas
Diesel Coal Lignite Wood MSW (non-
Biomass)
CO2 Emission Factors (T per MWh)
Dr. Ing. Petru Ruset/Energy Management Division
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2014-11-20Page 7
Cogeneration Applications
Cogeneration can be applied at any scale where
there is both a power and heat (or cooling) demand
• From a few kW to 100’s of MW
• Domestic
• Commercial
• Municipal
• District Heating/Cooling
• Hospitals / Swimming Pools
• Universities
• Industrial
• Chemicals, Pharmaceuticals, Food & Drink,
Automotive, Pulp & Paper, Textiles, Ceramics…
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2014-11-20Page 8
Cogeneration Technologies
A range of potential technologies exists
• Applicability often dependent on scale
MicroturbineReciprocating Engine
(Gas Engine)
Increasing Power
Reciprocating Engine
(Gas Engine)Gas Turbine Steam Turbine
Domestic Commercial Municipal Industrial
Stirling Engine
Reciprocating
Engine (Gas
Engine)
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2014-11-20Page 9
Choosing a Technology
Gas Turbines, Steam Turbines and Gas Engines
dominate the Cogeneration market
• Gas Turbines have the vast majority of recoverable
heat in the high temperature exhaust gases
• 30kW – 300MW+
• Different Steam Turbine configurations based on
heat demand
• Back-pressure
• Condensing with Steam Extraction
• kW to hundreds of MW
• Gas Engines have 2 waste heat streams
• High temperature exhaust gases
• Low temperature cooling circuits
• kW to ≈ 17MW
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2014-11-20Page 10
Choosing a Technology
Power Output, Heat to Power Ratio and the Type of Heat
will all have an impact on the optimum technology choice
• Technical and economic limitations on power output may apply
to some technologies
• Both at higher and lower ends of scale
• Electrical efficiency impacts on amount of heat recoverable
• Higher electrical efficiency, less waste heat
• Temperature of Waste Heat will affect type and amount of
process heat recoverable
• e.g. Steam requires high temperature waste heat
• High Electrical Efficiency does not necessarily mean high
overall energy efficiency
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2014-11-20Page 11
Choosing a Technology
Heat to Power Ratio
1.0
0.5
2.0
3.0
4.0
6.0
5.0
Gas Engine
Gas Turbine
Gas Turbine
with
supplementary
fired WHRU
Steam Turbine
Heat to Power Ratio
Total Efficiency of Gas Turbine and Reciprocating Engine
vs. Power / Heat Output
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5
Thermal / Electric Power Ratio
To
tal E
ffic
ien
cy
, H
ea
t a
nd
Po
we
r
SGT-500 + WHRU
Reciprocating Engine +
WHRU
Dr. Ing. Petru Ruset/Energy Management Division
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2014-11-20Page 12
Choosing a Technology
Using Supplementary Firing of GT exhaust gases to boost Heat to Power Ratio
Duct Burner
(Optional)
Gas Turbine Generator
Fuel Gas
HRSG
Boiler Feed
Water
Process
Steam
Exhaust
Stack
0
25
50
75
100
125
150
175
200
0 5 10 15 20 25 30 35 40 45 50
Power (MWe)
Ste
am
(to
nn
es/h
r) [
12 b
ar
satu
rate
d]
Unfired
Fired
SG
T-1
00
SG
T-3
00
SG
T-4
00
SG
T-5
00
SG
T-6
00
SG
T-7
00
SG
T-8
00
• Supplementary Firing can
double steam (heat) production
Fuel Gas
Boiler fired to 850 deg C
Dr. Ing. Petru Ruset/Energy Management Division
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2014-11-20Page 13
Choosing a Technology
Type of Process Heat required
• Low Temperature Hot Water (LTHW)
• Very high overall energy efficiencies as can
recover waste heat from low temperature cooling
circuits
• High Temperature Hot Water (HTHW)
• Needs higher temperature waste heat, so in some
cases not able to use all waste heat sources
• Steam
• Needs high temperature heat source, the higher
the steam pressure required, the higher the waste
heat temperature needs to be
• Hot Air
• Depends on application: Direct/Indirect Drying or
Space Heating
Gas
Engine
Gas
Turbine
Steam
Turbine
LTHW
HTHW
Steam
Hot Air
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2014-11-20Page 14
Choosing a Technology
Selecting the correct technology for the specific application can
lead to very high overall energy efficiencies
• LTHW Hot water > 90%
• Steam > 75%
• > 85% with supplementary firing
• Hot Air > 90%
• High energy efficiency
= lower fuel consumption
= lower fuel bills
= fewer emissions
= environmental benefits
Supplementary
firing to 815 C
(process gas)
29 bar
process
steam
Economizer cooled
by DH water
Net power output: 14.9 MW
Process steam: 29 bar / 13.9 kg/s / 35.2 MJ/s
District heat duty: 13.6 MJ/s
Fuel efficiency: 71 %/ 90%
Dr. Ing. Pentru Ruset/.Energy Management Division
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2014-11-20Page 15
Choosing a Technology
Or the correct combination of technologies !
Supplementary HRSG
firing from 545 to
740 C (All HRSG)
Air-cooled DH auxiliary
cooler allows
independent
Power generation
Heat-only boiler
for DH peaks
Multiple gas turbines for
extended load range
and part load efficiency
I-91
Customer:
Latvenergo Riga TPP1, Latvia
Business Concept: EPC / Power Plant
In operation: Oct 2005
Net power output: 140 MW
District heating duty: 140 MW
Fuel efficiency: 91%
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2014-11-20Page 16
Alternative Fuel Options
If Natural Gas is unavailable, other fuels can be utilized in
many technologies as the primary fuel or back-up fuel
• Diesel and high quality distillate fuels
• LPG, NGLs, Condensates and Naphtha
• Intermediate and Heavy Fuel Oils
• Crude Oil
• Biogases
• Digester (sewage) gas
• Landfill gas
• Process Off-Gases
• Refinery Gases
• Coke Oven Gas
• Blast Furnace Gas
MJW/ E P GT ST&P BD
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2014-11-20Page 17
Conclusions
Cogeneration
• The most efficient way to meet local power and
heat demand
• Offers Economic benefits
• Offers local and global Environmental benefits
• Especially on Natural Gas Fuel
• Multiple technologies available to all optimum
plant design
Dr. Ing. Petru Ruset/Energy Management Division
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2014-11-20Page 18
Thank you for your attention
Contact page
Dr. Ing. Petru Ruset
Country Division Lead Energy Management
Siemens srl
Bd. Preciziei 24; Complex West Gate Park
Cladirea CPSA; RO-062204; sector 1; Bucuresti
Romania
Phone: +40216296490
Mobile: +40744790527
E-mail:
petru.ruset@siemens.com
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