ME5701

ENERGY CONVERSION TECHNIQUES

UNIT 5
COMBINED HEAT, COOLING AND POWER
PRODUCTION (CHCP)
Dr. K. Arshad Ahmed
Teaching Fellow
Institute for Energy Studies
Department of Mechanical Engineering
CEGC, Anna University,
Chennai – 600 025
Dr. KAA, IES, DME, CEGC, AU 1
Dr. KAA, IES, DME, CEGC, AU 2
Dr. KAA, IES, DME, CEGC, AU 3
 What Is Combined Heat and Power?
• CHP, also known as cogeneration, is the concurrent production of
electricity or mechanical power and useful thermal energy (heating
and/or cooling) from a single source of energy.
• CHP is a type of distributed generation, which, unlike central station
generation, is located at or near the point of consumption.
• Instead of purchasing electricity from a local utility and then burning fuel
in a furnace or boiler to produce thermal energy, consumers use CHP to
provide these energy services in one energy-efficient step.

Dr. KAA, IES, DME, CEGC, AU 4

• As a result, CHP improves efficiency and reduces
greenhouse gas (GHG) emissions.
• For optimal efficiency, CHP systems typically are
designed and sized to meet the users’ thermal
baseload demand.

Dr. KAA, IES, DME, CEGC, AU 5

• CHP is not a single technology but a suite of technologies that
can use a variety of fuels to generate electricity or power at
the point of use, allowing the heat that would normally be lost
in the power generation process to be recovered to provide
needed heating and/or cooling.
• This allows for much greater improvement in overall fuel
efficiency, resulting in lower costs and CO2 emissions.

Dr. KAA, IES, DME, CEGC, AU 6

Dr. KAA, IES, DME, CEGC, AU 7
PRINCIPLE OF COGENERATION
• Mechanical energy may be used either to drive an
alternator for producing electricity, or rotating equipment
such as motor, compressor, pump or fan for delivering
various services
• Thermal energy can be used either for direct process
applications or for indirectly producing steam, hot water,
hot air for dryer or chilled water for process cooling
Dr. KAA, IES, DME, CEGC, AU 10
 NEED FOR COGENERATION
• Thermal power plants are a major source of electricity supply in India.

• The conventional method of power generation and supply to the

customer is wasteful in the sense that only about a third of the primary
energy fed into the power plant is actually made available to the user in
the form of electricity.

• In conventional power plant, efficiency is only 35% and remaining 65% of

energy is lost.
• The major source of loss in the conversion process is the heat
rejected to the surrounding water or air due to the inherent
constraints of the different thermodynamic cycles employed in
power generation
• Also further losses of around 10 – 15 % are associated with the
transmission and distribution of electricity in the electrical grid
• To improve energy efficiency
• To reduce use of fossil fuel
• To reduce emission of CO2
 COGENERATION SYSTEM - CYCLES
• Topping Cycle
• Bottoming Cycle
• Cogeneration system can be classified as either a topping or a
bottoming cycle on the basis of the sequence of energy use.
• In a topping cycle, the fuel supplied is used to first produce power and
then thermal energy, which is the by-product of the cycle and is used to
satisfy process heat or other thermal requirements.
• In a bottoming cycle, the primary fuel produces high temperature
thermal energy and the heat rejected from the process is used to
generate power through a recovery boiler and a turbine generator.
EXAMPLES
• Topping Cycles
• Water Desalination
• District Heating
• Sugar Industries

• Bottoming Cycles
• Cement Industries
• Steel Industries
• Ceramic and Gas Industries
• Petro-Chemical Industries
 TYPES OF TOPPING CYCLE
• A gas turbine or diesel engine producing electrical or mechanical power
followed by a heat recovery boiler to create steam to drive a secondary
steam turbine. This is called a combined-cycle topping system
• The second type of system burns fuel (any type) to produce high-pressure
steam that then passes through a steam turbine to produce power with
the exhaust provides low-pressure process steam. This is a steam-turbine
topping system
• A third type employs heat recovery from an engine exhaust flowing to a
heat recovery boiler, where it is converted to process steam / hot water
for further use.
• The fourth type is a gas-turbine topping system. A natural gas turbine
drives a generator. The exhaust gas goes to a heat recovery boiler that
makes process steam and process heat
 BOTTOMING CYCLE
• Bottoming cycles are suitable for manufacturing processes that require
heat at high temperature in furnaces and kilns, and reject heat at
significantly high temperatures
• Bottoming cycle plants are much less common than topping cycle
plants
What is cogeneration

Integrated system
Located at or near a building/facility
A way of local energy production
Uses heat that is lost otherwise
Way to use energy more efficient
Different areas of application
Different technologies
18
Cogeneration

Combined Heat and Power (CHP)

Cooling, Heating and Power (CHP)
Trigeneration (Trigen)
Integrated Energy Systems (IES)
Building Cooling, Heating, and
Power (BCHP)

19
 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
20
Schematic:

Dr. KAA, IES, DME, CEGC, AU 21

 HEAT TO POWER RATIO
• Heat-to-power ratio is one of the most important technical parameters
influencing the selection of the type of cogeneration system
• It is defined as the ratio of thermal energy to electricity required by the
energy consuming facility. It can be expressed in different units such as
Btu/kWh, kCal /kWh etc.,
• Cogeneration uses a single process to generate both electricity and
usable heat
• Cogeneration is likely to be most attractive under the following
circumstances :
(a) The demand for both steam and power is balanced i.e. consistent with the
range of steam : power output ratios that can be obtained from a suitable
cogeneration plant
(b) A single plant or group of plants has sufficient demand for steam and
power to permit economies of scale to be achieved
(c) Peaks and troughs in demand can be managed or, in the case of electricity,
adequate backup supplies can be obtained from the utility company
Utilization factor:
• In cogeneration, a larger fraction of energy transferred to the steam in
the boiler is utilized as either process heat and / or electric power
• The utilization factor (𝜀𝑈 ) for a cogeneration plant is,

(OR)

• Here qout indicates the heat rejected in the condenser and all
undesirable heat losses during process heat
• A best cogeneration plant will have Utilization factor as high as 70%
Dr. KAA, IES, DME, CEGC, AU 24
CHP SYSTEM:

Dr. KAA, IES, DME, CEGC, AU 25

Dr. KAA, IES, DME, CEGC, AU 26
TYPES OF EFFICIENCY:

Dr. KAA, IES, DME, CEGC, AU 27

Dr. KAA, IES, DME, CEGC, AU 28
Dr. KAA, IES, DME, CEGC, AU 29
Numerical:
1. In a single heater regenerative cycle, the steam enters the
turbine at 30 bar, 400 °C and the exhaust pressure is 0.1 bar.
The feed water heater is a direct contact type which operates
at 5 bar. Find,
(a) Efficiency and steam rate of the cycle,
(b) Increase in mean temperature of heat addition, efficiency
and steam rate as compared to the rankine cycle without
regeneration. Neglect pump work.
Dr. KAA, IES, DME, CEGC, AU 30
Dr. KAA, IES, DME, CEGC, AU 31
Dr. KAA, IES, DME, CEGC, AU 32
Dr. KAA, IES, DME, CEGC, AU 33
Dr. KAA, IES, DME, CEGC, AU 34
Dr. KAA, IES, DME, CEGC, AU 35
Dr. KAA, IES, DME, CEGC, AU 36
Dr. KAA, IES, DME, CEGC, AU 37
Dr. KAA, IES, DME, CEGC, AU 38
Numerical: (SOLVED IN CLASS)
2. Consider a cogeneration plant as shown in figure. Steam enters the turbine at 7 Mpa
& 500 °C. Some steam is extracted from the turbine at 500 kPa for process heating. The
remaining steam continues to expand to 5 kPa. Steam is then condensed at constant
pressure and pumped to the boiler pressure of 7 Mpa. At times of high demand for
process heat some steam leaving the boiler is throttled at 500 kPa. It is subsequently
pumped to 7 Mpa. The mass flow rate of steam through the boiler is 15 kg/s.
Disregarding any pressure drops and heat losses in the piping and assuming the turbine
and pump to be isentropic. Find,
(a) The maximum rate at which process heat can be supplied,
(b) The power produced and the utilization factor when no process heat is
supplied
(c) The rate of process heat supply, when 10% of the steam is extracted before it
enters turbine and 70% of the steam is extracted from the turbine at 500 kPa
for process heating
(d) Utilization factor for Case (C)

Dr. KAA, IES, DME, CEGC, AU 39

Numerical:
3. A steam power station has the following
cycle.
• Steam at boiler outlet – 150 bar, 550 °C
• Reheat at 40 bar to 550 °C
• Condenser at 0.1 bar
Using the Mollier chart and assuming
ideal process, find the (a) quality at turbine
exhaust, (b) Cycle efficiency and (c) Steam
rate.

Dr. KAA, IES, DME, CEGC, AU 40

 h3
3
h1 1

h2
2
h1 = 3465 kJ/kg
h2 = 3065 kJ/kg
h3 = 3565 kJ/kg
h4 4
h4 = 2300 kJ/kg
x = 0.88
Dr. KAA, IES, DME, CEGC, AU 41
Dr. KAA, IES, DME, CEGC, AU 42
Dr. KAA, IES, DME, CEGC, AU 43
Dr. KAA, IES, DME, CEGC, AU 44
 Binary vapour cycle
• Binary vapour cycle is the combination of two cycles, one operating at
higher temperature and the other operating at lower temperature.

• In binary vapour cycle, the condenser of the high temperature cycle

(topping cycle) serves as the boiler for the lower temperature cycle
(bottoming cycle).

• The heat rejection of topping cycle is used as heat input to the

bottoming cycle.

• Common working fluids used are mercury, sodium, potassium and

sodium potassium mixture.
Dr. KAA, IES, DME, CEGC, AU 45
• Mercury is the good working fluid for binary vapour cycle with critical
temperature of 898 °C, with its critical pressure being 18 MPa.

• The use of mercury is limited to high temperature cycle only.

• As it has lower specific enthalpy, mass flow rate of it in the binary

vapour cycle is several times higher than water (because it absorbs and
releases more heat at same pressure).

• The efficiency of binary cycle is more than the steam cycle.

Dr. KAA, IES, DME, CEGC, AU 46

 TS Diagram
Schematic
Dr. KAA, IES, DME, CEGC, AU 47
Combined gas-vapour cycle

TS Diagram
Schematic Dr. KAA, IES, DME, CEGC, AU 48
Numerical:
4. Steam at 40 bar, 500 °C flowing at the rate of 5500 kg/h expands in a h.p. turbine to 2 bar with an isentropic efficiency of 83%.
A continuous supply of steam at 2 bar, 0.87 quality and a flow rate of 2700 kg/h is available from a geothermal energy source.
This steam is mixed adiabatically with the h.p. turbine exhaust steam and the combined flow then expands in a 1.p. turbine to 0.1
bar with an isentropic efficiency of 78%. Determine the power output and the thermal efficiency of the plant. Assume that 5500
kg/h of steam is generated in the boiler at 40 bar, 500 °C from the saturated feedwater at 0.1 bar.

Dr. KAA, IES, DME, CEGC, AU 49

Dr. KAA, IES, DME, CEGC, AU 50
Now apply energy balancing:

Dr. KAA, IES, DME, CEGC, AU 51

Dr. KAA, IES, DME, CEGC, AU 52
Dr. KAA, IES, DME, CEGC, AU 53
Numerical:
5. In a cogeneration plant, the power load is 5.6 MW and the heating load is
1.163 MW. Steam is generated at 40 bar and 500 °C and is expanded isentropically
through a turbine to a condenser at 0.06 bar. The heating load is supplied by
extracting steam from the turbine at 2 bar, which is condensed in the process heater
to saturated liquid at 2 bar and then pumped back to the boiler. Compute
(a) the steam generation capacity of the boiler in t/h,
(b) the heat input to the boiler in kW,
(c) the fuel burning rate of the boiler in t/h if a coal of calorific value 25 MJ/kg is burned and the
boiler efficiency is 88%,
(d) the heat rejected to the condenser,
(e) the rate of flow of cooling water in the condenser if the temperature rise of water is 6°C.
Neglect pump work. Dr. KAA, IES, DME, CEGC, AU 54
Dr. KAA, IES, DME, CEGC, AU 55
Dr. KAA, IES, DME, CEGC, AU 56
 57
Dr. KAA, IES, DME, CEGC, AU
Numerical:
6. A mercury cycle is superposed on the steam cycle operating between
the boiler outlet condition at 40 bar, 400°C and the condenser
temperature of 40°C. The heat released by mercury condensing at
0.2 bar is used to impart the latent heat of vaporization to the water in
the steam cycle. Mercury enters the mercury turbine as saturated
vapour at 10 bar. Compute (a) kg of mercury circulated per kg of water,
and (b) the efficiency of the combined cycle. The property values of
saturated mercury are given below:

Dr. KAA, IES, DME, CEGC, AU 58

Dr. KAA, IES, DME, CEGC, AU 59
Dr. KAA, IES, DME, CEGC, AU 60
Dr. KAA, IES, DME, CEGC, AU 61
Numerical:
7. Consider the combined gas–steam power cycle shown in Figure.
The topping cycle is a gas-turbine cycle that has a pressure ratio of
8. Air enters the compressor at 300 K and the turbine at 1300 K. The
isentropic efficiency of the compressor is 80 percent, and that of the
gas turbine is 85 percent. The bottoming cycle is a simple ideal
Rankine cycle operating between the pressure limits of 7 MPa and 5
kPa. Steam is heated in a heat exchanger by the exhaust gases to a
temperature of 500°C. The exhaust gases leave the heat exchanger
at 450 K. Determine
(a) the ratio of the mass flow rates of the steam and the
combustion gases and
(b) the thermal efficiency of the combined cycle.
Dr. KAA, IES, DME, CEGC, AU 62
Dr. KAA, IES, DME, CEGC, AU 63
Dr. KAA, IES, DME, CEGC, AU 64
Numerical:
8. Consider the cogeneration plant shown in Figure. Steam enters
the turbine at 7 MPa and 500°C. Some steam is extracted from the
turbine at 500 kPa for process heating. The remaining steam
continues to expand to 5 kPa. Steam is then condensed at constant
pressure and pumped to the boiler pressure of 7 MPa. At times of
high demand for process heat, some steam leaving the boiler is
throttled to 500 kPa and is routed to the process heater. The
extraction fractions are adjusted so that steam leaves the process
heater as a saturated liquid at 500 kPa. It is subsequently pumped to
7 MPa. The mass flow rate of steam through the boiler is 15 kg/s.
Disregarding any pressure drops and heat losses in the piping and
assuming the turbine and the pump to be isentropic, determine (a)
the maximum rate at which process heat can be supplied, (b) the
power produced and the utilization factor when no process heat is
supplied, and (c) the rate of process heat supply when 10 percent of
the steam is extracted before it enters the turbine and 70 percent of
the steam is extracted from the turbine at 500 kPa for process
heating.
65
Dr. KAA, IES, DME, CEGC, AU
 The power plant operates on an ideal cycle and thus the pumps
and the turbines are isentropic; there are no pressure drops in the boiler,
process heater, and condenser; and steam leaves the condenser and the
process heater as saturated liquid.
The work inputs to the pumps and the enthalpies at various
states are as follows:

Dr. KAA, IES, DME, CEGC, AU 66

Dr. KAA, IES, DME, CEGC, AU 67
Dr. KAA, IES, DME, CEGC, AU 68
Dr. KAA, IES, DME, CEGC, AU 69
 STEAM TURBINE
• Steam turbines are the most commonly employed prime movers
for cogeneration applications
• In the steam turbine, the incoming high pressure steam is
expanded to a lower pressure level, converting the thermal energy
of high pressure steam to kinetic energy through nozzles and then
to mechanical power through rotating blades

Types of steam turbine used in cogeneration

– Back Pressure turbine
– Extraction Condensing turbine
DIFFERENT CONFIGURATIONS FOR
BACK PRESSURE STEAM TURBINES
 BACK PRESSURE TURBINE
• In this type steam enters the turbine chamber at High Pressure and expands to
Low or Medium Pressure
• Enthalpy difference is used for generating power / work
• Depending on the temperature levels at which process steam is required,
backpressure steam turbines can have different configurations
• In extraction and double extraction backpressure turbines, some amount of
steam is extracted from the turbine after being expanded to a certain pressure
level
• The extracted steam meets the heat demands at pressure levels higher than
the exhaust pressure of the steam turbine
EXTRACTION CONDENSING TURBINE
• In this type, steam entering at High / Medium Pressure is extracted at an
intermediate pressure in the turbine for process use while the remaining
steam continues to expand and condenses in a condenser and work is
done till it reaches the Condensing pressure ( vacuum )

• In a two stage extraction cum condensing turbine MP steam and LP steam

pass out to meet the process needs

• Balance quantity condenses in the surface condenser. The Energy

difference is used for generating Power.

• This configuration meets the heat-power requirement of the process

• The extraction condensing turbines have higher power to heat ratio in
comparison with backpressure turbines

• Although condensing systems need more auxiliary equipment such as the

condenser and cooling towers, better matching of electrical power and heat
demand can be obtained where electricity demand is much higher than the
steam demand and the load patterns are highly fluctuating
STEAM TURBINE COGENERATION SYSTEMS
• The two types of steam turbines most widely used are the back
pressure and the extraction - condensing turbine
• The steam turbine topping cycle cogeneration system is the
extraction - back pressure turbine
• Extraction - back pressure turbine can be employed where the end -
user needs thermal energy at two different temperature levels
• The full-condensing steam turbines are usually incorporated at sites
where heat rejected from the process is used to generate power
RECIPROCATING ENGINE
COGENERATION SYSTEMS
• These cogeneration systems have high power generation
efficiencies in comparison with other prime movers
• There are two sources of heat for recovery :
• Exhaust gas at high temperature
• Engine jacket cooling water system at low temperature
• As heat recovery can be quite efficient for smaller systems,
these systems are more popular with smaller energy
consuming facilities, particularly those having a greater need
for electricity than thermal energy and where the quality of
heat required is not high, e.g. low pressure steam or hot
water
RECIPROCATING ENGINE COGENERATION SYSTEMS
• Though diesel has been the most common fuel in the past, the prime
movers can also operate with heavy fuel oil or natural gas.
• These machines are ideal for intermittent operation and their
performance is not as sensitive to the changes in ambient
temperatures as the gas turbines.
• Though the initial investment on these machines is low, their
operating and maintenance costs are high due to high wear and tear
 IDEAL RANKINE CYCLE
The Rankine cycle is the ideal cycle for vapor power plants;
it includes the following four reversible processes,
Process 1-2
Isentropic compression Water enters the pump as state
1 as saturated liquid and is
compressed isentropically to the
operating pressure of the boiler.

Process 2-3 Const Pressure heat addition Saturated water enters the boiler
and leaves it as superheated
vapor at state 3

Process 3-4 Isentropic expansion Superheated vapor expands

isentropically in turbine and
produces work.

Process 4-1 Const Pressure heat rejection High quality steam is condensed
in the condenser

81
Dr. KAA, IES, DME, CEGC, AU
P 3’ 3 3’’ Superheated
2
steam • 1-2 : isentropic
compression process
Dry
saturated steam (pressure increases)
1 • 2-3: Const. pressure
4’ 4 4’’
heat addition
Wet steam
• 3-4: Isentropic
V expansion (power
T 3’’
production)
3’ 3
• 4-1: Const. pressure
2 heat rejection

1
4’ 4 4’’

82
S Dr. KAA, IES, DME, CEGC, AU
Dr. KAA, IES, DME, CEGC, AU 83
Energy Analysis for the Cycle
• All four components of the Rankine cycle are steady-state steady-flow devices.
• The potential and kinetic energy effects can be neglected.
• The first law per unit mass of steam can be written as:

Dr. KAA, IES, DME, CEGC, AU 84

Dr. KAA, IES, DME, CEGC, AU 85
The feed pump handles liquid water which is incompressible, meaning with increase
In pressure its density or specific volume undergoes little change.

Dr. KAA, IES, DME, CEGC, AU 86

Dr. KAA, IES, DME, CEGC, AU 87
 HOW CAN WE INCREASE THE EFFICIENCY OF THE RANKINE
CYCLE?
The basic idea behind all the modifications to increase the thermal efficiency of a power
cycle is the same: Increase the average temperature at which heat is transferred to the
working fluid in the boiler, or decrease the average temperature at which heat is
rejected from the working fluid in the condenser.

Lowering the Condenser Pressure (Lowers Tlow,avg)

To take advantage of the increased efficiencies
at low pressures, the condensers of steam power
plants usually operate well below the
atmospheric pressure. There is a lower limit to
this pressure depending on the temperature of
the cooling medium
Side effect: Lowering the condenser pressure
increases the moisture content of the steam at
the final stages of the turbine.

The effect of lowering the condenser pressure on the

ideal Rankine cycle.
 HOW CAN WE INCREASE THE EFFICIENCY OF THE RANKINE
CYCLE?
Superheating the Steam to High Temperatures (Increases Thigh,avg)

Both the net work and heat input increase

as a result of superheating the steam to a
higher temperature. The overall effect is an
increase in thermal efficiency since the
average temperature at which heat is added
increases.
Superheating to higher temperatures
decreases the moisture content of the
steam at the turbine exit, which is
desirable.
The temperature is limited by
metallurgical considerations. Presently the
The effect of superheating the highest steam temperature allowed at the
steam to higher temperatures on turbine inlet is about 620°C.
the ideal Rankine cycle.
 HOW CAN WE INCREASE THE EFFICIENCY OF THE
RANKINE CYCLE?
Increasing the Boiler Pressure (Increases Thigh,avg)
For a fixed turbine inlet temperature, Today many modern steam power
the cycle shifts to the left and the plants operate at supercritical
moisture content of steam at the turbine pressures (P > 22.06 MPa) and have
exit increases. This side effect can be thermal efficiencies of about 40% for
corrected by reheating the steam. fossil-fuel plants and 34% for nuclear
plants.

The effect of increasing the boiler

pressure on the ideal Rankine cycle.
The thermal efficiency of the rankine cycle can also be improved by following methods,

1) Regenerative Feed Heating

2) Reheating of Steam

3) Water Extraction

4) Using Binary Vapors

Dr. KAA, IES, DME, CEGC, AU 91

THANK
YOU
Dr. KAA, IES, DME, CEGC, AU 92