This document discusses a cogeneration project opportunity using a micro-turbine system at the KMITL Combustion Lab. It provides an introduction to cogeneration systems, examples of applications that can generate both electricity and steam/hot water, and analyses of the energy and cost benefits compared to conventional boiler systems. The document also examines the impact of micro-turbine exhaust gas temperature on boiler performance and efficiency.
At Euro Energy Services Renewable Energy in Scotland Open Day on October 23rd Thomas Dickson of Glow Worm discusses Air Source Heat Pumps and their application in dwellings across the UK
Thermal Efficiency of Buildings - Stefan Huber - Paul Heat Recovery ScotlandEuro Energy Services
At Euro Energy Services Renewable Energy in Scotland Open Day on October 23rd Stefan Huber talked about how the thermal efficiency of buildings and why well designed ventilation is vital to buildings.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Heating consists of the majority of the energy demand in Industries. Around 123 Gwh of energy is consumed every year.
The workshop was conducted to give an understanding of the various ways to sustainably provide heat for processes.
At Euro Energy Services Renewable Energy in Scotland Open Day on October 23rd Thomas Dickson of Glow Worm discusses Air Source Heat Pumps and their application in dwellings across the UK
Thermal Efficiency of Buildings - Stefan Huber - Paul Heat Recovery ScotlandEuro Energy Services
At Euro Energy Services Renewable Energy in Scotland Open Day on October 23rd Stefan Huber talked about how the thermal efficiency of buildings and why well designed ventilation is vital to buildings.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Heating consists of the majority of the energy demand in Industries. Around 123 Gwh of energy is consumed every year.
The workshop was conducted to give an understanding of the various ways to sustainably provide heat for processes.
Energy Efficiency in Steel Rolling Mills of Nepaleecfncci
This presentation provides detailed information about energy saving opportunties in Steel and Metal industries in Nepal. It focusses on energy management issues in Steel Rolling Mills. Case studies are presentated to show how energy audit can lead to enormous cost savings. The findings are based on a GIZ baseline study conducted in 200 industries in 2012.
ORC ElectraTherm Green Machine - waste heat to power, Power generationRado Irgl
ElectraTherm's Green Machine converts low temperature water flows into fuel-free, emission-free electric power. The Green Machine output range is from 20 kWe to 65kWe, based on temperatures and flows.
The Green Machine, is an Organic Rankine Cycle (ORC) based heat-to-power generating system. It captures waste energy from small, distributed hot water sources such as stationary engine jacket water, biomass boilers, solar thermal and co-produced (or geothermal) fluids to generate 25 - 65kWe of fuel-free, emissions-free electricity. Factory assembled and tested, it is skid mounted and available as a single unit or in multiples to match the available heat.
The patented twin screw expander and ElectraTherm’s ORC system specifically targets low temperature and abundant resources. Our current upper limit for input to the machine is 240°F/116°C. However, if there is potential to reduce the hot water source via a secondary loop, the Green Machine can be utilized.
A biogas plant that uses the Green Machine converts excess engine heat
into valuable electricity and reduces existing on-site electrical cooling loads
for the engine. The Green Machine increases biogas plant efficiency and lowers fuel requirements for the biogas engine. This means increased revenue
for the biogas plant.
http://www.cogenera.si/
Indian experiences on Energye Efficiency in Steel Rolling Millseecfncci
Since the establishement of Bureau of Energy Efficiency in 2001 India has been implementing a lot of activities in energy-intensive sector. In Steel Rolling Mills with low-end and high-end technolgies considerable energy and cost sanvings can be achieved. The presentation was prepared in the Context of GIZ NEEP programm in Nepal in 2012.
Combined Heat and Power is the simultaneous production of
electricity and heat using a single fuel such as natural gas. The heat produced from the electricity generation process is captured and used to produce steam or hot water that can then be used for industrial and commercial heating or cooling purposes, such as district energy systems. The dual output of CHP facility can make more efficient use of fuel than two separate facilities that each just produce just heat or electricity. Consequently a CHP facility can provide the same energy services with lower greenhouse gas emissions.
case study on dance food processing industry(process integration)Vikram Kataria
this presentation includes case study on dance food processing industry and the best process integration techniques that they used to solve problems in their industry.
The presentation discusses the various factors which affect the performance of Power Boilers including the quality of coal, airheater performance, air ingress etc.
Cogeneration is a system that produces heat and electricity simultaneously in a single plant, powered by just one primary energy source, thereby guaranteeing a better energy yield than would be possible to achieve from two separate production sources.
Cogeneration and its basics for energy managementAyisha586983
Cogeneration, also known as Combined Heat and Power (CHP), is a highly efficient energy production process that simultaneously generates electricity and useful thermal energy (such as steam or hot water) from a single fuel source. This integrated approach to energy production maximizes overall energy efficiency and reduces greenhouse gas emissions compared to separate generation of electricity and thermal energy.
Energy Efficiency in Steel Rolling Mills of Nepaleecfncci
This presentation provides detailed information about energy saving opportunties in Steel and Metal industries in Nepal. It focusses on energy management issues in Steel Rolling Mills. Case studies are presentated to show how energy audit can lead to enormous cost savings. The findings are based on a GIZ baseline study conducted in 200 industries in 2012.
ORC ElectraTherm Green Machine - waste heat to power, Power generationRado Irgl
ElectraTherm's Green Machine converts low temperature water flows into fuel-free, emission-free electric power. The Green Machine output range is from 20 kWe to 65kWe, based on temperatures and flows.
The Green Machine, is an Organic Rankine Cycle (ORC) based heat-to-power generating system. It captures waste energy from small, distributed hot water sources such as stationary engine jacket water, biomass boilers, solar thermal and co-produced (or geothermal) fluids to generate 25 - 65kWe of fuel-free, emissions-free electricity. Factory assembled and tested, it is skid mounted and available as a single unit or in multiples to match the available heat.
The patented twin screw expander and ElectraTherm’s ORC system specifically targets low temperature and abundant resources. Our current upper limit for input to the machine is 240°F/116°C. However, if there is potential to reduce the hot water source via a secondary loop, the Green Machine can be utilized.
A biogas plant that uses the Green Machine converts excess engine heat
into valuable electricity and reduces existing on-site electrical cooling loads
for the engine. The Green Machine increases biogas plant efficiency and lowers fuel requirements for the biogas engine. This means increased revenue
for the biogas plant.
http://www.cogenera.si/
Indian experiences on Energye Efficiency in Steel Rolling Millseecfncci
Since the establishement of Bureau of Energy Efficiency in 2001 India has been implementing a lot of activities in energy-intensive sector. In Steel Rolling Mills with low-end and high-end technolgies considerable energy and cost sanvings can be achieved. The presentation was prepared in the Context of GIZ NEEP programm in Nepal in 2012.
Combined Heat and Power is the simultaneous production of
electricity and heat using a single fuel such as natural gas. The heat produced from the electricity generation process is captured and used to produce steam or hot water that can then be used for industrial and commercial heating or cooling purposes, such as district energy systems. The dual output of CHP facility can make more efficient use of fuel than two separate facilities that each just produce just heat or electricity. Consequently a CHP facility can provide the same energy services with lower greenhouse gas emissions.
case study on dance food processing industry(process integration)Vikram Kataria
this presentation includes case study on dance food processing industry and the best process integration techniques that they used to solve problems in their industry.
The presentation discusses the various factors which affect the performance of Power Boilers including the quality of coal, airheater performance, air ingress etc.
Cogeneration is a system that produces heat and electricity simultaneously in a single plant, powered by just one primary energy source, thereby guaranteeing a better energy yield than would be possible to achieve from two separate production sources.
Cogeneration and its basics for energy managementAyisha586983
Cogeneration, also known as Combined Heat and Power (CHP), is a highly efficient energy production process that simultaneously generates electricity and useful thermal energy (such as steam or hot water) from a single fuel source. This integrated approach to energy production maximizes overall energy efficiency and reduces greenhouse gas emissions compared to separate generation of electricity and thermal energy.
Modeling and Valuing Cogeneration with AURORAxmpEPIS Inc
Regulatory & Cogeneration Services, Inc. uses AURORAxmp to model and value cogeneration plants.
AURORAxmp determines revenues, value and dispatch cost for all three configurations, based upon generation levels, fuel cost and consumption rate.
2. Introduction to cogeneration
KMITL COMBUSTION LAB
• conventional steam production in industrial
• What if we place Micro-turbine before the boiler ?
Air inlet
NGV inlet
3. Introduction to cogeneration
KMITL COMBUSTION LAB
• What if we place Micro turbine and afterburner before the boiler ?
• High value by product electrical generation
• Generating by product electrical power with the same cost of fuel heating value
• To generate by product electrical power while sustaining boiler capacity and
efficiency
Micro turbine
exhaust manifold
After burner
Exhaust stack
Air inletNGV inlet
Steam generation
Electrical
generation
4. Cogeneration introduction ( Micro turbine application )
KMITL COMBUSTION LAB
Duct combustor
Micro turbine & generator unit
Exhaust manifold duct
To boiler burner
Boiler unit
5. Cogeneration introduction ( piston engine application )
KMITL COMBUSTION LAB
• Considerable higher thermal efficiency ( around 40-45% )
• More complicate thermal recovery
• Exhaust direct combustion to boost temperature may not capable
6. Example of cogeneration application
KMITL COMBUSTION LAB
• Electrical & hot water generation ( commercial set )
• Electrical & steam generation with direct burner
• Electrical & cold water generation (trigeneration)
• Integration with ORC or Rankine bottom cycle ( >40% electrical efficiency )
Capstone with ORC integration
7. C65 electrical & hot water
generation commercial unit
KMITL COMBUSTION LAB
8. Capstone C65 energy analysis
KMITL COMBUSTION LAB
• Electrical & hot water generation, commercial package
246.67 KW
NGV burn C65
turbine
65 KW electrical generation
120 KW hot water generation
61.67 KW stack loss
9. Capstone C65 business analysis
KMITL COMBUSTION LAB
• Electrical & hot water generation, commercial package
398.31baht/hr
NGV burn C65
turbine
240.5 baht/hr electrical generation
193.77 baht/hr hot water generation
0 baht /hr
• profit = (240.5 + 193.77) – 398.31
= 35.96 baht / hr
= 315,009.6 baht / yr / unit
Note : NGV cost 17 baht/Kg , Electrical cost 3.7 baht / Kwh
NGV heating value @ 37.9 MJ/Kg
11. Energy analysis (compare with conventional boiler system )
KMITL COMBUSTION LAB
• Energy flow with conventional boiler
80 % boiler efficiency 85.4 KW stack loss
427 KW (fuel burn)
341.6 KW of steam generation
12. Business analysis (compare with conventional boiler system )
KMITL COMBUSTION LAB
341.6 KW of steam generation
• Money flow with conventional boiler
750 baht/hr (NGV burn)
80 % boiler efficiency 20 % stack loss
• pay 750 baht / hr for NGV fueled to generate steam 341.6 KW
Note : NGV cost 17 baht/Kg , Electrical cost 3.7 baht / Kwh
NGV heating value @ 37.9 MJ/Kg
13. Energy analysis ( C65 CHP application with afterburner )
KMITL COMBUSTION LAB
• Energy flow with CHP integrate system (micro turbine )
246.67 KW (fuel burn)
29 % GT efficiency 80 % boiler efficiency
341.6 KW of steam
generation
65 KW electrical generation
181.67 KW (exhaust gas)
246 KW (After burner)
427 KW (flue gas)
85.4 KW stack loss
14. Business analysis ( C65 CHP application with afterburner )
KMITL COMBUSTION LAB
• Money flow with CHP integrate system (micro turbine )
400 baht/hr (fuel burn)
29 % GT efficiency 80 % boiler efficiency
341.6 KW of steam
generation
240 baht/hr electrical generation
400 baht/hr (After burner)
427 KW (flue gas)
85.4 KW stack lossPay 800 baht to generate 341.6 Kw
Generate 240 baht of electrical power
Profit = 750 - (800 -240 )
= 190 baht / hr /unit
= 1,641,600 baht / yr /unit
15. Thermal process analysis on electrical and steam generation
with direct burner
KMITL COMBUSTION LAB
• Typical steam generation process
o Air / fuel was mixed and burned with burner
o Combustion hot gas temperature is nearly at adiabatic flame temperature
o Heat transfer characteristic in fire tube boiler is strongly depends on flame
temperature
• Heat transfer in fire tube boiler
o Radiation ( heat up tube surface of fire tube and hot gas )
o convection ( Transfer hot gas energy to water cooled tube surface )
o conduction ( Transfer energy from hot side tube surface to cool side )
• Hot gas temperature parameter is effect on heat transfer characteristic, boiler
capacity and boiler efficiency
16. Evaluation on boiler performance and efficiency on
combustion gas temperature and velocity (example)
KMITL COMBUSTION LAB
• Employ dimensionless approach
o Heat transfer through the tube wall electrical circuit analogy
o Fire tube boiler TA is known, temperature of the combustion gas
o Water temperature TB is know, temperature saturated water
o h1 is known by dimensionless approach correlation of …
o h2 can remodel to conduction analogy using K water approach or other
available correlation can be employed.
o Effect of radiation will resulting in raising of T1
17. Hot gas temperature analysis on electrical and steam
generation with direct burner
KMITL COMBUSTION LAB
• cogeneration application
Exhaust gas temperature was boosted by direct burner
• thermodynamics analysis (energy conservation )
The boosted exhaust gas temperature = (1-n)*(qin ) + (qad –qin ) / Cp air
Typical flue gas temperature = qad /Cp air
p
v
18. Thermal process analysis on electrical and steam generation
with direct burner
KMITL COMBUSTION LAB
• Micro-turbine with 30% thermal efficiency
• There is 15 % in temperature drop comparing to conventional burner ( for 2000K
adiabatic temperature fuel )
• How can we estimate boiler performance and capacity deteriorate due to this
effect ?
19. Business opportunity analysis (compare with conventional boiler system )
KMITL COMBUSTION LAB
80 Joule of steam generation
• Money flow with conventional boiler
100 baht (fuel burn)
80 % boiler efficiency 20 % stack loss
• Money flow with CHP integrate system (micro turbine )
xx baht (fuel burn)
xx baht electrical generation
29 % GT efficiency
xx baht (fuel burn)
80 % boiler efficiency
80 Joule of steam
generationxx joule (GT exhaust)
20. Heat transfer scaling law for systems prediction
KMITL COMBUSTION LAB
• Example NGV fueled Micro-turbine with 30% thermal efficienc