Cogeneration, also known as combined heat and power (CHP), is a process that captures and utilizes waste heat from industrial processes to simultaneously generate electricity and thermal energy from a single fuel source. It is more efficient than separate generation of heat and power as it can achieve efficiencies over 80%. Cogeneration systems can use various prime movers like gas turbines, steam turbines, or reciprocating engines to generate electricity while leftover heat is used for industrial processes, resulting in reduced emissions and lower energy costs compared to conventional generation.

1. Cogeneration
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2. Cogeneration –
A process in which an industrial
facility uses its waste energy to
produceheat or electricity
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3. •Cogeneration or Combined Heat and Power (CHP) are
defined as the sequential generation of two different forms of
useful energy from a single primary energy source, typically
mechanical energy and thermal energy. 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.
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4. •Cogenerationis an energy-efficient,
environmentally-friendly method of producing electricity
(power), steam and/or hot water at the same time, in
one process, with one fuel.
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5. Benefits of Cogeneration / CHP)
• Increased efficiency of energy conversion and use
• Lower Emissions, especially CO2.
• Ability to use waste materials.
• Large cost savings.
• Opportunity to decentralize the electricity generation.
• Promoting liberalization in energy markets.
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6. Cogenerationsolutionssimplyreducewaste,withonly10%-15%
losses,comparethatwiththe55%ormoreusingtraditional
generationmethodsanditisclearthatcogenerationusesfuel
moreefficiently.
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7. Cogenerationreducestheamountofexhaustinggreenhouse
gassuchasCO2(CarbonDioxide)andNOx(NitrogenOxides),it
cancontributealottopreventionofglobalwarming.
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8. Type of Cogeneration Systems:
prime movers
Reciprocating engines.
Combustion or gas turbines.
Steam turbines.
Microturbines.
Fuel cells.
Combined cycles.
Other classifications:
- Topping cycle
- Bottoming cycle
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9. Steam Turbine Cogeneration System
 Widely used in CHP applications
 Oldest prime mover technology
 Capacities: 50 kW to hundreds of MWs
• Most common types
 Back pressure steam turbine
 Extraction condensing steam turbine
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10. Back Pressure Steam Turbine
• Steam exits the turbine at a higher pressure that the
atmospheric
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 Simple configuration
 Low capital cost
 Low need of cooling
water
 High total efficiency

11. Extraction Condensing Steam Turbine
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 Steam obtained by extraction
from an intermediate stage
 Remaining steam is exhausted
 Relatively high capital cost,
lower total efficiency
 Control of electrical power
independent of thermal load

12. Gas Turbine Cogeneration System
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A- Open Cycle Gas Turbine

13. B-Closed Cycle Gas Turbine
• Any fuel, nuclear or solar energy can be used
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14. clen
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15. ReciprocatingEngineCogenerationSystems
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Four sources of usable waste heat

16. Combined cycle
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17. Type of Cogeneration Systems
• Topping Cycle
Supplied fuel first produces power followed by thermal energy
Thermal energy is a by product used for process heat or other
Most popular method of cogeneration
• Bottoming Cycle
Primary fuel produces high temperature thermal energy
Rejected heat is used to generate power
Suitable for manufacturing processes
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18. Manyindustrialprocessesoperatewithhightemperatureexhaustgases
(1000-1200oC).Aftertheprocess,thegasesarestillathightemperature
(500-600oC).Insteadofreleasingthemdirectlyintotheatmosphere,they
canpassthroughaheatrecoverysteamgenerator(HRSG)producing
steam,whichthendrivesasteamturbine
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Bottoming cycles

19. Bottoming cycle
cement industry
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20. Manyindustrialprocessesoperatewithhightemperatureexhaustgases
(1000-1200oC).Aftertheprocess,thegasesarestillathightemperature(500-
600oC).Insteadofreleasingthemdirectlyintotheatmosphere,theycanpass
throughaheatrecoverysteamgenerator(HRSG)producingsteam,which
thendrivesasteamturbine
• .
• Thus, the energy of fuel is first used to cover a thermal load and
then to produce electricity by a steam turbine system in a bottoming
cycle.
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21. Utilization factor
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22. Utilization factor
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23. Key decision factors
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24. Potential Sectors
Sugar industries
Textile industries
Chemical and Pharmaceutical industries
Paper industry
Refineries
Fertilizer
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