Economic and technical feasibility study of a combined-cycle cogeneration system associated with cellulose plants

In this paper, is presented an economical and technical feasibility study of a combined cycle cogeneration system proposed to be used in a pulp plant located in Brazil, where around 95% of country's pulp production is done by the use of Kraft Process. This process allows the use of black liquor and other by-products as fuel. This study is based upon actual data from a pulp plant with a daily production of 1000 tons., that generates part of the energy demanded by the process in a conventional cogeneration system with condensing steam turbine and two extractions. The addition of a gas turbine was studied to compare electricity production level and its related costs between original system and the new one, considering that the former can use industrial by-products and firewood as fuel, when required. Several parameters related to electric generation systems operation and production costs were studied. The use of natural gas in the combined cycle, in comparison with the use of firewood in the conventional system was studied. The advantages of natural gas fuel are highlighted. The surplus availability and the electricity generation costs are presented as a function of pulp and black liquor production.

Thermoeconomic functional analysis applied in cogeneration systems associated to cellulose plants

Thermoeconomic Functional Analysis is a method developed for the analysis and optimal design of improvement of thermal systems (Frangopoulos, 1984). The purpose of this work is to discuss the cogeneration system optimization using a condensing steam turbine with two extractions. This cogeneration system is a rational alternative in pulp and paper plants in regard to the Brazilian conditions. The objective of this optimization consists of minimizing the global cost of the system acquisition and operation, based on the parametrization of actual data from a cellulose plant with a daily production of 1000 tons. Among the several possible decision variables, the pressure and temperature of live steam were selected. These variables significantly affect the energy performance of the cogeneration system. The conditions which determine a lower cost for the system are presented in conclusion.

Potential and costs for the production of electrolytic hydrogen in alcohol and sugar cane plants in the central and south regions of Brazil

This project verified the potential for the production of hydrogen via water electrolysis by using the exceeding electrical energy resultant from alcohol and sugar plants that use sugar cane bagasse as fuel. The studies were carried out in cogeneration plants authorized by the Electrical Energy National Agency (ANEEL). The processing history of sugar cane considered was based on the 2006/2007 harvests. The total bagasse produced, electrical energy generated and exceeding electrical energy in a year were calculated. It was obtained an average energy consumption value of 5.2 kWh Nm(-3) and the hydrogen production costs regarding the amount of sugar cane processed that ranged from US$ 0.50 to US$ 0.75 Nm(-3). The results pointed that the costs for the production of hydrogen via the bagasse exceeding energy are close to the production costs that use other sources of energy. As the energy generated from the bagasse is a renewable one, this alternative for the production of hydrogen is economical and environmentally viable. (C) 2008 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.

Ecological efficiency and thermoeconomic analysis of a cogeneration system at a hospital

This work aims with an approach for cogeneration plants evaluation based on thermoeconomic functional diagram analysis. The second law of thermodynamics is used to develop a methodology to analyse cogeneration systems, based on exergoeconomics evaluation. The thermoeconomic optimisation method developed is applied to allow a better configuration of the cogeneration plant associated to a university hospital. Also ecological efficiency is evaluated. The method was efficient and contributes for thermoeconomics modelling and analysis and can be applied to any sort of thermal system, especially those with combined heat and power in thermal parity. (C) 2012 Elsevier Ltd. All rights reserved.

Cogeneration for small users: case studies for Brazilian tertiary sector

In this paper we present technical and economic studies of cogeneration systems utilizing combustion engines and gas turbines, applied in two establishments of the tertiary sector, regarding Brazilian conditions (according to Silveria, 1994). In the first step cogeneration systems utilizing combustion engines associated to absorption refrigeration systems are studied, in which electricity and cold air for a university building rate produced. In the second step some possibilities of the use of the gas turbine in cogeneration systems for a hospital are shown. In this case, the exhaust gases are utilized for the production of steam in a heat recovery steam generator (HRSG) or cold water in an absorption refrigeration system (for air conditioning) for the hospital building. The dynamic increment of the energy demand of Brazilian tertiary sector in last years can increase the installation of these cogeneration system (in compact version) as well as strengthen the development of the decentralized energy generation in Brazil.

Cogeneration system design optimization

Cogeneration system design deals with several parameters in the synthesis phase, where not only a thermal cycle must be indicated but the general arrangement, type, capacity and number of machines need to be defined. This problem is not trivial because many parameters are considered as goals in the project. An optimization technique that considers costs and revenues, reliability, pollutant emissions and exergetic efficiency as goals to be reached in the synthesis phase of a cogeneration system design process is presented. A discussion of appropriated values and the results for a pulp and paper plant integration to a cogeneration system are shown in order to illustrate the proposed methodology.

Thermoeconomic analysis: A criterion for the selection of cogeneration systems

The economical viability of three cogeneration schemes as supplying alternatives for a hypothetical industrial process has been studied. A cost appropriation method based on Valero's studies (1986) has been used. This method enables the determination of exergetic flows, the Second Law efficiency of equipment and the monetary costs of the products acquired by the industrial process (steam and electrical energy). The criterion adopted for the selection is the global cost of the supplied products to the industrial process as regarding in Brazilian conditions.

Thermoeconomic analysis of a cogeneration system of a university campus

In this paper, a thermoeconomic analysis method based on the First and the Second Law of Thermodynamics and applied to analyse the replacement of an equipment of a cogeneration system is presented. The cogeneration system consists of a gas turbine linked to a waste boiler. The electrical demand of the campus is approximately 9 MW but the cogen system generates approximately one third of the university requirement as well as 1.764 kg/s of saturated steam (at 0.861 MPa), approximately, from a single fuel source. The energy-economic study showed that the best system, based on pay-back period and based on the maximum savings (in 10 years), was the system that used the gas turbine M1T-06 of Kawasaki Heavy Industries and the system that used the gas turbine CCS7 of Hitachi Zosen, respectively. The exergy-economic study showed that the best system, which has the lowest EMC, was the system that used the gas turbine ASE50 of Allied Signal. © 2002 Elsevier Science Ltd. All rights reserved.

A techno-economic analysis for MCFC cogeneration system

In this paper, a methodology for the study of a fuel cell cogeneration system and applied to a university campus is developed. The cogeneration system consists of a molten carbonate fuel cell associated to an absorption refrigeration system. The electrical and cold-water demands of the campus are about 1,000 kW and 1,840 kW (at 7°C), respectively. The energy, exergy and economic analyses are presented. This system uses natural gas as the fuel and operates on electric parity. In conclusion, the fuel cell cogeneration system may have an excellent opportunity to strengthen the decentralized energy production in the Brazilian tertiary sector.

Experimental results and thermodynamic analysis of a natural gas small scale cogeneration plant for power and refrigeration purposes

In this work, experimental results are reported for a small scale cogeneration plant for power and refrigeration purposes. The plant includes a natural gas microturbine and an ammonia/water absorption chiller fired by steam. The system was tested under different turbine loads, steam pressures and chiller outlet temperatures. An evaluation based on the 1st and 2nd Laws of Thermodynamics was also performed. For the ambient temperature around 24°C and microturbine at full load, the plant is able to provide 19 kW of saturated steam at 5.3 bar (161 °C), corresponding to 9.2 kW of refrigeration at -5 °C (COP = 0.44). From a 2nd law point-of-view, it was found that there is an optimal chiller outlet temperature that maximizes the chiller exergetic efficiency. As expected, the microturbine presented the highest irreversibilities, followed by the absorption chiller and the HRSG. In order to reduce the plant exergy destruction, it is recommended a new design for the HRSG and a new insulation for the exhaust pipe. © 2013 Elsevier Ltd. All rights reserved.

Development of a knowledge-based system for cogeneration plant design: Verification, validation and lessons learned

This paper presents the development of a knowledge-based system (KBS) prototype able to design natural gas cogeneration plants, demonstrating new features for this field. The design of such power plants represents a synthesis problem, subject to thermodynamic constraints that include the location and sizing of components. The project was developed in partnership with the major Brazilian gas and oil company, and involved interaction with an external consultant as well as an interdisciplinary team. The paper focuses on validation and lessons learned, concentrating on important aspects such as the generation of alternative configuration schemes, breadth of each scheme description created by the system, and its module to support economic feasibility analysis. (C) 2014 Elsevier B.V. All rights reserved.

Experiences with control of evaporators using extensive vapour bleeding

FOR SUGAR factories with cogeneration plants major changes to the process stations have been undertaken to reduce the consumption of exhaust steam from the turbines and maximise the generated power. In many cases the process steam consumption has been reduced from greater than 52% on cane to ~40% on cane. The main changes have been to install additional evaporation area at the front of the set, operate the pan stages on vapour from No 1 or No 2 effects and undertake juice heating using vapour bleed from evaporators as far down the set as the penultimate stage. Operationally, one of the main challenges has been to develop a control system for the evaporators that addresses the objectives of juice processing rate (throughput) and steam economy, while producing syrup consistently at the required brix and providing an adequate and consistent vapour pressure for the pan stage operations. The cyclic demand for vapour by batch pans causes process disturbances through the evaporator set and these must be regulated in an effective manner to satisfy the above list of objectives for the evaporator station. The impact of the cyclic pan stage vapour demand has been modelled to define the impact on juice rate, steam economy, syrup brix and head space pressures in the evaporators. Experiences with the control schemes used at Pioneer and Rocky Point Mills are discussed. For each factory the paper provides information on (a) the control system used, the philosophy behind the control system and experiences in reaching the current system for control (b) the performance of the control system to handle the disturbances imposed by the pan stage and operate within other constraints of the factory (c) deficiencies in the current system and plans for further improvements. Other processing changes to boost the performance of the evaporators are also discussed.

Análisis exergético de planta de cogeneración con generación directa de vapor de proceso

[ES]La empresa de ingeniería SENER Ingeniería y sistemas S.A. tiene una larga experiencia en el desarrollo, diseño y construcción de plantas de cogeneración. La aplicación del análisis exergético a las plantas permite optimizar la eficiencia y reducir los costes. Este método basado en la exergía analiza si los recursos se utilizan de forma eficiente y proporciona las herramientas necesarias para mejorar su utilización. Este trabajo realiza dicho análisis exergético para posteriormente analizar los resultados y proponer mejoras para aumentar la eficiencia de la planta.

Dieselmotor-Kraft-Wärme-Kopplungsanlagen im Kontext der Integration Erneuerbarer Energien in die Energieversorgung

In dieser Arbeit werden die sich abzeichnenden zukünftigen Möglichkeiten, Stärken und Schwächen der Kraft-Wärme-Kopplung (KWK) untersucht. Dies geschieht vor dem Hintergrund des Klimawandels, der Integration steigender Anteile Erneuerbarer Energien in die Stromerzeugung und unter Berücksichtigung der sich damit ergebenden Herausforderungen, eine sichere und nachhaltige Stromversorgung zu gestalten. Der Fokus liegt auf der Dieselmotor-KWK und der Nutzung nachwachsender Kraftstoffe. Es wird davon ausgegangen, dass der Übergang zu einer reinen Stromerzeugung aus Erneuerbaren Energiequellen in Deutschland unter erheblicher Einbindung des hohen Potentials der kostengünstigen, umweltfreundlichen, aber in der Leistung extrem fluktuierenden Windenergie erfolgen wird. Als dezentrales Integrationswerkzeug wurde die Kraft-Wärme-Kopplung mit Dieselmotoren untersucht. Sie entspricht aufgrund ihrer großen Flexibilität und ihrer hohen Wirkungsgrade mit vergleichsweise kleinen Leistungen sehr gut den Anforderungen der gleichzeitigen dezentralen Wärmenutzung. In der Dissertation werden die Randbedingungen der Dieselmotor-KWK untersucht und beschrieben. Darauf aufbauend werden unterschiedliche Modelle der Windintegration durch KWK erarbeitet und in diversen Variationen wird der Ausgleich der Stromerzeugung aus Windenergie durch KWK simuliert. Darüber hinaus werden dezentrale KWK-Anlagen hinsichtlich eines koordinierten gemeinsamen Betriebs und hinsichtlich der optimalen Auslegung für den Windenergieausgleich betrachtet. Es wird für den beschriebenen Kontext der Erneuerbaren Energien und der Kraft-Wärme-Kopplung das Thema „Umweltwirkungen“ diskutiert. Es wird dargelegt, dass die heute verwendeten Ansätze zur Bewertung der KWK zu einer Verzerrung der Ergebnisse führen. Demgegenüber wurde mit der so genannten Outputmethode eine Methode der Ökobilanzierung vorgestellt, die, im Gegensatz zu den anderen Methoden, keine verzerrenden Annahmen in die Wirkungsabschätzung aufnimmt und somit eine eindeutige und rein wissenschaftliche Auswertung bleibt. Hiermit ist die Grundlage für die Bewertung der unterschiedlichen Technologien und Szenarien sowie für die Einordnung der KWK in den Kontext der Energieerzeugung gegeben. Mit der Outputmethode wird u.a. rechnerisch bewiesen, dass die gekoppelte Strom- und Wärmeerzeugung in KWK-Anlagen tatsächlich die optimale Nutzung der regenerativen Kraftstoffe „Biogas“ und „Pflanzenöl“ im Hinblick auf Ressourceneinsatz, Treibhausgaseinsparung und Exergieerzeugung ist. Es wurde darüber hinaus die Frage untersucht woher die für die Stromerzeugung durch Dieselmotor-KWK-Anlagen notwendige Bioenergie genommen werden kann. Es ist erwiesen, dass die in Deutschland nutzbare landwirtschaftliche Fläche nur zur Deckung eines Teils der Stromerzeugung ausreichen würde. Einheimisches Biogas und nachhaltiges importiertes Pflanzenöl, das in hohem Maße auf degradierten Böden angebaut werden sollte, können die notwendige Brennstoffenergie liefern. Um im Ausland ausreichend Pflanzenöl herstellen zu können, wird eine landwirtschaftliche Fläche von 6 bis 12 Mio. ha benötigt. Das Ergebnis ist, dass ein voller Ausgleich von Windenergie-Restlast durch KWK mit Erneuerbaren Energieträgern sinnvoll und machbar ist! Dieses Wind-KWK-DSM-System sollte durch ein Stromnetz ergänzt sein, das Wasserkraftstrom für den Großteil der Regelenergieaufgaben nutzt, und das den großräumigen Ausgleich Erneuerbarer Energien in Europa und den Nachbarregionen ermöglicht.

Thermoeconomic analysis method for optimization of combined heat and power systems

This article presents an thermoeconomic analysis of cogeneration plants, applied as a rational technique to produce electric power and saturated steam. The aim of this new methodology is the minimum exergetic manufacturing cost (EMC), based on the Second Law of Thermodynamics. The decision variables selected for the optimization are the pressure and the temperature of the steam leaving the boiler in the case of using steam turbine, and the pressure ratio, turbine exhaust temperature and mass flow in the case of using gas turbines. The equations for calculating the capital costs of the components and products are formulated as a function of these decision variables. An application of the method using real data of a multinational chemical industry located in São Paulo state is presented. The conditions which establish the minimum cost are presented as finals conclusions.