A PROJECT REPORT

On
Collect information about nearby cogeneration plant.
Submitted By
Somesh Kota
Roll No: 45
Enrollment No: 1900150521
Of
Diploma in engineering and Technology
In
Mechanical

GOVERNMENT POLYTECHNIC, SOLAPUR

MAHARASHTRA STATE BOARD OF TECHNICAL
EDUCATION,
MUMBAI

CERTIFICATE
MAHARSHTRA STATE BOARD OF
TECHNICAL EDUCATION, MUMBAI
GOVERNMENT POLYTECHNIC
SOALAPUR

This is to certify that, Mr. Somesh Kota

Roll NO. 45 of Fifth Semester of Diploma in Mechanical Engineering of
Institute Government Polytechnic Solapur (Code: 0015) have
completed the micro-project work satisfactorily under my supervision
and guidance in subject Power Plant Engineering (22566) for the
academic year 2021-2022 as prescribed in the curriculum.

Prof. A. S. Kapekari HOD Principal

(Project Guide)
ACKNOWLEDGEMENT
We wish to express our profound and sincere gratitude to our guide, who
guided us into the intricacies of this micro project non-chalantly with matchless
magnanimity. We are indebted to his constant encouragement, co-operation and
help. It was his enthusiastic support that helped us in overcoming the various
obstacles in this project.
We would also like to express our thankfulness to our beloved Principal,
H.O.D. and other faculty members of our Second Year Department for extending
their support and motivation.
Finally, we would be failing in our duty, if we don’t acknowledge the
cooperation rendered during various stages of this micro-project by our group
members.
Thank you.......!
(Part-A)
Micro Project Proposal

Title of Micro Project: -

Report Showing Information of Cogeneration plant.

Brief Introduction:-
This report summarizes the basic information and working of
cogeneration power plant. This also includes need of cogeneration
power plant, technical options, it’s classification of cogeneration.

Aim of micro project :-

Aim of this micro project is to learn and understand the
cogeneration plant its principal and its need.
(Part – B)
Micro Project Report

Introduction:-
A typical fossil-fuel power plant has an average thermal-to-power
efficiency of 35–45%, because its steam turbine can only extract so
much electrical energy from high-pressure steam, and because the low-
pressure steam that exits the turbine cannot be used.

In a cogeneration system, steam that passes through the turbines is

maintained at an outlet pressure high enough to be used by process
units. Because energy at the turbine outlet is re-used, cogeneration
systems have overall efficiencies that can be higher than 85%, which
allows industrial plants to generate electrical power at lower-than-
market costs.

Therefore, the steam exiting the turbine must be condensed, and its
potential energy is lost.

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 inthe form of electricity (Figure 7.1). 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.

Principle of Cogeneration:-
Cogeneration or Combined Heat and Power (CHP) is defined as the
sequential generation of two different forms of useful energy from a
single primary energy source, typically mechanical energy and thermal
energy.

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.

Cogeneration provides a wide range of technologies for application

in various domains of economic activities. The overall efficiency of
energy use in cogeneration mode can be up to 85per cent and above in
some cases.
An industry requires 24 units of electrical energy and 34 units of heat
energy. Through separate heat and power route the primary energy
At the macro level, it allows a part of the financial burden of the
national power utility to be shared by the private sector; in addition,
indigenous energy sources are conserved. At the micro level, the overall
energy bill of the users can be reduced, particularly when there is a
simultaneous need for both power and heat at the site, and a rational
energy tariff is practiced in the country.

Advantages of Cogeneration:-
1) Enhancing operational efficiency to lower overhead costs.
2) Reducing energy waste, thereby increasing energy efficiency.
3) Offering greater energy independence by moving a portion of the
load off the grid.
4) Allowing companies to replace aging infrastructure .

Disadvantages of Cogeneration:-
1) risk that clients may not want to sign long term heat contracts
2) risk that if some clients fail to meet their obligations, others may
need to contribute more
3) many modern buildings need cooling as well as heating
4) the heat generated in summer may go to waste
5) most organization want to be in control of their own costs

Application of Cogeneration:-
Cogeneration is the integration of nuclear power plants with other
systems and applications. The heat generated by the nuclear power
plants can be used to produce a vast range of products such as
cooling, heating, process heat, desalination and hydrogen. The use of
nuclear energy for cogeneration provides many economic,
environmental and efficiency-related benefits. Cogeneration options
may be different; depending on the technology, reactor type, fuel
type and temperature level.

Cogeneration mode. The working temperature ranges of SCWR (430-

625°C), GFR (~850°C) and MSR (750-1000°C) make them suitable for
production of hydrogen, process heat and desalination of sea water
when they are used as cogeneration systems.

Technical Options for Cogeneration:-

Cogeneration technologies that have been widely commercialized
include extraction/back pressure steam turbines, gas turbine with heat
recovery boiler (with or without bottoming steam turbine) and
reciprocating engines with heat recovery boiler.
 Steam Turbine Cogeneration systems:-
The two types of steam turbines most widely used are the backpressure
and the extraction-Another variation of the steam turbine topping cycle
cogeneration system is the extraction-back pressure turbine that can be
employed where the end-user needs thermal energy at two different
temperature levels.
The specific advantage of using steam turbines in comparison with the
other prime movers is the option for using a wide variety of
conventional as well as alternative fuels such as coal, natural gas, fuel
oil and biomass. The power generation efficiency of the emand for
electricity is greater than one MW up to a few hundreds of MW.
Due to the system inertia, their operation is not suitable for sites with
intermittent energy demand.

 Gas turbine Cogeneration Systems:-

Gas turbine cogeneration systems can produce all or a part of the
energy requirement of the site, and the energy released at high
temperature in the exhaust stack can be recovered for various heating
and cooling applications (see Figure 7.4). Though natural gas is most
commonly used, other fuels such as light fuel oil or diesel can also be
employed. The typical range of gas turbines varies from a fraction of a
MW to around 100 MW.
Though it has a low heat to power conversion efficiency, more heat can
be recovered at higher temperatures. If the heat output is less than
that required by the user, it is possible to have supplementary natural
gas firing by mixing additional fuel to the oxygen-rich exhaust gas to
boost the thermal output more efficiently.

On the other hand, if more power is required at the site, it is possible to

adopt a combined cycle that is a combination of gas turbine and steam
turbine cogeneration. Steam generated from the exhaust gas of the gas
turbine is passed through a backpressure or extraction-condensing
steam turbine to generate additional power. The exhaust or the
extracted steam from the steam turbine provides the required thermal
energy.

 Reciprocating Engine Cogeneration Systems:-

Also known as internal combustion (I. C.) engines, 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 and engine jacket cooling water
system at low temperature (see Figure 7.5). As heat recovery can be
quite efficient for smaller systems, these systems are more popular
with smaller energy consuming facilities, particularly those having
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.

Classification of Cogeneration Systems:-

Cogeneration systems are normally classified according to the sequence
of energy use and the operating schemes adopted.
A 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. Topping cycle
cogeneration is widely used and is the most popular method of
cogeneration.

Topping Cycle:-
The four types of topping cycle cogeneration systems:-
TYPES OF TOPPING CYCLES Diagram
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 and/or jacket
cooling system 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.

Typical Cogeneration Performance Parameters:-

The following Table 7.4 gives typical Cogeneration Performance
Parameters for different Cogeneration Packages giving heat rate,
overall efficiencies etc.
TABLE 7.4 TYPICAL COGENERATION PERFORMANCE PARAMETERS
Efficiencies, %
Prime Nominal Electrical Electrical Thermal Overall
Mover in Range Generatio Conversion Recover Cogeneration
Cogen. (Electrical) n Heat y
Package Rate -
kCal/kWh
Small 10-500kW 2650- 20-32 50 74-82
Reciprocati 6300
ng Engines
Large 500- 2400- 26-36 50 76-86
Reciprocati 3000kW 3275
ng
Engines
Diesel 10- 2770- 23-38 50 73-88
Engine 3000kW 3775
Smaller Gas 800- 2770- 24-31 50 74-88
Turbines 10000kW 3525
Larger Gas 10-20MW 2770- 26-31 50 78-81
Turbines 3275
Steam 10- 2520- 17-34 - -
Turbines 100MW 5040

Cogeneration plant in India:-

Name Mitsubishi Power Private
Limited
Incorporation 1995 (Started Mitsubishi Heavy
Industries (MHI) India)
Headquarter: Delhi
ISO Certified ISO 9001:2015 Certified EPC
Company.
Managing Director and CEO Tatsuto Nagayasu
Capital 100% owned by Mitsubishi
Power Ltd.
Locations Registered Office(Delhi, India)
Corporate office(Bangalore,
India)
GEC office(Bangalore, India)
Branch(DUBAI)

Mitsubishi Power India Private Limited (MP-

IND) successfully completed cogeneration
facility, with company's H-25 gas turbine as
the core equipment , for Indian Farmers
Fertiliser Cooperative Limited (IFFCO). The H-
25 gas turbine is a state-of-the-art high-
reliability, heavy-duty gas turbine that offers outstanding ease of
maintenance.

The co-generation plant is built within IFFCO's existing complex in

Phulpur, Uttar Pradesh, Northern India. The project was completed in
record time of 16 months maintaining MHPS global safety and quality
standards. The rated output of this facility is 22 megawatts (MW) of
power and supply of process steam of 60 tonnes per hour.

The new facility is stably supporting the power and steam consumption
demands of IFFCO's Phulpur Complex and is also contributing to overall
energy savings by increased overall efficiency.