Combined Heat & Power

Cogeneration (CHP)

Cogeneration also known as combined heat and power (CHP) is used across multiple industries in the industrial/ commercial market sector. The cogeneration model is used to maximize the overall plant efficiency while simultaneously introducing substantial cost savings versus the conventional method of importing electricity and installing gas fired plant for process purposes.

What is Cogeneration?

In CHP electricity is generated by a Gas Turbine and heat recovered by a waste heat recovery system (WHR) located after the exhaust of the Gas Turbine. The recovered heat is then used for plant processes which maximizes the consumption of gas.

Combined heat and power, also known as cogeneration, is the use of electrical power and heat at a single power plant simultaneously. Exhaust gases leaving a gas turbine still contain a large amount of energy. In simple cycle gas turbine power plants, this exhaust is ducted to the atmosphere via an exhaust stack. However, in cogeneration plants the exhaust is used for heat generation. As a result, cogeneration provides more useful energy from the same fuel input, which gives a higher overall efficiency. It also decreases specific CO2 emissions. The fuel used in cogeneration projects is most often natural gas.

Benefits of Cogeneration

There are multiple benefits of Cogeneration in industry. Cogeneration has the potential to save significant amounts of energy, which reduces costs and CO2 emissions in the plants. This is a win-win situation for producers that requires electricity and heat in their process.

Lower CO2 emissions

Installing a cogeneration system enables the customer to achieve lower CO2 emissions meaning their process is environmentally better which often allows them to avail of reduction in taxes.

Reduction in plant operating costs

Cogeneration or combined heat and power allows for savings on energy consumption, gas and electricity compared to that of a conventional solution.

Investment payback of less than 3 years

Introducing a CHP system into an existing process using OPRA equipment often enables the customer to achieve a quick payback period with additional options for project financing available if required.

The OP16 Gas Turbine

The OP16 Gas Turbine driven cogeneration is a very efficient solution and the investment costs can be recovered as quickly as three years. The gas turbine-based cogeneration technology generates electricity for the plant and the exhaust hot gas can be used to produce steam or hot air. Gas turbine exhaust gases have a high-grade thermal energy available that is typically above 450°C. As a result of this high temperature, it is possible to utilize its energy in various ways.
One OP16 can produce around 1.8 MWe (@ISO conditions) of electrical power along with 8.9 kg/sec of hot exhaust gases at 573⁰C that can then be recovered for applications such as direct drying, steam, hot water and thermal oil or absorption cooling. In addition to this, the exhaust gases have around 15% Oxygen content which enables supplementary duct firing in to further increase the steam output.

OP16 CHP Application Examples

The OP16 in cogeneration applications gives a clean, flexible and efficient method for industrial/ commercial clients to maximize savings on operational costs and the ability to focus on core business growth. Cogeneration’s commercial applications include district heating for cities, hotels and hospitals. Industrial applications include facilities that produce building materials, chemicals, food, paper, textiles and ceramic products. The fact that industrial applications usually require a continuous supply of heat and power often makes investment in cogeneration facilities very attractive

Direct drying

OPRA develops, manufactures, markets and services OP16 gas turbine genset. OP16 is an industrial, single-shaft, constant speed, all-radial gas turbine. The genset is delivered as a fully-contained 20ft standard container. It takes fuel and air as inputs and delivers electrical power and hot exhaust gases as output. One OP16 can produce around 1.8 MWe(@ISO conditions) of electrical power along with 8.9 kg/sec of hot exhaust gases at 573⁰C that can be used for Direct drying, Steam (6.5 tons/h of steam without additional duct firing), Hot Water, Thermal oil or Absorption Cooling. In addition to this, the exhaust gases have around 15% Oxygen which enables supplementary duct firing in order to further increase the steam output.

Steam

The OP16 Gas Turbine can be used in CHP installations for steam production, the heat recovery plays a very important role in the feasibility of the plant. With the OP16 Gas Turbines is possible to produce around 6.2 Ton/h of saturated steam or 12 Ton/h using supplementary firing, which is possible due to the 15% of oxygen content.

Why the OP16 Gas Turbine is ideal for CHP

OPRA’s OP16 gas turbine proves an ideal fit for cogeneration projects as it produces a high heat to power ratio resulting in clean exhaust gas and high exhaust temperatures which can be used as an independent heat and power source on-site.

Advantages of the OP16 Gas Turbine

There are several advantages when applying the OP16 Gas turbine:

High exhaust gas temperature

The innovative design of OPRA’s turbine allows the generation of high exhaust temperatures perfect for the industrial and commercial market sector needs.

Heat-to-power ratio 3:1

The high heat to power ratio 3:1 generated by the OP16 turbine makes it a suitable solution for cogeneration and heat to power applications.

Clean exhaust gas

Due to its robust and advanced design with bearings located in the cold part of the turbine, the OP16 turbine generates clean guaranteed oil-free exhaust gas.

Independent heat and power source on-site

Advanced technology and the innovative design of OPRA’s equipment ensure security of power supply and guaranteed availability. Optimized LTSA’s, long term service agreements, helps the customer to ensure a long and healthy life for their equipment. .

Jan 13
EXHIBITION & CONFERENCE IPTC,13-15 January 2020

OPRA will exhibit at IPTC, International Petroleum Technology Conference, in Saudi Arabia, from 13-15 January 2020.