MCFC-based CO2 capture system for small scale CHP plants

Carbon dioxide emissions into the atmosphere are considered among the main reasons of the greenhouse effect. The largest share of CO₂ is emitted by power plants using fossil fuels. Nowadays there are several technologies to capture CO₂ from power plants' exhaust gas but each of them consumes a significant part of the electric power generated by the plant. The Molten Carbonate Fuel Cell (MCFC) can be used as concentrator of CO₂, due to the chemical reactions that occurs in the cell stack: carbon dioxide entering into the cathode side is transported to the anode side via CO₃⁼ ions and is finally concentrated in the anodic exhaust. MCFC systems can be integrated in existing power plants (retro fitting) to separate CO₂ in the exhaust gas and, at the same time, produce additional energy. The aim of this study is to find a feasible system design for medium scale cogeneration plants which are not considered economically and technically interesting for existing technologies for carbon capture, but are increasing in numbers with respect to large size power plants. This trend, if confirmed, will increase number of medium cogeneration plants with consequent benefit for both MCFC market for this application and effect on global CO₂ emissions. System concept has been developed in a numerical model, using AspenTech engineering software. The model simulates a plant, which separates CO₂ from a cogeneration plant exhaust gases and produces electric power. Data showing the effect of CO₂ on cell voltage and cogenerator exhaust gas composition were taken from experimental activities in the fuel cell laboratory of the University of Perugia, FCLab, and from existing CHP plants. The innovative aspect of this model is the introduction of recirculation to optimize the performance of the MCFC. Cathode recirculation allows to decrease the carbon dioxide utilization factor of the cell keeping at the same time system CO₂ removal efficiency at high level. At anode side, recirculation is used to reduce the fuel consumption (due to the unreacted hydrogen) and to increase the CO₂ purity in the stored gas. The system design was completely introduced in the model and several analyses were performed. CO₂ removal efficiency of 63% was reached with correspondent total efficiency of about 35%. System outlet is also thermal power, due to the high temperature of cathode exhaust off gases, and it is possible to consider integration of this outlet with the cogeneration system. This system, compared to other post-combustion CO₂ removal technologies, does not consume energy, but produces additional electrical and thermal power with a global efficiency of about 70%.     

Integration of absorption cooling systems into micro gas turbine trigeneration systems using biogas: Case study of a sewage treatment plant

Absorption chillers can help to increase the performance of biogas-driven micro gas turbine (MGT) cogeneration plants. In this paper we analyse various integrated configurations of several types of commercially available absorption cooling chillers and MGT cogeneration systems driven by biogas. MGTs are fuelled with biogas and their waste heat is used to drive absorption chillers and other thermal energy users. The chillers considered in this study include single- and double-effect water/LiBr and ammonia/water chillers. The exhaust gas from the MGT can be used directly to drive the chiller or indirectly to produce hot water to drive the chiller. In this paper we conduct a case study for an existing sewage treatment plant. Chilled water is used to reduce humidity in the biogas pre-treatment process and cool the combustion air of the MGT. We identify the most interesting integrated configurations for trigeneration systems that use biogas and micro gas turbines. We analyse these configurations and compare them with conventional configurations using operational data from an existing sewage treatment plant. The best configurations are those that completely replace the existing system with a trigeneration plant that uses all the available biogas and additional natural gas to completely meet the heating demands of the sewage treatment plant.     

Development of a case-based reasoning prototype for cogeneration plant design

This paper deals with the design problem associated with natural gas cogeneration systems. Despite the task complexity, this design process is strongly based on knowledge that experts formally apply in their activities. Through an appropriate knowledge representation scheme this study demonstrates that the knowledge-based system (KBS) is an approach well-suited to cogeneration plant design. The research involves the use of rule-based expert systems (RBES) and case-based reasoning (CBR). In this paper, the basic concepts of the CBR technique and a CBR prototype for assistance in cogeneration plant design are presented. An RBES prototype for natural gas cogeneration system design previously developed by the authors is used to generate cases for the CBR prototype. A solution generated by the CBR prototype for a plant design requiring 4 MW of power and 0.7 kg/s of saturated steam at 0.9 MPa is presented. The application of CBR in cogeneration plant design represents an original and important contribution of this work.     

Trigeneration in the food industry

In the food industry cogeneration plants are widely introduced. Many industries use cogeneration plants with either gas engines or turbines to cover their steam, hot water and electrical demands. The combination of an absorption refrigeration with a cogeneration plant allows to use all generated heat for the production of cooling. Absorption refrigeration plants working with ammonia as refrigerant can be driven either by steam, pressurised hot water or directly with the exhaust gases. Examples of typical plants are illustrated on different sectors in the food industry.     

Study of a fuel cell network with water electrolysis for improving partial load efficiency of a residential cogeneration system

A fuel cell energy network which connects hydrogen and oxygen gas pipes, electric power lines and exhaust heat output lines of the fuel cell cogeneration for individual houses, respectively, is analysed. As an analysis case, the energy demand patterns of individual houses in Tokyo are used, and the analysis method for minimization of the operational cost using a genetic algorithm is described. The fuel cell network system of an analysis example assumed connecting the fuel cell cogeneration of five houses. If energy is supplied to the five houses using the fuel cell energy network proposed in this paper, 9% of city gas consumption will be reduced by the maximum from the results of analysis. Two per cent included with 9% is an effect of introducing water electrolysis operation of the fuel cells, corresponding to partial load operation of fuel cell cogeneration. Copyright © 2005 John Wiley & Sons, Ltd.     

Modeling of solid oxide fuel cells for dynamic simulations of integrated systems

Solid oxide fuel cell (SOFC) stacks are at the core of complex and efficient energy conversion systems for distributed power generation. Such systems are currently in various stages of development. These power plants of the future feature complicated configurations, because the fuel cell demands for a complex balance of plant. Moreover, proposed SOFC-based systems for stationary applications are often connected to additional components and subsystems, such as a gasifier with its gas-cleaning section, a gas turbine, and a heat recovery system for thermal cogeneration or additional power production. For the simplest SOFC configurations, and more so for complex integrated systems, the dynamic operation of the power plant is challenging, especially because the fluctuating electrical load of distributed energy systems demand for reliable transient operation. Issues related to dynamic operation must be studied in the early design stage and simulation results can be used to optimize the system configuration, taking into account transient behavior. This paper presents the development and the validation of a non-linear dynamic lumped-parameters model of a SOFC stack suitable for integration into models of complex power plants. Particular emphasis is placed on the systematic approach to model development. The model is implemented using the open-source Modelica language, which allows for a high degree of flexibility and modularity, the main features of the model herein presented. The SOFC stack model will be incorporated into ThermoPower, a freely distributed library of reusable software components for the modeling of thermo-hydraulic processes and power plants.     

Exergy analyses and parametric optimizations for different cogeneration power plants in cement industry

The cement production is an energy intensive industry with energy typically accounting for 50–60% of the production costs. In order to recover waste heat from the preheater exhaust and clinker cooler exhaust gases in cement plant, single flash steam cycle, dual-pressure steam cycle, organic Rankine cycle (ORC) and the Kalina cycle are used for cogeneration in cement plant. The exergy analysis for each cogeneration system is examined, and a parameter optimization for each cogeneration system is achieved by means of genetic algorithm (GA) to reach the maximum exergy efficiency. The optimum performances for different cogeneration systems are compared under the same condition. The results show that the exergy losses in turbine, condenser, and heat recovery vapor generator are relatively large, and reducing the exergy losses of these components could improve the performance of the cogeneration system. Compared with other systems, the Kalina cycle could achieve the best performance in cement plant.     

Typical off-design analytical performances of internal combustion engine cogeneration

Based on experimental data, typical off-design characteristic curves with corresponding formulas of internal combustion engine (ICE) are summarized and investigated. In combination with analytical solution of single-pressure heat recovery steam generator (HRSG) and influence of ambient pressure on combined heat and power (CHP) system, off-design operation regularities of ICE cogeneration are analyzed. The approach temperature difference ΔT _a, relative steam production and superheated steam temperature decrease with the decrease in engine load. The total energy efficiency, equivalent exergy efficiency and economic exergy efficiency first increase and then decrease. Therefore, there exists an optimum value, corresponding to ICE best efficiency operating condition. It is worth emphasizing that ΔT _a is likely to be negative in low load condition with high design steam parameter and low ICE design exhaust gas temperature. Compared with single shaft gas turbine cogeneration, ΔT _a in ICE cogeneration is more likely to be negative. The main reason for this is that the gas turbine has an increased exhaust gas flow with the decrease in load; while ICE is on the contrary. Moreover, ICE power output and efficiency decrease with the decrease in ambient pressure. Hence, approach temperature difference, relative steam production and superheated steam temperature decrease rapidly while the cogeneration efficiencies decrease slightly. It is necessary to consider the influence of ambient conditions, especially the optimization of ICE performances at different places, on cogeneration performances.     

Effects of gas recycle on performance of solid oxide fuel cell power systems

An energy analysis of solid oxide fuel cell (SOFC) power systems with gas recycles fed by natural gas is carried out. Simple SOFC system, SOFC power systems with anode and cathode gas recycle respectively and SOFC power system with both anode and cathode gas recycle are compared. Influences of reforming rate, air ratio and recycle ratio of electrode exhaust gas on performance of SOFC power systems are investigated. Net system electric efficiency and cogeneration efficiency of these power systems are given by a calculation model. Results show that internal reforming SOFC power system can achieve an electrical efficiency of more than 44% and a system cogeneration efficiency including waste heat recovery of 68%. For SOFC power system with anode gas recycle, an electrical efficiency is above 46% and a cogeneration efficiency of 88% is obtained. In the case of cathode gas recycle, an electrical efficiency and a cogeneration efficiency is more than 51% and 78% respectively. Although SOFC system with both anode and cathode gas is more complicated, the electrical efficiency of it is close to 52%.     

Grid integration policies of gas-fired cogeneration in Peninsular Malaysia: Fallacies and counterexamples

Despite the abundance of natural gas reserves in Malaysia coupled with serious government thrusts to promote cogeneration, its (cogeneration) development pace lags far off expectations. There are widespread fallacies among potential cogeneration developers and concerned professionals that cogeneration is uncompetitive in Malaysia due to existing policies of subsidized gas prices and grid-connection charges. This paper exposes these fallacies through counterexamples of practical cogeneration system design and evaluation of some segments of the industrial and service sectors in Peninsular Malaysia. The electrical and thermal characteristics of the cogeneration were modeled based on heat rate characteristics at partial loading patterns. A hierarchical mathematical programming approach that uses mixed-integer nonlinear optimization and dynamic programming principle, if necessary, is employed to determine the optimal size of cogeneration and its related auxiliary equipment as well as the optimal operation schedule. Financial assessment is integrated at a later stage to assess the economic viability of the system. Analyses of the cogeneration potential for several facilities of miscellaneous activities were carried out using various gas and electricity prices. Results obtained consistently rebuff the perpetuated fallacies and confirm that there is no real barrier to cogeneration development in Malaysia under current policies of gas prices and electricity tariffs.     

Characteristics and economics of high-efficiency gas turbine cogeneration systems using low BTU gas

Characteristics of high-efficiency gas turbine cogeneration systems using low Btu gas (LBG) are first analysed. Raising the turbine inlet temperature and incorporating a regenerator are both investigated as methods to improve the efficiency of the cogeneration system (CGS). Taking a gas obtained by pyrolyzing municipal refuse as an example of an LBG, various thermodynamic characteristics of the CGS are analysed using a simulation model developed by the authors. Secondly, authors investigate the economics of a CGS for district heating and cooling using the pyrolysis gas, making use of the estimated characteristics. It is shown that the CGS is estimated to be economically feasible, whereas a CGS using conventional high Btu fuel gas (methane gas) is estimated to be economically infeasible under assumed conditions. The impacts of changes in various parameters which determine the economics of the CGS are also investigated, and it is shown that the economics of the system using refuse-recovered LBG can be expected to be further improved owing to future developments in the technology of generating and refining pyrolysis gas.     

Aspen Plus model of an alkaline electrolysis system for hydrogen production

A model of an alkaline electrolysis plant is proposed in this paper, including both stack and balance of plant, with the objective of analyzing the performance of a complete electrolysis system. For this purpose, Aspen Plus has been used in this work due to its great potential and flexibility. Since this software does not include codes for modelling the electrolysis cells, a custom model for the stack has been integrated as a subroutine, using a tool called Aspen Custom Modeler. This stack model is based on semi-empirical equations which describe the voltage cell, Faraday efficiency and gas purity as a function of the current. The rest of the components in the electrolysis plant have been modelled with standard operation units included in Aspen Plus. Simulations have been carried out in order to evaluate and optimize the balance of the plant of an alkaline electrolysis system for hydrogen production. Also, a parametric study has been conducted. The results show that increasing the operation temperature and reducing the pressure can improve the overall performance of the system. The proposed model in this work for the alkaline electrolyzer can be used in the future to develop a useful tool to carry out techno-economic studies of alkaline electrolysis systems integrated with other process.     

考虑减排措施的蒸汽动力系统结构优选

建立了五种典型的蒸汽动力系统结构,分别是燃烧后带减排措施的普通煤粉炉(带脱硫脱硝系统)热电联产系统(PC+ FGD+ DeNOx系统)、循环流化床锅炉(加石灰石)热电联产系统(CFB系统)、水煤浆锅炉(洗煤)热电联产系统(CWS系统)、燃气-蒸汽联合循环系统(NGCC系统)、整体煤气化联合循环系统(IGCC系统),建立...     

Analysis and optimization of a cogeneration system based on biomass combustion

The paper deals with analysis and optimization of the performance of the combustion process in a biomass furnace at a biomass cogeneration plant. For the purpose a thermodynamic model for the biomass burning process in a grate furnace was developed. The mathematical model describes both, the thermal decomposition of the fuel on the grate as well as gas phase combustion in the secondary zone. The presented approach is based on energy equations for each individual step of the biomass combustion process.Measurement results from a biomass-fired cogeneration plant were used to validate the model. Comparison between simulation and measurement results shows good agreement. The model predicts accurately the temperature profiles in the combustion chamber.The presented approach is suitable for model based analysis and optimization of control strategies. The developed model was used to optimize the performance of the recirculation system of the combustion appliance. The simulation based analysis showed, that the flow rate of the recirculated exhaust fumes can be significantly reduced which results in energy savings of 17% of the auxiliary electrical power demand.     

Thermoeconomic assessment of an absorption refrigeration and hydrogen-fueled diesel power generator cogeneration system

The thermoeconomic assessment of a cogeneration application that uses a reciprocating diesel engine and an ammonia–water absorption refrigeration system for electrical power and cold production from hydrogen as fuel is presented. The purpose of the assessment is to get both exergetic and exergoeconomic costs of the cogeneration plant products at different load conditions and concentrations of hydrogen–diesel oil blends. The exhaust gas of the reciprocating diesel engine is used as an energy source for an ammonia–water absorption refrigeration system. The reciprocating diesel engine was simulated using the Gate Cycle™ software, and the ammonia–water absorption refrigeration system simulation and the thermoeconomic assessment were carried out using the Engineering Equation Solver software (EES). The results show that engine combustion is the process of higher exergy destruction in the cogeneration system. Increased hydrogen concentration in the fuel increases the system exergetic efficiency for all load conditions. Exergy destruction in the components of the ammonia–water absorption refrigeration system is increased with increasing load due to the rise of heat transfer. At intermediate and high loads energy efficiency is increased in the power system, and low values of unit exergetic cost and competitive specific exergoeconomic costs are noticed. The cogeneration system operation at intermediate and high engine loads was proven to be feasible.     

A district heating system based on absorption heat exchange with CHP systems

In order to decrease the energy consumption of large-scale district heating systems with cogeneration, a district heating system is presented in this paper based on absorption heat exchange in the cogeneration system named Co-ah cycle, which means that the cogeneration system is based on absorption heat exchange. In substations of the heating system, the temperature of return water of primary heat network is reduced to about 25°C through the absorption heat-exchange units. In the thermal station of the cogeneration plant, return water is heated orderly by the exhaust steam in the condenser, the absorption heat pumps, and the peak load heater. Compared with traditional heating systems, this system runs with a greater circuit temperature drop so that the delivery capacity of the heat network increases dramatically. Moreover, by recovering the exhausted heat from the condensers, the capacity of the district heating system and the energy efficiency of the combined heat and power system (CHP system) are highly developed. Therefore, high energy and economic efficiency can be obtained.     

Performance of ONSI PC25 PAFC cogeneration plant

Supported by the Ministry for Environment, Energy and Federal Affairs (HMUEB) of the German State of Hesse, the local electricity supplier Hessische Elektrizitäts-AG HEAG demonstrated a 200 kW PAFC cogeneration plant of type ONSI PC25 at Darmstadt, Germany. The demonstration was accompanied by an experimental program dealing with the transient and long-term behaviour of the unit and investigating its gas process technology.The relevant cell parameters such as cell voltage, current, cell and system efficiency have been monitored continuously during almost 20000 h of hot time.The concentrations of carbon monoxide, hydrocarbons and nitrogen oxides of the stack gas amount to less than 6.5, 5.5 and 1.5 ppm. The product water released from the plant is free of heavy metals and other contaminants.Still, ageing seems to proceed too fast and cell and maintenance costs are too high, resulting in electric energy costs of 0.28 DM/kWh. The next generation of this fuel cell type, however, may well be able to compete with diesel cogeneration plants.     

A district heating system based on absorption heat exchange with CHP systems

In order to decrease the energy consumption of large-scale district heating systems with cogeneration, a district heating system is presented in this paper based on absorption heat exchange in the cogeneration system named Co-ah cycle, which means that the cogeneration system is based on absorption heat exchange. In substations of the heating system, the temperature of return water of primary heat network is reduced to about 25°C through the absorption heat-exchange units. In the thermal station of the cogeneration plant, return water is heated orderly by the exhaust steam in the condenser, the absorption heat pumps, and the peak load heater. Compared with traditional heating systems, this system runs with a greater circuit temperature drop so that the delivery capacity of the heat network increases dramatically. Moreover, by recovering the exhausted heat from the condensers, the capacity of the district heating system and the energy efficiency of the combined heat and power system (CHP system) are highly developed. Therefore, high energy and economic efficiency can be obtained.     

Development of efficiency-enhanced cogeneration system utilizing high-temperature exhaust-gas from a regenerative thermal oxidizer for waste volatile-organic-compound gases

We have developed a gas-turbine cogeneration system that makes effective use of the calorific value of the volatile organic compound (VOC) gases exhausted during production processes at a manufacturing plant. The system utilizes the high-temperature exhaust-gas from the regenerative thermal oxidizer (RTO) which is used for incinerating VOC gases. The high-temperature exhaust gas is employed to resuperheat the steam injected into the gasturbine. The steam-injection temperature raised in this way increases the heat input, resulting in the improved efficiency of the gas-turbine. Based on the actual operation of the system, we obtained the following results:     

Reduction of irreversibility generation in sugar and ethanol production from sugarcane

Sugarcane is one of the most important industries of the Brazilian economy, and its main products are sugar and ethanol. Most of the industrial plants produce both products in an integrated process, in which the sugarcane bagasse is a by-product that can be used as a fuel in the cogeneration system. The bagasse is used as the only fuel of the plant, supplying all energy required for the process, and also producing electricity surplus that may be sold to the grid. In this paper, exergy analysis is used to assess an integrated sugar and ethanol plant with its cogeneration system. The plant was divided into eight sub-systems to evaluate the irreversibility generation in each separately. Data from typical sugarcane factories in Brazil, which produce sugar and ethanol, were used in the process simulation. The analysis has shown that the sub-systems with the highest contribution for the total irreversibility generation of the plant were co-generation, juice extraction and fermentation. Some improvements are proposed, including process thermal integration and the introduction of more efficient equipments for prime mover and steam and electricity generation. The analysis indicated that the total irreversibility could be reduced by 10% should those changes be implemented.