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NORWEGIAN UNIVERSITY OF SCIENCE AND TECHONOLOGY DEPARTMENT OF PETROLEUM ENGINEERING AND APPLIED GEOPHYSICS
Natural Gas in Trigeneration
Generation of Electricity, Heat and Cooling
Oluwatosin Ajayi
Lorenzo Angelo Veronelli
Davide Genini
Hui-Gyeong Jang
Ho Jung Jung
TPG4140 Natural gas
Trondheim, November 2011
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Abstract
This work presents a technical illustration of the operation of Trigeneration systems using
Natural Gas as fuel and outlines the possibilities for future Trigeneration systems powered
by fuel cells. It demonstrates these possibilities by comparing the feasibility of Trigeneration
systems based on fuel cell with Trigeneration systems using conventional fossil fuel. Primary
Energy Saving index and first law efficiency were solved to demostrate that Trigeneration
Systems are visible solutions to the spiralling demand for energy across the globe. Although
not well explored at present but with many developed plans and new researches for
trigeneration underway, Trigenration systems signal themselves as a viable energy solution
in the very near future.
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Content
Abstract ..................................................................................................................................i
1. Introduction ....................................................................................................................1
2. Reasons for trigeneration ...............................................................................................2
3. How it works ...................................................................................................................3
4. Gas turbines ....................................................................................................................3
4.1 Operating principle ..............................................................................................................3
4.2 Technical components .........................................................................................................4
4.3 Emissions.............................................................................................................................5
4.4 State-of-art ..........................................................................................................................6
5. Internal combustion engine ............................................................................................6
5.1 Operating principle ..............................................................................................................6
5.2 Technical Components ........................................................................................................7
6. Absorption chiller ...........................................................................................................7
6.1 Compressor chiller and absorption chiller ............................................................................8
7. Fuel cell application ........................................................................................................9
7.1 Operating principle ..............................................................................................................9
7.2 High temperature fuel cells................................................................................................ 10
7.3 Hybrid systems: gas turbine and fuel cells .......................................................................... 10
7.4 Solid Oxide Fuel Cell .......................................................................................................... 11
7.5 Molten Carbonate Fuel Cell ............................................................................................... 11
7.6 Internal reforming ............................................................................................................. 11
7.7 Fuel cells versus traditional combustion engines and small gas turbines in cogeneration ... 12
8. Exergy analysis ..............................................................................................................12
9. Indices for trigeneration and cogeneration ..................................................................13
10. Trigeneration and cogeneration now and in the future................................................15
10.1 Pfizer Singapore API manufacturing facility ........................................................................ 17
11. Conclusions ...................................................................................................................18
12. References ....................................................................................................................19
13. Tables ...........................................................................................................................21
14. Figures ..........................................................................................................................23
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1. Introduction
Trigeneration is the combined generation of electricity, heat and cooling, all simultaneously
produced from a fuel source often referred to as Combined Heat Power and Cooling CHCP.
Trigeneration takes cogeneration of heat and electricity further with the utilization of waste
heat for cooling purposes through an absorption chiller. A Trigeneration system is an
integration of two major technologies: The combined heating and power CHP or
cogeneration technology and cooling technology through compression or absorption
systems. CHP technologies based on gas reciprocating engines and combustion turbines are
the most mature technologies. Fuel cells are entering into the market of Trigeneration.
Natural Gas is the most appealing fuel for driving Trigeneration Systems because of its
reliability, efficiency, low environmental effects and low maintenance costs. It burns
efficiently in the combustor ensuring lower emissions of local pollutants than heavier fuels.
Natural Gas contains mainly methane, a gas with high hydrogen to carbon ratio which leads
to lower CO2 emissions per unit of energy produced. According to the U.S. Department of
Energy in the year 2009, 2.5 billion tons of CO2 were emitted by power plants in the U.S.,
which correspond to 576g of CO2 per kWh. A wide use of Trigeneration would reduce the
amount of green- house gases emitted per unit of electricity.
The most intriguing development in the quest for efficient and cost saving Trigeneration
systems to match Energy Demand is the possibility of using Fuel Cells as alternative engine
for Trigeneration systems. A technical analysis shows that fuel cells provide the next
possibility for making Trigeneration System at a very low operating cost, maintained high
efficiency, with no waste nuisance to the environment (Casalegno 2010). It presents an
environmentally clean technology for the future Trigeneration Applications. Fuel cells can be
fed via syngas produced with steam reforming CH4 + H2O → CO + 3 H2 and Water gas shift CO +
H2O → CO2 + H2.
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2. Reasons for trigeneration
Energy cost is growing, and trigeneration technology in the long term offers a cheaper and
affordable technology for producing energy when compared to other conventional energy
generating technologies. The reduction in cost in trigeneration is achieved with higher
overall cycle efficiency which decreases the amount of fuel used to produce one unit of
usable energy. Governments also offer subsidies to energy made in cogeneration
comparable to the ones given to renewable energy, making the investment more profitable.
Microtrigeneration is becoming common in warm countries that are developing the idea of
“distributed power generation” (small machines placed close to the consumers). The
application of cogeneration and trigeneration as well, in residential places has always been
obstructed by the high variability of loadings and humongous costs of long thermal energy
networks. Distributed power generation and microtrigeneration go together because the
trigenerative application compensates the inevitable lower efficiency of the small machines
and the higher costs. Distribute generation can be applied in crowded places where the
structures are shared by many people, and the cost of the insulated pipes to transport heat
is acceptable because they don’t have to be too long.
Distributed power generation diminishes the transport losses, since energy does not have to
travel long distances to reach the customers. With the increased need of energy in
populated areas new power lines have to be built to transfer the power from the generation
sites in a business as usual scenario. Dispersed power generation can avoid the invasion of
pristine areas by new power lines, preserving the environment and saving money.
The technology challenge in developed countries is the reduction of air pollution and
greenhouse gases. The application of Trigeneration in cities is an effective way to solve this
challenge because of the use of clean fuel such as natural gas and the high efficiency of the
system. Pollution in populated areas of developing countries is a huge problem which at the
moment is not taken into account, but it will be in the near future.
Trigeneration systems have usually very short start-up times because of their small
dimensions and low thermal inertia. Therefore, they can also be used for peak shaving to
help the grid to handle the rising amount of renewable energy connected to the net. Such
dispersed systems can be remotely controlled, operated by the network management
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company as an integration of the grid. The ability of the system to store thermal energy
allows a flexible management of electricity production, giving the opportunity to make
electrical power when it’s required by the grid.
3. How it works
Trigeneration is a new form of power generation that is becoming common in numerous
countries placed in the warm region of the world. In these countries the heating required
during the year is mainly concentrated in the winter season, while in summer the demand of
refrigeration is no more negligible (for air conditioning – household or industry), as shown in
figure 3. A constant demand of electrical power, heating and cooling comes from different
structures such as hospitals, public buildings, universities, shopping malls and gyms.
A Trigeneration plant is similar to a cogeneration power plant plus an absorption chiller to
produce a cold flow with the heat recovered from the hot flue gases. Regarding the electric
power generation, it can be provided by different kind of engines: internal combustion
engines, gas turbine cycles, and Stirling engines (to name a few). They can be evaluated
according to cost, efficiency and environmental effects.
4. Gas turbines
4.1 Operating principle
In micro turbines, electricity comes from a common Joule-Brayton cycle fitted with a
regenerator. Air is sucked up by a compressor that can work with a lower pressure ratio than
usual, just between 2 and 12 (G. Lozza, 2006). A combustor burns the fuel and presents flue
gas at 1000 °C to the first rotator of the expander. After the expander, the exhaust gas
enters to a regenerator to recover some heat by warming up the air coming out of the
compressor. This is a practice that is required to elevate the efficiency, which is deeply
affected by the temperature of exhausted gas that is again affected by the pressure ratio. If
the pressure ratio goes down, the temperature of the flue gas goes up and the efficiency
lessens. A Pressure-Volume and a Temperature-Entropy graph are attached (Figures 4.1a-
4.1b).
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The heating is obtained by cooling down the exhausted gas coming from the regenerator in a
gas-fluid heat exchanger. Here water can be warmed up to 90 °C-115 °C (M. Sileo, 2006), so
the ability of producing steam is not very high in micro turbines with regenerators. It is
evident that this heat is useful where the thermal demand is at low temperature like in
residential buildings, hotels and sport structures. The thermal efficiency is around 50 %,
while the electrical efficiency is approximately 30% considering the energy coming from the
Low Heating Value of the fuel used. Therefore, approximately 80% of the energy in the fuel
is used.
The cooling is provided by an absorption chiller. This device is based on the phase change of
water together with a specific salt. The low temperature that the water can reach when is
warmed up by the exhausted gas is enough in order to make this system working properly.
4.2 Technical components
Micro turbines could be still out of the market if the design of the machine had not been
completely altered. They are characterized by radial machines that work at an impressively
high RPM to ensure good performances keeping the dimensionless parameters in an optimal
range.
The turbo machines (expander and compressor) have been dramatically modified to face
different needs in respect of common large gas turbines (G. Lozza, 2006). They have to
rotate at 70000-120000 RPM, sustained by magnetic bearings because the low power
produced requires treating low flow rates of air and exhausted gas (0.2-0.5 kg/s). These
radial velocities come out considering that the peripheral speed (u = ω*r) is limited by
material resistance: if the radius(r) is small, then the angular speed (ω) has to be high.
Furthermore, from performance optimization analysis, it’s understandable that a high RPM
is necessary. The small radius forces to choose a centrifugal compressor and a centripetal
expander that are able to cope with high pressure ratios (4-6) with a single stage, providing
good performances even with a small rotor. Considering the relatively low temperatures
(950 °C), the rotators can be made up of nickel alloys and they don’t need any cooling
systems.
Small pressure ratio causes a high temperature of the exhausted gas released in the
atmosphere while the inlet temperature of the combustor is low: the efficiency is negatively
affected. The adoption of radial single stage machines implies smaller pressure ratio than
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usual. For example, with a pressure ratio of 4, the outlet temperature of the flue gas is 710
°C and the inlet temperature of the combustor only 184 °C with an efficiency of 16, 45 %. To
overcome this problem, a common solution is the regenerator, which is a decisive device in
the development of a micro turbine. Regenerator can be of two types: a surface regenerator
or a rotary matrix regenerator. The former is a common exchanger with a physical
separation between pressurized air and exhausted gas; it has a particular geometry
optimized to improve forced convection. The latter is based on a package of metal or
ceramic material rotating slowly, that acquires heat when is on the hot side and releases
heat to the air in the cold side. This system provides a high thermal exchange efficiency (85-
90 %), reduced costs (because of compact surfaces and long life) and space, but it must be
taken into account that the two fluids could contact each other.
The combustor is not very different from the combustor of a common gas turbine cycle. The
only difference from usual combustors comes from the opportunity of reaching low NOx
emissions, since lower combustion temperatures reduce the NOx formation. This helps save
money because no emissions treating system is required. Usually the combustor of a micro
turbine emits 10-15 of NOx which is ten times lower than a common gas turbine
(G. Lozza, 2006).
The generator is designed in order to avoid the use of gear-reducers to improve the
efficiency. For these reasons, it is usually equipped with permanent magnets incorporated in
carbon fiber matrices, and it rotates together with the shaft of the expander producing
electrical energy at high frequency (for example 3000 Hz AC with 90000 RPM 4 poles). Then
this energy is converted in a static rectifier and carried to 50 Hz (or 60 Hz) tri-phase 400V by
a static inverter (G. Lozza, 2006). Usually the generator can work at variable speeds: this
peculiarity prevents the remarkable decline of performance typical of gas turbines at partial
loads. This is a noticeable property of a trigeneration system, because it makes easier to
follow the loads imposed by consumers. The efficiency of the generator is usually close to
92-94 %.
4.3 Emissions
Combustion in a gas turbine cycle is designed for reducing NOx emissions. The combustor
works with a great excess of air that quenches down the flame temperature. A low
temperature inhibits the formation of nitrogen oxides, while the excess of air prevents the
formation of CO and unburned gas (G. Lozza, 2006). According to this condition the gas
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turbine doesn’t need any other device to reduce emissions, but catalysts to improve the
environment effect are being studied. (Table 4.3)
4.4 State-of-art
Some international-famed societies have been developing micro turbines for some years
with good results. General Electric, Honeywell and Siemens have commercialized machines
for 30-250 kW, with an electrical efficiency of 24-30 % and Turbine Inlet Temperature of
1000 °C (Table 4.4). At the moment these turbines offer a good availability and reliability
even after long working time. According to Capstone- one of the most important companies
in the field, a micro turbine costs about 1300$ per kW installed. And the forecasts are for a
sharp decrease in prices.
5. Internal combustion engine
5.1 Operating principle
For trigenerative applications only a four-stroke engine can be used, that can be based both
on an Otto cycle or Diesel cycle. The Otto cycle is made up of four transformations: two
isochoric and two isentropic processes. The piston goes from the bottom dead center to the
top dead center causing a high increase of pressure then combustion takes place. Then the
piston does the opposite movement of before producing work and finally the exhausted gas
goes out from the cylinder. In reality, two other operations take place: the exhausted gases
are expelled through a drain valve and the fuel-air mixture is sucked up by an inlet valve.
The Diesel cycle ideally differs from the Otto cycle only because the combustion should
occur at constant pressure instead of constant volume.
The Otto cycle engines fuelled with natural gas have pressure ratios oscillating between 9:1
and 12:1 similar to gasoline engines, even if natural gas has a higher antiknock (M. Sileo,
2006) . The gas is injected into the carburetor forming required stoichiometric mixture which
is compressed in the cylinder.
The Diesel cycle engines are “dual fuel”, they are mainly fed with methane with a small
addition of gas oil to avoid detonation. The gas oil is usually injected at high pressure. The
gas can follow two ways: direct injection at high pressure, or injection in the collector and
then compression as in an Otto cycle. The choice among the two solutions depends on the
gas pressure in the distribution network: if it’s at low pressure the direct injection is better
to avoid expenses and maintenance related to a compressor to pressurize gas.
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5.2 Technical Components
The internal combustion engines can use a wide variety of fuels both liquid (gas oil, gasoline,
heavy oil) and gas (natural gas, propane, and biogas). It’s not easy modeling the emissions
coming from an internal combustion engine. This is because of numerous parameters that
affect emissions in different ways: piston movement, passage of the combustion from
laminar to turbulent, low wall temperature. Generally, the main pollutants emitted are NOx,
HC, soot and CO.
An internal combustion engine for a trigeneration system using natural gas ensures low
emissions, but the environmental norms are actually very strict and will get stricter in the
future. Therefore, this engine requires proper devices for reduction of emissions. These
devices are different according to the type of cycle used.
Inside the exhaust pipes, it’s common practice using systems that react with catalysts to
reduce the emissions. When air and fuel are mixed in a stoichiometric ratio, like in Otto’s
cycles, trivalent catalysts are used. They are called trivalent, because they can reduce
contemporaneously emissions of three pollutants: NOx, CO, HC. To guarantee that this
catalyst works, a strong control of stoichiometry is necessary. To do that a lambda sensor
measures the percentage of O2 in the exhaust gases, and a feedback control system
regulates the percentage of O2.
6. Absorption chiller
Absorption chillers are a practical alternative to compression chillers. Their main advantage
is that they don’t require any electrical power consumption except for the pump moving the
solutes.
An absorption chiller works with a mixture of two fluids. The fluid with the lowest vapor
pressure is the solvent; the fluid with the highest vapor pressure is the solute. Usually the
couple of fluids used can be water (solvent) and ammonia (solute) or lithium bromide
(solvent) and water (solute).
There are different kind of absorption chillers that can be chosen according to the
constraints of the project and the type of heat source available. They can use directly the
exhausted gases that pass through a heat exchanger integrated with the chiller. An
alternative is to use the fluid flowing in the engine jacket, or a combination of the options.
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An absorption chiller is made of four main parts: evaporator, absorber, generator, and
condenser. (Figure 6)
The evaporator is the heat exchanger in which the refrigerant absorbs the heat from the
source at low temperature and becomes vapor. Considering that the refrigerant it’s at low
pressure, its boiling point is low and evaporates absorbing heat from the stream which
needs to be cooled.
The absorber is the device in which the vapor, produced in the evaporator, turns back into a
liquid solution at constant pressure. The solute is absorbed by the liquid mixture coming
from the generator. The absorption process takes place here because of the affinity between
solute and solvent, producing heat. The pump raises the pressure of the rich solution coming
from the absorber. The generator receives this mixture and separates solute from solvent in
a process similar to distillation using the heat source available. The condenser is the heat
exchanger in which the vapor, produced from the generator, condenses releasing heat to the
environment. The two lamination valves cause an isenthalpic expansion of the fluid: water
from the condenser passes through one of them, the solution coming out the generator
passes through the other. A regenerator is used to improve the performance of the system,
exchanging heat from the flows between the absorber and the generator.
The cooling effect is usually provided between 7 °C and 12 °C when water is used as
refrigerant. When temperatures under 0 °C are required, mixtures of glycol-water or other
mixtures are used.
An absorption chiller uses refrigerants which are known not to have a high Green House Gas
potential or to cause harm to the ozone layer. It doesn’t require to run a compressor, so
there are no emissions coming from power generation.
6.1 Compressor chiller and absorption chiller
The comparison between an absorption chiller and a compression chiller is not easy. Looking
at the investment, an absorption chiller is 30 % to 100 % more expensive than a compression
chiller. This comes from cooling towers for an absorption chiller that must be 2 or 2.5 larger
than the ones for a compression chiller. But, according to M. Sileo (2006), an absorption
chiller offers evident management advantages: no problems during blackout, silent
operation, 20 years of lifetime (it has no moving parts), recovers heat that otherwise would
have been wasted. A good way of comparing should be the cost of energy, but considering
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that the prices of natural gas and electricity are variable, it’s hard to say which device is
better. A careful analysis should be made for each case to find the best solution that suits
the situation.
7. Fuel cell application
7.1 Operating principle
A fuel cell is a device capable of converting directly the chemical energy in the fuel into
electrical energy. Normal energy systems, which involve combustion, have first to pass
through thermal, mechanical and finally electrical energy conversion. The combustion of the
fuel is the biggest source of inefficiency of the energy converting system (Pedrocchi, 2011).
This is due to the fact that the combustion is never done at adiabatic temperature and the
heat exchange between the flue gas and the fluid is done with high temperature differences.
Heat transfer under high temperature gradient destroys huge amounts of exergy (the ability
of a system to make work). Fuel cells provide solutions to these challenges.
ADVANTAGES
High efficiency, not limited by Carnot’s theorem.
Efficiency independent from dimension and just slightly dependent from the load,
modular system and flexible working condition.
High availability and reliability, no moving mechanical parts, gradual performance
decline (predictable).
Low environmental impact, no emissions of secondary pollutants.
DISADVANTAGES
Cost, depending on the type, on average not less than 5000$/kW.
Short life cycle.
Most of the fuel cells work with expensive high quality and purity fuel such as
hydrogen.
LOSSES
A fuel cell has an intrinsic efficiency depending on the type and the boundary conditions of
operations, above all the current output (Groppi, 2010). Fuel cells skip all the passages of
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energy conversions but they pay different energy “tolls” from normal energy converting
systems (Figure 7.1), such as:
Activation losses: due to kinetic reasons at the electrodes.
Ohmic losses: they increase with the increase of current flowing and they are due to
resistivity.
Mass transport losses: they occur when high current is flowing through the cell
during high loads.
Crossover: the un-reacted fuel passes through the membrane and it is oxidized on
the cathode without any real benefit for electrical production.
7.2 High temperature fuel cells
High temperature fuel cells are perfect to be combined with a cogeneration plant for
industrial purposes, giving high temperature heat as a byproduct. They can work with
different fuels such as Natural Gas converted by an internal reformer into hydrogen, carbon
monoxide and dioxide. This kind of fuel cell can run with “dirty” fuels containing a lot of
impurities, for example there has been studies at the Georgia Institute of Technology
regarding the possibility to run SOFC (Solid Oxide Fuel Cells) with gasified coal. Other
advantages of this type of fuel cells are the higher efficiencies, lower costs and longer term
stability when compared with low temperature fuel cells.
Working at high temperatures brings some serious problems concerning long startup times
and hard thermal stresses on the components. For these reasons high temperature fuel cells
are more suited for power generation combined with high temperature (high exergy)
cogeneration(Galliani et al, 2006). Instead low temperature fuel cells find better applications
in portable electronic devices, automotive and small stand-alone micro-power generation
systems.
7.3 Hybrid systems: gas turbine and fuel cells
Another interesting application of high temperature fuel cells is their combination in gas
turbines, replacing the normal combustor. Fuel cells need a source of cooling in all cases and
the use of the excess heat to generate power in a Joule Brayton cycle is a natural
consequence. This system is designed to reduce the losses due to normal combustion with
high air excess, taking complete advantage of the chemical exergy in the fuel. To increase
even more the efficiency of the plant the heat can be recovered from the flue gases coming
from the turbine with a Heat Recovery Steam Generator. The steam produced can be used
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both to run a steam turbine and make more power, as a source of heat or to cool down a
fluid with an absorption cycle. This kind of complex plant working at full electric generation
reaches efficiencies close to 70%, 10% more than the best available technology for normal
combined cycle (Campanari S. et al, 2002).
7.4 Solid Oxide Fuel Cell
These types of fuel cells are characterized by the use of a solid oxide as electrolyte usually
made of ceramic material such as YSZ (Yttria Stabilized Zirconia). Instead the anode is made
with nickel –zirconia ceramic-metal, with the first component promoting the internal
reforming and the second one inhibiting the nickel sinterization at high temperature. They
can work flexibly with a wide range of sulphur-free fuels ranging from hydrogen to light
hydrocarbons. With a pre-reformer they can even work with normal “heavy fuels” such as
gasoline, diesel or biofuels. Normal “sandwich geometry” SOFCs stacks require a few hours
of start-up time, but new tubular geometries SOFCs promise to lower this time down to a
few minutes. The main advantage of these classes of fuel cells is that they don’t require
expensive platinum based catalyzer since they work at temperatures approaching 1000°C
and consequently they don’t have problems with carbon monoxide poisoning, though
materials working at such high temperature are expensive (Groppi, 2011).
7.5 Molten Carbonate Fuel Cell
The electrolyte used in this fuel cell is a molten mixture of alkali metal carbonate held in a
ceramic matrix. At low temperature the electrolyte is not conductive, when the temperature
rises above 600-700°C the material becomes highly ionic conductive. The unique feature,
and disadvantage, of this fuel cell is the necessity of having CO2 at the cathode side to make
carbonate ions. Carbon dioxide is recycled from the anode side and the flue gas from the
anode is mixed with air to preheat it and oxidize the unreacted carbon monoxide and
hydrogen.
7.6 Internal reforming
The fuel fed to the fuel cells is usually natural gas which has to be converted to hydrogen
and carbon monoxide via a steam reforming reaction. For example considering a natural gas
made with just methane:
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We can have direct reforming where the catalyzer, usually nickel, is spread directly on the
anode, and indirect reforming where the reaction takes place separately close to the anode.
Since this reaction is endothermic we need to provide thermal heat, this is usually done with
the excess heat from the fuel cell itself. The steam needed comes from the combustion of
hydrogen. Fuel cells with internal reforming are a technology which is still in a developing
phase, while external reformers are a mature technology.
7.7 Fuel cells versus traditional combustion engines and small gas turbines in cogeneration
Presently, the open window for fuel cell as a commercial application in cogeneration is for
systems under 2 MW, in this case fuel cells can be a great alternative to conventional power
generation units. Combustion engines have great characteristics: they are cheap, reliable
and efficient even at partial loads, but they are noisy and they make great amounts of
pollutants. Small gas turbines with centrifugal compressor are not efficient and noise-free. A
great advantage of fuel cells used in residential areas is the ability to produce electric power
and heat with virtually zero-emissions of local pollutants such as carbon monoxide, NOx and
soot. Fuel cells are stationary machines which require only pumps and fans as moving
components, this unique characteristic enables them to work practically noiseless. Having
high efficiencies Fuel Cells produce less carbon dioxide per energy unit produced. At the
moment costs and lifetime limit the application of fuel cells but it is definitely a promising
technology for the future.
According to Casalegno (2010), fuel cells around 1-100 MW to be competitive in power
generation, have to cut down their costs from 12 M$/MW to 1.5 M$/MW, which is a very
hard to achieve. More research has to be done on fuel cells to get these systems on the
market at a reasonable price. In contrary gas turbine, intrinsically more complicated from a
thermo-fluid-dynamic point of view, took the advantage of extensive research for military
aviation (heavily financed by governments in the past).
8. Exergy analysis
Exergy combines the concept of energy and entropy. Exergy expresses the idea of the
amount of work theoretically extractable from a fuel in a given environment at a certain
temperature, pressure and composition. A system in equilibrium with the environment has
an exergy equals to zero. Theoretically it would be possible from a fuel to produce an
amount of work nearly equal to its calorific value with a reversible process where entropy is
13
not generated. The real amount of work which can be produced has to take into account
exergy losses:
A very basic example regarding the use of 1kg of natural gas (chemical exergy approximately
50MJ/kg) to heat a house at 20°C with an ambient temperature of 0°C can be made (Table
8).Concluding:
Burning natural gas in a gas-fired power plant making electricity to heat a house with
an electric resistance is a thermodynamic disaster. A smarter way to use electricity to
produce heat consists of a heat pump.
Burning the same amount of gas in a cogeneration unit close to the customer to
produce heat as a by-product and electricity to run a heat pump is the most efficient
way to accomplish the same task.
Burning the natural gas in a boiler on site to make heat is the cheapest way in terms
of overall investment costs but it is very inefficient.
The amount of exergy delivered in the cogenerative case is 3.6 times higher than the case
with no cogeneration and no heat pump. This can be easily explained with an exergy
analysis, taking into consideration that the heat is produced at a temperature close to the
environment one. The greatest inefficiency is the one generated in the resistance,
downgrading valuable electricity into low temperature heat. With a reversible process one
unit of electricity can be transformed in nearly 15 units of heat, though heat pumps do not
reach such great conversions.
Exergy losses are much easier to understand than entropy loss since it’s something that can
affect directly the ability of the system to produce work. Exergy is closely related to the
money that will be spent for fuel. It is a useful tool to understand where improvement can
be made, measuring the efficiency of each power conversion step.
9. Indices for trigeneration and cogeneration
A trigeneration system can save lots of energy (and money) to produce the same amount of
electricity, heat and cold from the same source as compared to a separated generation of
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these forms of energy. To evaluate this saving, it is common to use two specific indices: PES
and first law efficiency (according to the European Ministry of Economic Development). PES
stands for Primary Energy Saving index, and it quantifies the energy saving obtained by a
cogeneration system providing the same amount of electrical and thermal energy of two
separated plants:
In which:
Efuel = energy coming from the fuel consumed
Eel = electrical energy produced
Qrec = thermal energy produced
ηel = reference electrical efficiency
ηgrid,ref = reference grid efficiency
ηth,ref = reference thermal efficiency
If the PES index of a cogeneration (or trigeneration) plant is greater than a certain value ( 10
% in Italy), that plant gets the right of being considered cogenerative, then gets subsidies. A
high efficiency utilization allows to produce some surplus energy (which is comparable as a
renewable source) that otherwise would be wasted in a normal plant. This index can change
for the same plant according to the reference efficiencies decided by the government. In
fact, the reference electrical efficiency can be the efficiency of the Best Reference
Technology (almost 60 % for Combined Cycles) or a national average among the power
generation plants available(usually lower than 40%). Using high reference electrical
efficiency lowers the value of PES. The reference grid efficiency is taken into account
because a trigeneration system saves the energy related to the transport of electricity, since
it’s really close to the users. The reference thermal efficiency instead is usually fixed over 90
%.
The first law efficiency comes from thermodynamic concept. It’s computed as follows:
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In which:
PME=total useful electric (or mechanical) power
QU= total thermal power, net of losses due to heat transmission
PF= total power coming from the primary energy source
This is mainly for cogeneration systems, but can be applied to trigeneration systems as well.
Of course it underestimates the overall efficiency of the trigenerative system, because it
doesn’t take into account the cooling part of the cycle.
In Italy (AEEG, 2002), another index has to be computed before a plant can be considered
cogenerative: the Thermal Limit. It considers the proportion between electrical and thermal
energy:
In which:
= thermal energy sent to the users
= electrical energy produced
= thermal energy sent to the civil use
= thermal energy sent to the industrial use
In order to be considered as an effective cogeneration plant, the LT of the system has to be
greater than 15 %.
10. Trigeneration and cogeneration now and in the future
Trigeneration is not so spread in the world at the moment because of costs and climate
conditions. The investment necessary for such a technology is higher compared to other
power plants (G. Lozza, 2006), because all the machines are more complicated than the
16
usual sized ones. In cold countries a trigenerative system can’t appear as an interesting
solution, because the requirement of cold is negligible. But even in these countries
application of Trigeneration could take place: in systems requiring comparable amounts of
heat, electricity and cold, such as supermarkets.
Trigeneration benefits the same subsidies given to cogeneration, because their development
is strongly linked together. The support given by the government can be classified into four
categories: special taxation, low interest loan, investment subsidy, and subsidy for new
technology development. This reduction in taxation and subsidy policies will help
trigeneration to become more cost competitive. (Environment and Development Division ,
2000)
Each country has a different policy to promote the application of cogeneration and
trigeneration. For example, E. ON which is one of the world's largest investor-owned power
and gas companies in Germany supports cogeneration and trigeneration. According to their
own press, under a nationwide support program, E. ON gives buyers of micro-CHP units a
subsidy of 1000EUR, if they sign a gas supply contract with E.ON. UK also has subsidy policies
for supporting cogeneration which can be applied to Trigeneration market as well. It is
estimated that about 1000 micro-CHP systems were in operation in the UK in 2002. Since
2005, the UK government has cut the taxation from 17.5% to 5% for micro-CHP systems (E.
ON, 2011).
The National Energy Plan by the American Council for an Energy Efficiency Economy (ACEEE)
has a specific chapter to promote CHP. This association estimates that an additional 95GW of
cogeneration capacity could be added before 2020. It is expected that cogeneration and
trigeneration will cover 29% of total power generation capacity according to ACEEE (Monty
Goodell, 2006).
In ASIA, many countries have also policies and plans to support cogeneration and
Trigeneration in the electrical network. For example, Japan supports 30% of the installation
costs, and provides loans with low interest (2.3% per year). In large scale Trigeneration and
Cogeneration plant, the government pays 15% of the investment, up to a maximum of
US$5million (Environment and Development Division, 2000).
Australia, a country in which coal has a large share in electricity production, has energy plans
to reduce its emissions of greenhouse gases. For example, The City’s Sustainable Sydney
17
2030 plan commits the city to produce by 2030 70% of the electricity from trigeneration
using natural and waste gas. Many projects have been undertaken to achieve the goal, and
even the city of New York is interested in this experiment (Sydney 2030 Plan, 2011).
Governments are interested in promoting trigeneration to achieve Renewable penetration in
power generation. Europe, particularly Germany and England, are experiencing a huge
increase in electricity production from wind energy which requires strong back up power in
periods of low wind (Eurostat, 2006). Remotely controlled Distributed Trigeneration
applications fuelled with natural gas will help this country to achieve high penetration of
renewable sources in the grid.
10.1 Pfizer Singapore API manufacturing facility
In the past years Singapore has had problems caused by energy shortage - increases in sea
level and sudden changes in climate. Therefore, many companies in Singapore changed their
traditional energy plants to cogeneration or trigeneration system. Pfizer is also one of those
companies which, due to plant expansion, adopted a trigeneration system in 2008 (Figure
10.1). This facility used a conventional system whose average power consumption was: 6.5
MW Electricity bought from the grid, 5MW heat to produce steam with a gas fired boiler, and
8.8MW of refrigeration power subtracted from chilled water via a normal refrigeration cycle.
This system’s first law efficiency was 65%, given by: the boiler’s thermal efficiency 85% and
an average efficiency of 45% in a common gas fired generation plant (Pfizer Asia Pacific Pte
Ltd, 2008).
Now, this facility adopts a single integrated Trigeneration system (Figure 10.2) which
comprises: Gas Fired Turbine (5MW), Waste Heat Recovery Boiler (8MW) and Absorption
Chiller (9.1MW). Trigeneration improved energy efficiency compared to the old system, and
its energy efficiency is almost 83% now. Figure 10.3 shows the comparison of thermal
efficiency between these two systems.
Using trigeneration system brought two more good impacts: reduction of electricity
consumption adopting an absorption chiller and lower greenhouse gas emissions. 17 %
reduction in CO2 emissions, which corresponds to 5976 ton/year when compared to the old
system. The higher efficiency is responsible for saving 587000 $/year in fuel cost, as shown in
Table 10.1.
18
11. Conclusions
Trigeneration can be considered as one of the most environmentally friendly fossil fuel
utilization. The overall efficiency is so high that emissions/kWh is much lower than other
fossil fuel plants. Distribute power generation reduce the environmental impact caused by
power lines. The application of Trigeneration can easily help renewable energy to get into
the market, supplying energy when the sun, wind or other are not available. Furthermore,
with the improvement in fuel cell technology trigeneration will be even more appealing.
The economic good point of a Trigeneration system is represented by its operational costs.
Its efficiency reduces the fuel required to produce the same amount of heat, electricity and
cold as other power generation plants. In this way it offers a sort of surplus of energy from
the same source with a resultant cost saving. This also brings to a low impact of a CO2 tax on
the economic balance of the plant. Even if natural gas is not the cheapest fuel, Trigeneration
system will be economically competitive.
19
12. References
1. AEEG, “Delibera n. 42, AEEG”, Italy, 19.03.2002
2. Baldini M., Simeoni P, Mattiussi A., “Trigenerazione, fare freddo con il calore di
scarto”, Supplemento dell’informatore agrario, 40/2008
3. B.C. Chung - Century Corporation Korea, “Trend and application of absorption
chiller”
http://www.eurocooling.com/index1.htm, read 20.10.2011
4. Campanari S., Macchi E. “Future potentials of MTGs: hybrid cycles and tri-
generation”, in “Micro Turbine Generators”, ISBN 1-86058-391-1, pp. 43-66,
Institution of Mechanical Engineers, England, 2002
5. Campanari S. “microcogenerazione e trigenerazione:come trasformare le opportunità
in un mercato reale.”, Energy Department, Politecnico di Milano, 2007
6. Casalegno Andrea, “Fuel cell technology”, Energy department, Politecnico di Milano,
2010
7. Chwieduk D, Pomierny W, Restuccia G, Freni A, De Boer R, Smeding S.F., Malvicino C.,
“Trigeneration in the tertiary sector”, paper presented at the world renewable energy
congress VIII, USA, 2004
8. Environment and Development Division (EDD), “Guidebook on Cogeneration as a
Means of Pollution Control and Energy Efficiency in Asia”, pp. 49-63, 2000
9. E.ON, “E.ON supports micro cogeneration”,
http://www.eon.com/en/media/news-detail.jsp?id=10452, 22.07.2011
10. European Environment Agency, “EN20 Combined Heat and Power”,
http://www.eea.europa.eu/data-and-maps/indicators/en20-combined-heat-and-
power-chp, 01.04.2007 read 25th September
11. European Ministry of Economic Development, “Regulatory framework for high
efficiency cogeneration”, Department of Energy, 2004
12. Galliani A., Pedrocchi E., “Exergy analasys”, Polipress, ISBN 8873980252, 2006.
13. Groppi Gianpiero “Fuel cells”, hand-outs from the course “Fundamentals of Chemical
Processes”, Energy Department, Politecnico di Milano, 2010
14. Malico I., Carvalhinho A.P., Tenreiro J., “Design of a trigenereration system using
high-temperature fuel cell”, International Journal of Energy Research, pp. 144-151,
2009
20
15. Monty Goodell, M.B.A., “Trigeneration”, 2006
http://cogeneration.net/Trigeneration.htm, , read 17.11.2011
16. Pfizer Asia Pacific Pte Ltd, “Trigeneration facility at Pfizer”,
http://www.e2singapore.gov.sg/docs/Case_Study_of_Trigeneration_Project_in_Pfize
r.pdf, 2008, read 1.11.2011
17. PolyGeneration in Europe (Front Page Image), “Trigeneration”, 2011
http://www.polygeneration.org/cms/front_content.php?idcat=77, read 11.11.2011
18. Rayment C., Sherwin S.,“Introduction to Fuel Cell Technology”, Department of
Aerospace and Mechanical Engineering, University of Notre Dame, IN 46556, 2003
19. Sileo Michele, “The micro-combined heat and power production: A new way for
energy saving”, Ambiente e diritto, 2006
20. Sydney 2030 Plan website,
http://www.sydney2030.com.au/, 2011
21. U.S. Department of Energy, “Emissions from Energy Consumption at Conventional
Power Plants and Combined-Heat-and-Power Plants”,
http://www.eia.gov/cneaf/electricity/epa/epat3p9.html, read 25.09.2011
21
13. Tables
Table 4.3 Emissions from Gas Turbines (M. Sileo, 2006)
Table 4.4 Gas Turbines Efficiencies (M. Sileo, 2006)
Table 8 Exergy Use of 1kg of Natural Gas (Lozza G., 2006)
Builder and model Power (kW)
Flue gas flow rate
(kg/s)
NOx ppm
(15% O2)
CO ppm
(15% O2)
Noise dB (A) (10 m)
Capstone C30 30 0.31 <9 n.d. 58
Capstone C60 60 0.49 <9 n.d. 65
Turbec T100 100 0.81 <15 <15 70 (1m)
IngersollRand MT70 70 0.73 <9 <9 58
IngersollRand MT250
250 2.0 <9 <9 n.d.
Elliott TA 100 100 0.79 14 <24 <65
Manufacturer Electrical
Power (kW)
Thermal Power (kW)
ηe %
ηt %
ηg %
Capstone C30 30 55 24 50 74
Capstone C60 60 115 28 54 82
Turbec T100 100 167 30 48 78
IngersollRand MT70 70 112 29 46 75
IngersollRand MT250 250 383 30 46 76
Elliott TA80 80 135 28 47 75
Elliott TA 100 100 165 29 46 75
no-cog
no-cog hp
Ηcycle 0,55
ηcycle 0,55
Ηline 0,9
ηline 0,9
Ηres 1
COP hp 3,5
Ex(kJ/kg) 1689,42
Ex(kJ/kg) 5912,969283
Cog
boiler
Ηel 0,4
ηboiler 0,9
Ηth 0,45
Ex(kJ/kg) 3071,672355
COP hp 3,5
Ex(kJ/kg) 6313,993
22
Table 10.1 Pfizer CO2 emissions (Pfizer Asia Pacific Pte Ltd, 2008)
Conventional System
Package Boiler
Steam Pressure 8 Bar
Steam Output 8 T/h
NG Used(boiler@85% efficiency) 15120 mmBtu/mt
h
CO2 Emission 0.19 kg/kWh
CO2 Emission per month(Boiler) 826 T/mth
Power from power station
Power from Power Station 6.5 MW
CO2 Emission (Average Power Station) 0.45 kg/kWh
CO2 Emission per month (Power Station) 2106 T/mth
Total CO2 Emission per month
(Conventional)
2932 T/mth
Trigeneration System
Power generated 4.6 MW
Steam generated from Trigen 11 T/h
TriGen Output (Electricity + Steam) 12.4 MW
CO2 Emission 0.22
9
Kg/kWh
CO2 Emission per month(TriGeneration) 2045 T/mth
Power from Power Station
Power from Power Station (less 0.7MW
from Absorption Chiller)
1.2 MW
CO2 Emission (Average Power Station) 0.45 kg/kWh
CO2 Emission per month (Power Station) 389 T/mth
Total CO2 Emission per month
(Trigeneration)
2434 T/mth
23
14. Figures
Figure 3 Typical annual energy demand for a warm country (S. Campanari, 2007)
Figure 4.1a: Pressure - Volume chart Joule Brayton cycle (M. Sileo, 2006)
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Load
(kW
)
Month
Energy demand
Heat Load Electricity Coldness
24
Figure 4.1b Temperature – Entropy chart Joule Brayton cycle(M. Sileo, 2006)
Figure 6 Absorption Chiller Cycle (B.C. Chung)
25
Figure 7.1 Fuel Cell Losses (Casalegno, 2010)
Figure 10.1 Pfizer Facility (Pfizer Asia Pacific Pte Ltd, 2008)
26
Figure 10.2 Pfizer Trigeneration System (Pfizer Asia Pacific Pte Ltd, 2008)
Figure 10.3 Efficiency comparison between conventional and trigeneration system in Pfizer
(Pfizer Asia Pacific Pte Ltd, 2008)