part 1: overview of cogeneration and its status in asia - Fire

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78 Part II: Cogeneration experiences in Asia and elsewhere P. Shell P. Fiber Hot Water for Boiler BOILER Sterilizer Digester 350 psig Crude Oil Tank Turbine #1 Turbine #2 (Future) Back to Pressure Receiver Distributor Figure 2.6 Steam turbine cogeneration in the palm oil mill The total investment cost of the cogeneration plant amounted to US$ 523,000 and the annual cost savings expected from the self-generated electricity is estimated as US$ 243,700. The factory expects to recover the investment within 3 years after the commissioning of the cogeneration plant. Encouraged by the results, the company plans to achieve a ‘zero waste’ level in the factory. There is a plan to fully exploit the excess energy by generating up to 2.5 MW of electricity and integrating the operation of downstream activities such as the kernel crushing plant and medium density fibreboard project. 2.6 Cogeneration in an Industrial Estate Clarification (Oil Room) Exhaust: 45 psig (3 bar) 1,200 kW Power Supply to Mill Supply to other integrated activities to harness excess energy Oil Storage Tank Kernel Dryer The Thai Government policy of initiating and decentralizing economic development has led to the successful creation of several industrial complexes away from the capital. These industrial complexes require considerable amount of reliable power and process steam. Many industries inside these complexes are excellent customers of large-sized cogeneration plants. One such 300 MW gas-fired cogeneration power plant was launched in Map Ta Phut Industrial Estate as early as in 1994. 5 5 Y. Le Scraigne, “The first IPP project developed in Thailand – The Map Ta Phut cogeneration plant”, Paper presented at the 1994 Cogeneration Conference, AIC Conferences, Bangkok, 20-21 June 1994.
Examples of cogeneration projects implemented in Asia 79 2.6.1 Description of the cogeneration project The cogeneration project was developed in two identical phases. Taking the environmental concerns into consideration, natural gas-fired combined cycle cogeneration option was retained which minimizes the level of exhaust emissions and reduces the cooling water requirement by half in comparison with a conventional power plant. Each phase included 3 gas turbines (35 MW each), a heat recovery steam generator (HRSG) to recover heat from the flue gases of the gas turbines, a steam turbine of 50 MW capacity, and the auxiliary equipment necessary to produce and distribute the generated electricity and steam to industrial customers and the utility grid (see Figure 2.7 for details). In each phase, 150 MW of electricity and 145 tons/hour of process steam were generated at two different pressures required by the industries: 60 tons/hour at 52 bar and 425°C, and 85 tons/hour at 19 bar 250° C. The high pressure steam is taken directly from the boiler. The medium pressure steam is bled off the steam turbine, with a back up provided by the high pressure steam supply through a turbine by-pass fully equipped with a pressure reducing and desuperheating station. Fuel: 100% 11.7%: 3×15.1 MW 88.3%: 3×114.6 MW Air Comb. C T 61 .3 % 238.7 MW G Electricity 64.2% 3 ×83.5 MW 27%: 3×35 MW 12.3%: 47.8 MW Stack 8.8%, 34.3 MW HP Steam: 6.8%: 26.3 MW MP Steam: 13.9%: 53.8 MW Cooling Water 31.2%%: 121.4 MW Figure 2.7 Combined cycle cogeneration (Phase 1) at the Industrial Estate The cogeneration plant assures electricity, steam and demineralized water supply to several petrochemical and downstream industries. Customers have signed long-term contracts to take or pay for a minimum off-take quantity of steam. The steam price has three components: capacity, energy and transportation. Steam is supplied to the customers with an availability guarantee. A part of the electricity generated is sold to the customers whose price has capacity and energy components, the remaining amount is sold to the utility grid according to the tariff set for small power producers. H R S G Water
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PART 1: OVERVIEW OF COGENERATION AN
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4 Part I: Overview of cogeneration
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