Combined heat and power

your key to energy savings

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 Combined heat and power...
your key to energy savings
What is combined heat and power?
Combined heat and power (CHP), or co-generation as it is sometimes known, is simply the simultaneous
generation of heat and electricity.

The generation of electricity produces a large amount of heat which, using conventional methods, is often
wasted.

CHP recovers this ‘waste’ heat and converts it into a useful form - usually steam or hot water, which can then
be used for a wide variety of process, heating, and sometimes cooling applications.

CHP versus conventional CHP everywhere

electricity generation CHP is not a new idea. Its vast benefits have been
reaped by several areas of industry and commerce for
many years.

Electricity Commercial buildings

30 - 40 % Industrial sites
Losses Public buildings
60 - 70 %
Food, pharmaceuticals and paper are just a few
examples of industrial applications for CHP, while the
concept is equally suited to leisure complexes, public
buildings and even royal palaces.

Wherever there is a significant demand for electricity

Conventional generation and thermal energy all year round, CHP is an option
worth considering. The thermal energy does not have
to be used for heating - it may be more appropriate to
use it for a cooling application.

Heat Electricity
40 - 65 % 15 - 40 %

Losses
10 - 20 %

CHP generation

By recovering the heat produced in the generation of

electricity, the fuel conversion efficiency is increased
substantially.

Typically, conventional electricity generation plants

operate at an efficiency of around 36 %. CHP plant will
normally operate at an efficiency level well in excess
of 75 %, sometimes even 90 %.

When CHP is implemented as a retro-fit scheme,

tremendous fuel and electricity cost savings can be Photograph showing typical absorption chiller
achieved as a result of the increased efficiency levels. utilising steam.

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 CHP components

Prime mover

Fuel Electricity

Generator

Air Exhaust
Heat recovery
Steam to process
steam generator

Optional supplementary firing

Simple cycle CHP

Prime mover

Fuel

Generator Steam to process

Electricity
Air Exhaust Steam turbine Generator
Heat recovery
steam generator

Optional supplementary firing Steam to process

Combined cycle CHP

At the heart of any CHP system is the prime mover. This plant can range from a small diesel engine to a large
scale gas turbine.

The 'engine' produces electricity by turning a generator. The engine also produces heat energy by virtue of its
operation.

The high temperature exhaust from the engine is commonly fed into a waste heat boiler where either steam or
hot water is generated.

If the heat is converted into steam, the waste heat boiler is termed a Heat Recovery Steam Generator (HRSG).
The product of the HRSG can then be treated as conventional plant steam. This is known as Simple Cycle CHP.

For larger plants it may prove economical to maximise the output of electricity by including a steam turbine to
turn another generator. The pass-out from this turbine provides low pressure plant steam. This arrangement is
called Combined Cycle CHP.

CHP for the environment User benefits

● Reduced site energy bills.
The environment benefits from the high efficiency of
CHP plant. ● Increased control over utility supply.
Carbon dioxide emissions are reduced in compliance ● Flexible, making it suitable for many types of site.
with targets to stem the effect of global warming and
● Environmental benefit from more efficient
fuel reserves are conserved as a result of their more
fuel consumption.
efficient consumption.

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 Spirax Sarco CHP and steam system specification
Feedwater storage, Boiler level controls Boiler blowdown controls
conditioning and supply and heat recovery
1 Feedtanks 6 Water level alarms 9 Auto TDS control systems
2 Deaerator heads 7 Modulating feedwater valves 10 Timed blowdown valves
3 Steam injection systems and controls 11 Blowdown vessels
4 Modulating feedwater valve controls 8 Feedpump check valves 12 Cooling water systems
5 Recirculating systems 13 Residual blowdown heat exchangers
14 Sample coolers
15 Vent heads

6
15

22

2 4

1
19 5

18

Gas turbine
13 Exhaust

Generator

General layout only. Some detail has been omitted for clarity. Your local Spirax Sarco Engineer will be pleased to advise.

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 Steam start-up Process and pipeline Condensate recovery and
equipment monitoring
16 Steam main start-up systems 20 Steam traps Mechanical and electric pumps*
17 Steam separators 21 Strainers 26 Condensate contamination detection
22 Air vents
Metering Vacuum breakers* Heat recovery
18 Steam, fluid and gas meters Sight glasses* Plate heat exchangers*
23 Check valves Flash vessels*
Pressure and temperature controls 24 Trap monitoring
Pressure and temperature controls* 25 Isolation valves Humidification
High temperature cut-off valve* Steam injection humidifiers*
19 Safety valves
*Not shown in schematic

16

17
26

21 18

23
20
24

15
19 6

7
9
11
8
25
14 23

12
10

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 Spirax Sarco
in combined heat and power plant
For more than 85 years Spirax Sarco has been
the leader in improving plant efficiency, providing
knowledge, high quality products and packaged systems to
fluid plant in all branches of industry, including CHP.

We understand the specific needs of CHP,

and that each CHP application has its
own special requirements.

Whilst our key speciality lies with steam systems we also

provide technical support for other fluid systems,
including hot water.

Steam
distribution

Steam control
Heat recovery and
from HRSG management

Condensate
management

The complete system

From factories to hospitals it is essential that the steam from the recovery boiler or steam turbine is conditioned to
ensure optimum operation and maximum efficiency.

To achieve this it is necessary to consider the design and operation of the complete steam and condensate
system. The type of connected plant, the local environment and the different processes being served must all
be taken into account.

Consideration should also be given to future expansion and plans to upgrade existing production plant.

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 Steam generation
Level control
High integrity self-monitoring level controls enable the
boiler to operate on a completely automated basis
therefore ensuring round-the-clock optimised operation.

TDS control
Automatic TDS controls ensure that ideal water
conditions are maintained within the boiler , thus
creating steam of the highest quality for process or
heating requirements.

Steam distribution
Steam pipeline equipment
Control equipment including steam traps, separators,
strainers and bellows sealed isolation valves all make
for an energy efficient steam system whose operation
and maintenance is very simple.

Automatic performance monitoring

Steam traps can be automatically monitored on a
continuous basis to ensure that they are performing
at their optimum. Such automated monitoring systems
can be linked to existing energy management systems.
Their installation reduces maintenance downtime to
an absolute minimum.

Condensate management
Condensate removal
It is essential that condensate is drained from the
steam system quickly and effectively by use of an
Temperature, pressure and
appropriate steam trap.
flow control
Control equipment Condensate contamination
Electronic and pneumatic control equipment provides A simple automatic system can be installed which
close control of temperature, pressure or flow. This will allow the quality of condensate to be assessed
equipment is ideally suited to the efficient operation of prior to return to the feedtank. Any contamination will
de-superheaters and plate heat exchanger packages. be detected and the condensate discharged to drain.

Flowmetering equipment Condensate recovery

Flowmetering equipment suitable for saturated steam, Condensate is a valuable asset, and should be returned
superheated steam, liquids and gases enables to the boiler for reuse where possible. Under certain
monitoring of the chosen heating medium or fuel used circumstances, electrical or mechanical pumps may be
in the CHP application. required to help in the return of this condensate.

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 Spirax Sarco provides knowledge,
service and products worldwide for the control
and efficient use of steam and other industrial fluids
associated with CHP plant.
As your business partner, Spirax Sarco will provide you with:-

● Worldwide support from a team of 3 500 dedicated

employees.

● Local access to Spirax Sarco's expertise and products

through 35 group companies in 30 countries.

● Valuable information, advice and interchange of ideas

from customer training courses held in any of our
32 training centres worldwide.

● A comprehensive range of the highest quality products.

Spirax Sarco locations

Europe
Austria Vienna Belgium Zwijnaarde
Czech Republic Prague Denmark Copenhagen Finland Helsinki France Trappes
Germany Konstanz Hungary Budapest Ireland Dublin Italy Milan Netherlands Maarn
Norway Oslo Poland Warsaw Portugal Lisbon Russia St. Petersburg Spain Barcelona
Sweden Stockholm Switzerland Zurich - Zollikon United Kingdom Cheltenham

Australasia Americas Africa

Australia Sydney Argentina Buenos Aires Brazil São Paulo Kenya Nairobi Nigeria Lagos
New Zealand Auckland Canada Toronto Mexico Monterrey South Africa Johannesburg
USA Allentown

Asia & Middle East

China Shanghai Hong Kong lndia Poona
Indonesia Jakarta Japan Tokyo Korea Seoul Lebanon Beirut Malaysia Kuala Lumpur
Pakistan Karachi Philippines Manila Singapore
Taiwan Taipei Thailand Bangkok

A further 46 agencies operate throughout the world.

CHP

If you have difficulty finding a local contact please fax us at the number shown below.

Spirax-Sarco Limited, Charlton House,

Cheltenham, Gloucestershire, GL53 8ER UK.
Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342
E-mail: [email protected]
Internet: www.spirax-sarco.com
© Copyright 1996 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

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SB-GCM-14 CM Issue 1