Cogeneration Technology Alternatives Study (CTAS) Volume 5: Analytical approach and results

Data and information in the area of advanced energy conversion systems for industrial cogeneration applications in the 1985 to 2000 time period are provided. Six current and thirty-six advanced energy conversion systems were defined and combined with appropriate balance of plant equipment. Twenty-six industrial processes were selected from among the high energy consuming industries to serve as a framework for the study. Each conversion system was analyzed as a cogenerator with each industrial plant. Fuel consumption, costs, and environmental intrusion were evaluated and compared to corresponding traditional values. Various cogeneration strategies were analyzed and both topping and bottoming (using industrial by-product heat) applications were included. The advanced energy conversion technologies indicated reduced fuel consumption, costs, and emissions. Typically fuel energy savings of 10 to 25 percent were predicted compared to traditional on site furnaces and utility electricity. Gas turbines and combined cycles indicated high overall annual cost savings. Steam turbines and gas turbines produced high estimated returns. In some applications, diesels were most efficient. The advanced technologies used coal derived fuels, or coal with advanced fluid bed combustion or on site gasification systems.