LionRock Corporate Nigeria Limited9B, Kafayat Abdulrazak street, Lekki Phase 1, Lagos, Nigeria.Tel:081 8942 0743 / 080 9908 9084 / 080 6688 5978 www.lionrocknigeria.com Email: nigeria@lionrockpower.com

3Tech Corporate LimitedUnit 904, 9/F., Fu Hang Industrial Building,1 Hok Yuen Street East, Hung Hom, Kowloon, Hong Kong.Tel: +852-2766 9787 Fax: +852-2766 9774www.3tech.net

Cogeneration, also known as combined heat and power (CHP) because this is the most popular configuration of cogeneration.

Electricity generator is the most popular form of using fossil fuel to produce an energy that can be easily transmitted over long distance by cables. For this reason, many of the different form of energy such as heat, cooling and mechanical power were derived from electricity.

However, the best electricity generator using various types of reciprocating engine and turbine engine is still not able to achieve electrical efficiency over 50%. That means more than half of the potential energy in the fuel is lost.

EXHAUST HEAT

FUEL

ELECTRICITY

COOLANT HEAT ENGINE GENERATOR

01

COGENERATION

Typical diesel and gas reciprocating engines are able to achieve electrical efficiency over 35% for a small 200 to 300kW generator and over 40% for 1000kW and over. The bigger the engine, the higher the electrical efficiency.

In contrast, gas turbine engine is only able to achieve electrical efficiency of 23 to 24% for a 1MW gas turbine engine, 30% for over 5MW and achieve 40% when the gas turbine engine rated over 30MW.

Therefore, reciprocating engine is the best choice if electricity is the main product required.

AIR INTAKE COMPRESSION COMBUSTION EXHAUST

Intake air CompressorFuel Combustor

TurbineExhaust gas

Output shaft

02

In the combustion of fossil fuel, the mechanical output is used to turn a generator to produce electricity. Remaining heat energy is normally dissipated in the atmosphere to keep the combustion engine in operation.

By recovering the waste heat for other work is the key concept of “Cogeneration”.

The most popular internal combustion engines are reciprocating engine and turbine engine.

4-stroke Reciprocating engine

Single shaft Industrial gas turbine engine

03 04

*:Distribution between coolant and exhaust depends on different engine design. Some engine has more energy in the exhaust while some has more energy in the coolant.

Electrical output =40%Cooling water = 25%*Exhaust gas = 25%*Radiation and alternator loss =10% (typically 5% each)

Typical Energy Split of diesel and gas reciprocating engines

100%Applied FuelEnergy(Combustion)

40% Electricity

5% Radiation loss5% Generator loss

25% Coolant

25% Exhaust

As cooling water is typically at 90 deg C only, it is good to provide hot water supply, heating and low temperature heating requirement. Various industries such as food processing industry and hospital are good examples of using this heat.

Exhaust gas temperature is typically over 400 deg C and hence is possible to provide steam through a heat recovery steam generator (HRSG) which provides more flexible use of the heat for other industrial process such as drying, laundry system etc.

Heat recovery steam generator, HRSG

It is quite clear that there is a saving of 50 units of fuel cost (or 33% reduction) by using cogeneration to produce the same amount of electricity and heat.

Apart from fuel cost saving, the reduction of fossil fuel usage also reduce the greenhouse gas emission from the system and hence a lower carbon footprint by same portion.

Radiation & generator loss Losses

Thermaldemand

Electricitydemand

100

50

100

150

40

40

Cogeneration

Boiler

Electricitygenerator

40

40

Losses

10

60

1010

Loss during heat recovery

Power + Steam + Hot Water Generation:

Exhaust Gas Steam

Fuel Electric Power

HRSG

High Temp. water Hot Water

Benefit of Cogeneration

Below is a comparison of a cogeneration system against a traditional way of electricity generation and heat generation through a boiler.

All reciprocating engines over 100kW are water cooled. Below is a typical 1000kW reciprocating engine generator energy distribution.

05 06

Trigeneration

The cooling principle

The input heat energy heats LiBr solution to 140°C and generate vapour, which is then condensed into liquid by cooling water. When the re f r ige rant water en te rs evaporator (in high vacuum condition), its temperature goes down immediately to 5°C. And it is sprayed over the tubes, and chilled water from 14°C drop down to 7°C to make cooling. The water a b s o r b s h e a t f r o m a i r cond i t ion ing sys tem and evaporates, then is absorbed b y c o n c e n t r a t e d L i B r s o l u t i o n f r o m t h e g e n e r a t o r s . T h e c o o l i n g water takes away the heat and rejects it into the air. Diluted solution is pumped into HTG and LTG separately to be heated to begin the process all over again.

Notes: Lithium Bromide is a s t rong hyg roscop i c sa l t , nontoxic and harmless, with no geenhouse effect and no damage to the ozone layer. A much environmental friendly refrigerant.

Similar to cogeneration, trigeneration is also known as combined cooling, heat and power (CCHP). The third form of energy to provide cooling is achieved by absorption chiller.

Absorption chiller working principle

Water soffener

City w

ater

Chiller

Cooling tow

er→W

ater distribution system→

Pumpset

Auto

Cooling w

ater pump

Dosing

Chilled w

ater pump

Hot w

ater pump

Chilled water 7/14°C

Hot water 80/60°C

1.High temperature generator(HTG)

2.Low temperature generator(LTG)

3.Condenser4.Absorber5.Evaporator6.High temperature heat

exchanger(HTHE)7.Low temperature heat

exchanger(LTHE)

Heat enegry

Concentrated solutionDiluted solutionRefrigerant waterRefrigerant vapor Chilled waterCooling waterHot waterFlow meter

The heating principle

The input heat energy heats the LiBr solution. The vapor produced by the solution heats the heating water or hot water in tubes, while condensate returns to the solution to be heated and t h e c y c l e r e p e a t s . A s " s e p a r a t e h e a t i n g " i s adopted, the heating cycle becomes very simple, just l i k e a v a c u u m b o i l e r . Therefore, the life span of the chiller can be doubled.

A separate heat exchanger can provide dedicated hot w a t e r w h i l e c o o l i n g o r h e a t i n g o p e r a t i o n i s stopped.

SolutionVaporHeating waterHot waterNo operationFlow meter

Heating water 65/55°C

Heating w

ater pump

Hot water 80/60°C

Hot w

ater pump

High temperature generator(HTG)

Heat energy

As the absorption chiller is able to provide heating water during winter and cooling water during summer, it is a complete HVAC system to replace electric chiller and hot water boiler by one piece of equipment.

In terms of recovering the waste heat from a reciprocating engine, exhaust heat can be used to provide hot water through waste heat recovery boiler (WHRB). By combining with the engine cooling water, hot water is provided as one source of heat energy to be fed to the absorption chiller. This is also called single effect or single stage absorption chiller.

Power + Hot Water or Chilled Water Generation with single stage absorption chiller:

In order to simplify the interface of the absorption chiller and a reciprocating engine in terms of waste heat recovery, there is another type of absorption chiller that can be fed with the engine cooling water and exhaust gas directly. This is the two stages or double effect absorption chiller.

Power + Hot Water or Chilled Water Generation with two stage absorption chiller:

Exhaust GasHot Water(winter)

Fuel Electric Power

WHRB

High Temp. water Chilled Water(summer)

Absorption chiller

Exhaust Gas

Fuel Electric Power

High Temp. water Double effect absorption chiller

Hot Water(winter)

Chilled Water(summer)

07 08

LionRock's Products for Cogeneration/TrigenerationLionRock offers full range of equipment for cogeneration and trigeneration application from Power Generator of various fuel including natural gas, LPG, biomas gas and diesel.

Power GeneratorsLionRock offers wide range of internal combustion engines as the prime power drives. Below is the summary of the key ranges.

Gas engine generator sets

Natural gas is an ideal fuel for cogeneration and trigeneration because of the cleaner exhaust gas that allow efficiency operation of heat recovery system and minimise maintenance.

LionRock offers a standard range of gas reciprocating engine powered generator set from 30kW upto 600kW. This range is stoichiometric combustion range. Although the electrical efficiency is lower, they are suitable for island mode operation with very good response to load transient. The overall cogeneration efficiency is still as high as 80% with hot water supply.

Biomass gas version is also available with some derating.

Electricity Output (kW)

Engine

ConfigurationDisplacement

(Litres)Electrical Efficiency

LRGC30

LRGC80

LRGC100

LRGC120

LRGC160

LRGC200

LRGC300

LRGC500

LRGC600

30

80

100

120

160

200

300

500

600

Four in line

Six in line

Six in line

Six in line

Six in line

Six in line

Six in line

Vee 12

Vee 16

3.9

5.9

6.7

8.3

8.9

14.0

18.9

37.7

50.3

28.7%

30.6%

30.8%

31.0%

31.8%

28.5%

32.2%

32.9%

32.0%

ModelLRGC Series

Tseng Kwan O Landfill Site in Hong Kong - LRGC160 derated to 100kW

09 10

LionRock also offers the ENERGIN GEN gas engine generator from Germany with capacity of 140kW to 500kW and extremely high electrical and cogeneration efficiency. With the latest lean burn technology, this series of product is ideal in parallel operation with mains or separate diesel generators as they are less responsive to transient load change.

Other than Biomass gas models with the same output , another ser ies of LPG models are available with minor derating.

High Capacity Gas eng ine generator s t a r t a t 1 0 0 0 k W a n d s u i t a b l e f o r natural gas, coal bed methane gas as well as natural gas.

Higher capacity gas engine generators a r e o f f e r e d o n project by project basis.

Electricity Output (kW)

Engine

ConfigurationDisplacement

(Litres)Electrical Efficiency

M06 GEN G140

M06 GEN G200

M06 GEN G250

M08 GEN G260

M08 GEN G333

M12 GEN G400

M12 GEN G500

140

200

250

260

333

400

500

Vee-Six

Vee-Six

Vee-Six

Vee-Eight

Vee-Eight

Vee-Twelve

Vee-Twelve

11.3

11.3

11.3

15.1

15.1

22.6

22.6

38.6%

41.0%

41.8%

41.0%

41.9%

41.1%

42.1%

ModelENERGIN

Electricity Output (kW)

Engine

ConfigurationDisplacement

(Litres)Electrical Efficiency

LRGL 1000 1000 Vee 12 53.1 39.5%

ModelLRGL Series

Diesel engine generator sets

Natural gas is not necessary available in every facility and hence diesel engine is also an alternative. LionRock has wide range of diesel generators with various engines combination as below that are suitable for cogeneration purpose.

Perkins Engine Range : 100 to 1600kWMitsubishi Engine Range : 600 to 1800kWMTU Engine Range : 600 to 2400kW

One of the problem with diesel engine for cogeneration is the particulate in the exhaust gas that contaminate the heat recovery boiler over time. LionRock offers top class soot filter to deal with the particulate in the diesel engine exhaust to ensure efficient operation of heat recovery equipment in the cogeneration system.

The soot filter is a self- cleaning type with minimum maintenance. However, high pressure alarm and special by-pass relief function is available to safeguard the exhaust system.

Soot filter

Soot filter with bypass

11 12

®Bi-Fuel System Operation and Performance

Bi-fuel engine generator sets

Bi-fuel is the best option for existing diesel engine generator when natural gas becomes available to enjoy the benefit of the low cost and clean fuel.

When gas supply is not stable or not available at early stage of project, the easy swing to full diesel operation is the key to guarantee the generator set full capacity at any time.

Gas substitution rate is as high as 65%~70%, i.e. 30% diesel and 70% natural gas combined to power the reciprocating engine. Substantial saving in fuel cost can be achieved with the much lower cost natural gas.

LionRock offers factory fully tested bi-fuel engine generator set as well as retrofit bi-fuel system on site for existing diesel generator set.

Heat recovery equipment

LionRock offers both shell tube type and stainless steel plate type heat exchanger for hot water energy recovery as well as engine cool ing system dumping using electric radiator and cooling tower t o m e e t v a r i o u s t h e r m a l a n d electricity demand.

LionRock also offers exhaust heat r e c o v e r y h o t w a t e r o r s t e a m generator to su i t the var ious thermal load requirement.

Heat exchanger

Heat recovery water boiler, HRWB

Cogeneration Module

A p a r t f r o m s e p a r a t e h e a t recovery equipment, LionRock also offers ENERGIN CHP fully p a c k a g e d a n d t e s t e d c o g e n e r a t i o n m o d u l e a s a complete system on skid and in optional enclosure of 70dBA at 1m to minimise the site work and greatly reduced the space requirement.

140

200

250

260

333

400

500

90.1%

90.4%

87.3%

90.7%

87.7%

90.7%

87.5%

187

241

272

315

364

483

539

Engine

ConfigurationDisplacement

(Litres)Cogen

Efficiency

M06 GEN G140

M06 GEN G200

M06 GEN G250

M08 GEN G260

M08 GEN G333

M12 GEN G400

M12 GEN G500

Vee-Six

Vee-Six

Vee-Six

Vee-Eight

Vee-Eight

Vee-Twelve

Vee-Twelve

11.3

11.3

11.3

15.1

15.1

22.6

22.6

ModelENERGIN kWe kWt

Electricity Output

Electrical Efficiency

38.6%

41.0%

41.8%

41.0%

41.9%

41.1%

42.1%

13 14

Absorption chiller

LionRock offers full range of world leading Broad Absorption chiller including single and two stages design as well as with additional burner to further increase the chilling capacity.

Exhaust gas absorption chiller

Code Mode

Coolingcapacity

Heatingcapacity

kW kW

Chilled W.

Flowrate

Pressuredrop

3m /h kPa

Cooling W.

Flowrate

Pressuredrop

3m /h kPa

Heating W.

Flowrate

Pressuredrop

3m /h kPa

Exhaustconsumption

Cooling Heating

kg/h kg/h

Powerdemand

kW

SolutionWt.

t

Unit ship.

t

Mainshellship.

Chilleropera-tion

Wt.Wt.t t

Wt.

Exhaust chiller BEexhaust500°C

20305075

100125150200250

233349582872

11631454174523262908

153230384575767959

115115341918

28.642.971.4107143179214286357

303030303040404050

47.571.2119178238297357476595

505050505050505080

13.119.632.749.065.481.898

131163

144021583606541472159025

108321443918057

202020202020203030

153022893819572276389553

114451529919036

2.13.23.23.65.35.36.48.68.9

1.11.72.43.54.05.06.58.09.2

6.08.3

10.513.517.218.623.231.0

/

2.54.25.05.66.57.68.9

12.714.8

6.59.0

11.515.019.220.625.234.138.9

Hot water Absorption chiller

Code ModeCoolingcapacity

kW

Chilled W.

Flowrate

Pressuredrop

3m /h kPa

Cooling W.

Flowrate

Pressuredrop

3m /h kPa

Powerdemand

kW

SolutionWt.

t

Unit ship.

t

Chilleropera-tion

Wt.t

Wt.

Hot waterchiller BDHhot water98°C

20305075

100125150200250

Hot W.consump-tion

3m /h

209302512767

10231279153520462558

25.237.662.994.2125157188251313

252525252530303040

58.686.5145218291363436582727

757575757575757590

23.935.859.889.7

119.6149.6179.6239.4299.2

2.52.52.84.74.94.95.67.59.3

0.60.71.11.41.82.32.84.05.0

3.35.46.98.19.6

11.813.318.421.7

3.96.48.4

10.412.014.315.822.226.7

Higher capacity absorption chillers are also available for specific projects.

LionRock's Solution for Cogeneration / TrigenerationThe success of a cogeneration or a trigeneration system depends on a lot of factors from electricity demand, thermal load requirement, balance of energy at different time and season, fuel option and availability, space requirement, integration with existing system, modification of existing system to allow suitable interface, electricity tariff, fuel cost etc.

It is a very long list of factors need to be considered. Therefore, the first step is a feasibility study to review all the factors to decide if cogeneration is the best option to address customer's energy need.

LionRock's inhouse team has strong experience and highly qualified electrical and mechanical engineers. Their extensive experience in dealing with building services in different type of facility from commercial office, hospital, data centre to residential blocks allow design of suitable cogeneration system to meet the various energy needs of such facility.

In terms of industrial application, LionRock offers full energy audit of customer production process to identify all areas of energy need and their interaction.

A two stage absorption chiller working with a 1000kW gas engine generator set LionRock offer full turnkey solution from project planning, engineering design, procurement and construction to commissioning before handover a system to customer. Aftersales and maintenance services are to be followed to ensure hassle free services to customer.