Co-Generation System

The Gas Turbine Co-Generation System

Environmental problems caused by energy consumption have been attracting more and more concern in recent years. Kawasaki Gas Turbine Co-Generation Systems contribute to solving these problems by efficiently converting high-temperature exhaust gas from the power generation process into an energy source to produce steam, hot or cold water, or for drying.

What's co-generation?

Co-generation is an effective energy saving system to produce two or more forms of useful energy, e.g. electricity and steam, from a single energy source. For example, heat obtained from the combustion of fuels is converted into electric or mechanical energy, while the exhaust heat is utilized as an energy source to produce steam for air-conditioning or drying.

Co-Generation Configuration Applications (Examples)

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Features of Gas Turbine Co-Generation

1. High Combined Efficiency
   By effectively using the high-temperature gas released during power generation, Gas Turbine Co-Generation can significantly increase combined energy efficiency.
2. Reliability
   The core part of the system is a simple, single-shaft gas turbine. The turbine, and other components such as the alternator and heat recovery steam generator, are all designed with durability in mind.
3. Outstanding Environmental Benefits
   Low emission technologies such as dry low emission (DLE) combustion or catalytic combustion have great environmental benefits. Also, the gas turbine is a rotary engine, therefore mitigating the machine's vibration compared to other engine types with reciprocating movements. Furthermore, the system's high combined efficiency has important environmental advantages, namely a substantial reduction in carbon dioxide emissions.
4. Easy Operation and Maintenance
   The gas turbine runs automatically by a simple button operation. The maintenance work is straightforward, as the turbine is composed of a limited number of parts.
5. Light-weight and Compact
   The whole system is skillfully designed to be light-weight and compact. It can be installed anywhere, even in small spaces on the roof or underground.

Product Lineup

GPB Model Product Data (PDF:475KB) 

System Examples

Mechanical-drive System

This system equips a 1500kW Class M1A-13A gas turbine engine driving a turbo compressor. The co-generation energy output is compressed air and saturated steam and the total electricity required to operate the existing compressor is reduced. Exhaust gas (O2=16%) from the gas turbine will be utilized as part of the combustion air for the existing steam generator.

Mechanical-drive System Flow (PDF:248KB) 

Drying System

Equipped with a 700kW class S7A-01 regenerative cycle gas turbine, this system achieves high efficiency in electrical output. As the existing hot water tank in the plant supplies water to the steam generator, the system can produce about two tons of saturated steam per hour without an economizer. The exhaust gas from the turbine is then directed to the drying furnace, where the waste heat if effectively used.

Drying System Flow (PDF:372KB) 

Combined Cycle System

A 6,500kW steam turbine is driven by steam produced from a combination of three 6,500 kW M7A-02D gas turbines and three heat recovery steam generators. NOx emissions are reduced by using a Lean Premixed Combustion Method, eliminating the need for water injection and its associated equipment. The system's heat recovery steam generators, equipped with duct burners, can respond to substantial fluctuations in process steam demand and can adjust the heat-to-power ratio of the energy output.

Combined Cycle System Flow (PDF:284KB) 

Hybrid Power System

This hybrid system combines a co-generation system driven by an M1A-13D gas turbine (1,500kW class, DLE) and a photovoltaic power generation system. The solar-powered system meets the demand for electricity according to the supply of sunshine, but in case of power failure, a co-generation gas compressor is also in place, allowing this system to function even during blackouts. In addition, the co-generation system has a steam turbine attached to the motor shaft of the gas compressor, to effectively utilize excess steam to drive the compressor and to reduce the required auxiliary power.

Hybrid Power System Flow (PDF:278KB) 

Flexible Heat and Power Co-Generation System

This system equips a 6,500kW class M7A-01ST gas turbine. When the demand for steam is high, the system operates in normal mode. As priority is given to meeting the steam demands of the plant, the minimum requirement of steam is injected into the gas turbine, to reduce NOx emissions while still maintaining productivity. When the electricity demand is high, the system operates under PLUS mode, which gives priority to the production of electric power. Under PLUS mode operation, up to eight tons per hour of steam is injected into the turbine to boost the power output.

Flexible Heat and Power Co-Generation System Flow (PDF:253KB) 

Manufacturing Process of Co-Generation Equipment

Co-generation systems consist of gas turbines, alternators, heat recovery steam generators, auxiliaries, control panels and other devices. The key component, the gas turbine, is manufactured at Kawasaki's Akashi works. The turbine, equipped with a gear box and an alternator, is fixed to a base and covered with a protective enclosure, completing the generator package. Once civil engineering work on the installation site is finished, all the necessary equipment, including a generator package, heat recovery steam generators, auxiliaries and control panels, will be delivered from the works for assembly, completing the construction of the co-generation system. After passing field tests, the system is delivered to the customer.

The following is an example of the construction process of a combined cycle system, consisting of a co-generation system combined with a steam turbine generator, presented in order of construction.

Installation Examples