Small-scale industrial cogeneration with high efficient gas turbine

Panel: 4. Technology, products and system optimisation

Matti Malkamäki, Aurelia Turbines, Germany
Maija Mäkinen, Aurelia Turbines, Germany


The small-scale process and SME industry uses over 20% of the total energy consumed in Europe. This sector includes small factories in iron & steel, food, chemical, pharmaceutical, building materials, and other industries. All these factories need Combined Heat and Power (CHP) generated locally, but power only in relatively small amounts, generally less than 2 MW. A majority of these factories are using very inefficient energy systems, that cannot handle the fluctuating power demand and varying ratios of power/heat needs.

The potential of energy savings in industrial processes of the SME sector is vast. According to the German Energy Agency, process heat is the most energy intensive application field by covering 64% of industrial total final energy consumption. Process steam (between 100 and 500 °C) accounts for 21% of industrial final energy consumption in EU. A study by IEA shows that the industrial sector can save up to 30% in process heat costs through energy efficiency measures. According to German CHP association, steam-CHP technology targeted at the small scale and SME industry can reduce fuel consumption up to 40% by enhancing efficiency and allowing the use of a range of different, also renewable fuels.

In distributed energy generation the power and heat needs can vary significantly depending on the production degree and time of day, week or year. The power and heat demand of a particular time do not necessarily correlate. Major energy savings can be achieved with efficient flexible CHP generation technologies. This presentation shows simulations of power/heat demand and on-site generation of three different small industrial sites in Germany using three different technologies; reciprocating engine, conventional micro gas turbine and a novel, high efficiency micro gas turbine.

Small-sized gas turbines have gained increased attention due to their multiple benefits compared to conventionally used reciprocating engines: lower emissions and lower operating and maintenance costs and wider variety of allowed fuels, including biofuels. Additionally, in a novel, innovative two-spool variable speed gas turbine the two spools can be controlled independently of each other, which allows the turbines to be operated with high efficiency in a broader operating range. The operation of this kind of gas turbine can be easily controlled on the basis of the current power/heat ratio demand.


Download this presentation as pdf: 4-032-18_Malkamaki_pres.pdf