Automatic control of excess air ratio in steam boilers

Cogeneration – combined generation of electricity and heat

The implementation of a cogeneration system enabled simultaneous production of electricity and heat with flexible unit operation. DB Energy achieved annual savings of 2.89 million PLN and increased the plant's energy efficiency.

The challenge

In the client’s industrial plant, the analysis of heat and electricity supply balances revealed the possibility of increasing energy efficiency through the use of a cogeneration system. The boiler operation characteristics and variable demand for heat and electricity required a solution that ensures flexible energy production with minimal losses and high efficiency.

The goal was to provide a constant source of heat while simultaneously generating electricity, optimizing the use of cogeneration units during both low and high demand periods.

Our approach

The DB Energy team conducted:

  • detailed heat and electricity demand balances,
  • selection of optimal cogeneration units in terms of heat and electricity capacity,
  • technical and logistical analysis of unit installation along with supporting infrastructure,
  • investment profitability calculation and estimation of potential savings.

Based on the analysis, 2 cogeneration units with 1.2 MWc each were selected, enabling heat production starting from 700 kWc and flexible capacity increase up to 1.9–2.4 MWc during peak demand periods.

DB Energy engineers during project implementation
DB Energy engineers during project implementation

Solution

Cogeneration - DB Energy diagram
Cogeneration - DB Energy diagram

The modernization included:

  • installation of two cogeneration units in soundproof containers,
  • integration of heat recovery systems from the engine jacket and exhaust,
  • ensuring flexible operation of the system depending on current heat demand,
  • implementation of supporting installations: energy distribution centers, chillers, and control systems enabling optimal unit utilization and system mobility.

The total investment cost amounted to 8.16 million PLN.

Results

The installation of cogeneration units resulted in:

  • annual financial savings: 2.89 million PLN,
  • increased energy efficiency through combined electricity and heat production,
  • flexible coverage of heat demand from low to peak levels,
  • reduction of energy losses and improvement of the plant’s energy balance,
  • mobility and possibility of relocating the system if electricity demand changes.
CHP - cogeneration unit
CHP - cogeneration unit

Conclusions

The use of cogeneration in an industrial plant allows simultaneous production of electricity and heat, increasing energy efficiency and reducing costs. The implementation of a flexible cogeneration system enables optimal unit utilization under variable heat demand, and the investment pays off in measurable savings from the first year of operation.

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