Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering

Copyright 2012 by ABCM November 07-10th, 2016, Vitria, ES, Brazil

THERMODYNAMIC EVALUATION OF THE REGENERATION EFFECT

IN COGENERATION SYSTEMS FOR BRAZILIAN SUGAR AND
ALCOHOL INDUSTRY

Madson John Arcanjo Batista, madsonj.arcanjo@gmail.com

Andr Pereira de Souza Lima, andrepsl7@hotmail.com
Jos Carlos Escobar Palacio, jocescobar@unifei.edu.br
lvaro Adolfo Daz Prez, aldiper@hotmail.com
Osvaldo Jos Venturini, osvaldo@unifei.edu.br
Arnaldo Martn Martnez Reyes, ammr451111@yahoo.es
Dimas Jos Rua Orozco, dimas.rua@hotmail.com
Filipe Ferreira de Oliveira Leite, filipe.ferole@yahoo.com.br
Federal University of Itajub (UNIFEI), Av. BPS, 1303, Bairro Pinheirinho, Itajub - MG, CEP 37500 903, Brazil

Abstract. This paper presents a thermodynamic evaluation of effects caused by regeneration in cogeneration systems of
the Brazilian sugar and alcohol sector focusing on actions that lead to increase the overall performance of the plant in
order to increase the availability of surplus bagasse. Eighteen sets were analyzed in the cogeneration system of a sugar
and alcohol mill divided into two groups. In Group I, the power is set at 50 MW and there is surplus bagasse. In Group
II, all the bagasse is used for the generation of steam. Steam operating parameters for both groups are 65 bar and 480
C. Each group consists of a base scenario (conventional) and eight regenerative scenarios in which the number of
regenerators varies gradually from one to eight. To simulate the different schemes, the commercial software GateCycle
was used. It was established as the main parameters a milling capacity of 500 tc/h with electrified mills; a specific steam
consumption of 450 kgv/tc and operation with condensing turbine with extraction. The impact of regeneration is assessed
with reference to the base scenario of each group, since both groups represent different realities of the real context of
the Brazilian sugar and alcohol sector. Whereas cogeneration systems produce electricity and useful thermal energy
simultaneously, the case studies for each scenarios are now based on the analysis of two indicators, Exergetic efficiency
and surplus bagasse index. Increases in Exergy efficiency of 7.27% and 6.00% for group I and II, respectively were
obtained.

Keywords: cogeneration, regeneration, Rankine cycle, sugar and alcohol.

1. INTRODUCTION

The anthropic activities today are the main source of greenhouse effect since the world energy matrix is based, mainly,
in burning fossil fuels which in turn has close relationship with climate change (especially global warming) as has been
demonstrated by research held throughout the XX century. To maintain an average temperature of the planet below the 2
C by the end of XXI century compared to pre-industrial period (1850-1900), it takes a reduction in the emission of
greenhouse gases (GHGs) in the range of 40-70 % compared to 2010 by 2050, as shown by the IPCC report (IPCC,
2014).. The scenario presented shows the imperative need to use a sustainable energy source that reduces the emission of
pollutants so as to maintain the rate of production without affecting environmental safety. In this context, the plants of
the Brazilian sugar and alcohol sector are very important, since in most cases, they are self-sufficiency to satisfy the
demands of mechanical / electrical and thermal energy (Hassuani et al., 2005). In addition, there is the possibility of
commercialization of electrical surplus with the national grid. Nowadays, 40% of the industry's plants participate in the
sale of surplus (Markestrat, 2014), which establish an important factor of attractiveness of a given enterprise. In 2014, the
generation capacity using biomass energy represented to 8.94% of the Brazilian energy matrix, corresponding to the
sugarcane bagasse about 82% of that amount (MME, 2015). Still for the same year, the total financial volume for the
bioelectricity trading was estimated at R $ 2.01 billion (Markestrat, 2014).
The use of bagasse in other industrial sectors has received attention from enterprising, since its use as input in
production stages has been shown as an important source of foreign currency. Namely, there has been a substantial growth
in the pulp and paper industries, industrial plastics and also in the production of lignocellulosic ethanol.
Given the above, the implementation of improvements in the performance of a cogeneration plant is presented as a
necessity. Thus, the present work is inserted in this context; in which the use of regeneration aims to achieve greater
efficiency improvements.

2. GENERAL ASPECTS

The plants of the Brazilian sugar and alcohol sector are characterized generally as cogeneration systems with energy
self-sufficiency, since the bagasse is also an input for the production of electrical, mechanical and thermal energy. These
plants operate in its large majority in a steam power system or real Rankine cycle.
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November, 07-10th, 2016, Vitria, ES, Brazil

There is a difference between an ideal and real thermal cycle due to the existence of losses due to heat transfer to the
environment and the irreversibility generated in processes such as compression and expansion in the system. The
efficiency of the thermal cycle dependent fundamentally on average thermodynamic temperature of addition and rejection
of heat. According to Panosso (2003), an increase in the average temperature of heat addition can be achieved through:
superheating the steam, increasing the heat supply pressure, by reheating the steam or using regeneration. In turn, a
reduction in the average temperature of heat rejection is possible by reducing the turbine outlet pressure, however, should
be avoided both efficiency loss and corrosion in the turbine blades as a result of a reduction in steam quality in the last
stages of the turbine.
The concept of average thermodynamic temperature is critical during this type of analysis. For a reversible process
between two states, the average thermodynamics temperature is given by the quotient between the amounts of heat divided
by the entropy change (Souza, 1980)
The regeneration technique consists in raise the temperature of the steam generator feed-water to thereby increase the
average temperature of addition of heat in the cycle. Badr et al. (1990) says that the first heating stage in the steam
generator (sensible heat transfer) is a major source of irreversibility of the cycle; which is a consequence of the large
thermal potential between the combustion gases and the water supply. In this scenario, many works were proposed to get
the maximum efficiency using regeneration.
Bejan (1988) and Badr and Probert (1990) proposes that the regenerators are equally spaced so as to saturate the gain
energy between the condenser outlet and the steam generator. Bejan (1988) makes an approach as a function of enthalpy
and disregarding the pumping power. Badr (1990) indicates that the gain at each temperature regenerator should be equal
and establish a relationship which limits the possible generation throughout the boiler feedline. The optimal temperature
difference is obtained, having as limits the saturation temperature of the steam generator pressure and the saturation
temperature of the condenser operating pressure.

= (1)
+1

where and corresponding to the saturation temperature at the operating pressure of the steam generator
and condenser, respectively and n is the number of regenerators.

The application of the regeneration is intrinsically dependent on the positioning of the regenerators and configuration
thereof. Since heat exchangers are real (finite area of heat exchange) the choice of parameters that measure the temperature
difference between the input and output streams is required. For a closed regenerator and operating under countercurrent,
there are two parameters that stand out: DCA (Drain Cooler Approach) given as the temperature difference between the
extracted steam and condensate to the feedwater in the regenerator input; and TTD (Terminal Temperature Difference)
given as the difference between the saturation temperature of the extracted steam and the temperature of the feed-water
in the heat exchanger outlet (Suresh et al., 2010). The saturation temperature under the extraction pressure for nth
regenerator can be obtained by Eq. (2); relationship obtained from Eq. (1) consideering the parameterss regenerator, TTD
e DCA.

(2)
= + +

where , , , and TTD are saturation temperature corresponding to the pressure of the nth regenerator
extraction, optimum temperature difference, the saturation temperature of condenser pressure and end temperature
difference, respectively.

The indicators used in this study to measure the performance when applied to cogeneration systems were:
Exergetic efficiency: is the sum of exergy the cogeneration plant products divided by the fuel exergy.

+
=
(3)
where BP is the exergy of the electricity produced (kW), B Q is the exergy of the heat consumed by the process (kW),
and BF exergy fuel (kW).

Bagasse surplus: The availability of bagasse considers the fiber content, initial system biomass and mass crushed of
cane.

=
(4)
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November 07-10th, 2016, Vitria, ES, Brazil

where available is the amount of bagasse available for use in the cogeneration system and consumed is the amount of
bagasse consumed in the steam generator.

3. CASES OF STUDY

The studies were conducted for two groups, and the difference between them is in the form of use of bagasse. For
Group I, whose power was set at 50 MW, was obtained surplus bagasse, while Group II uses all bagasse for steam
generation in to achieve greater overall efficiency and power output. The concepts of the first and second laws of
thermodynamics allow the measurement of the two indicators used: exergetic efficiency and surplus bagasse.

Group I Basis I
Fixed Power
Regeneratives I- A1,2,3,...,8
Group II Basis II
Fixed Bagasse Consumption
Regeneratives II- B1,2,3,...,8
Figure 1. Structure of the groups.

The power of the Group I was determined considering that 85% of Brazilian mills have a smaller capacity than 55
MW (ANEEL, 2015), with steam parameters of 65 bar and 480 C. Bagasse consumption for Group II was adopted
considering the percentage of biomass for system startup and operational capacity of the plants. Table 1 shows the
parameters adopted and Fig. 2 and Fig. 3 shows the configuration used in the simulations.

high pressure low pressure 20

Gen.
turbine turbine

boiler
7
5 6

13 desuperheater
1 18
condenser
14 19

makeup
12

16 process

8
pump

15
17
pump 11 aerator
10
9 pump

Figure 2. Conventional cogeneration system

The methodology proposed by Badr et al. (1990) was applied to position the regenerators in the simulations and
measure the behavior of the plant. As an example, the regenerative layout is shown in Fig. 3. However, this proposal does
not apply to a cogeneration plant of sugar and alcohol sector, since it can be observed of Basis scenarios I and II which
83% and 80% of the vapor flow generated, respectively, feeds the process, and does not flow to the condenser. This fact,
in agreement the above proposition, makes it more plausible to establish as the numerator of Eq. 1 the range of the
saturation temperature under return process pressure and steam generator feedwater temperature. The aerator present in
the layouts of Fig. 2 and Fig. 3 is a regenerator of the open type and also play a security role to the system through the
elimination of non-condensable gases. Once it pressure is fixed by the same operating pressure of the process, it confirms
the consideration of the analyzed temperature range.
The usual number of extractions is 5 to 7 (NAG, 2008), however it was opted eight to allow a greater impact
comparison between the first and last regenerators. The model employed is closed, operating on counter current and drains
cascading to back; the main parameters considered for the regenerators designs are the TTD and DCA, Tab. 1.
Through GateCycle parameters and mentioned considerations were applied to obtain the evaluation indicators of
the cogeneration plant.
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November, 07-10th, 2016, Vitria, ES, Brazil

boiler high pressure low pressure 30

Ger
1
turbine turbine

Regenerator
14 3
n

15 13
4

Regenerator
16
3

17
12
23 desuperheater
26
Regenerator
18 condenser
2
24 27
19
11 Makeup
22
Regenerator 28 process
20
1
21 6
pump

10 25
29

pump 9 Desareador
8
7 pump

Figure 3. Cogeneration system with multiple regenerators

The main parameters considered in the simulations are summarized in Tab. 1.

Table 1. Main common operating parameters to Groups I and II

Air atmospheric temperature 25C
Atmospheric pressure 1 bar
Condensing pressure (CGEE, 2009) 0.12 bar
Bagasse moisture (Camargo et al. 1990) 50%
Sugarcane fiber content (CGEE, 2009) 14%
Bagasse LHV (CGEE, 2009) 7524 kJ/kg
Bagasse exergy (REN, 2011) 9842 kJ/kg
Boiler thermal efficiency (CGEE, 2009) 85%
Steam turbines isentropic efficiency (Alves, 2011) 84%
Pump isentropic efficiency (CGEE, 2009) 65%
Electric generator efficiency (Souza, 2013) 95%
Biomass for system startup (CGEE, 2009) 10%
Plant operation Days (CGEE, 2009) 167
Mills capacity (Souza, 2013) 500 t/h
Power demand of electric drives of mills (CGEE, 2009) 16 kWh/t
TTD (BADR et al., 1990) 4C
DCA (SURESH, 2010) 5C
Process electric power consumption (CGEE, 2009) 18 kWh/t
Process steam consumption (BNDES; CGEE, 2008),
450 kg/t
(HASSUANI et a., 2005)
Process steam pressure (CGEE, 2009) 2.5 bar
Return temperature of the process (CGEE, 2009) 79C
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November 07-10th, 2016, Vitria, ES, Brazil

4. RESULTS AND DISCUSSION

The results for groups I and II are shown in Tab. 2 and 3, where bag, vap, Pel, Tce, Pext., (T)ot., TAli, exe correspond
to bagasse used in boilers, steam generated, electric power, temperature saturation extraction, extraction pressure, optimal
temperature difference, temperature of the steam generator feed water and exergetic efficiency, respectively.

Table 2. Parameters for scenarios A1,2,3,;8 and B1,2,3,; 8 - Groups I and II

Regenerator (T)ot. (C) Order Tce (C) Pext.(bar)

1 76.75 1 208.15 18.37
1 182.57 10.63
2 51.17
2 233.73 29.91
1 169.78 7.88
3 38.38 2 208.15 18.37
3 246.53 37.45

1 148.46 4.56
2 165.51 7.10
3 182.57 10.63
4 199.62 15.42
8 17.06
5 216.68 21.74
6 233.73 29.91
7 250.79 40.26
8 267.84 53.15

Table 3. Main Results Achieved for simulations of Regenerative Cycle for Groups I and II

Power Fixed for 50 MW (65 bar and 480 C) - Group I

Scenarios Basis I A1 A2 A3 A4 A5 A6 A7 A8
Reg. - 1 2 3 4 5 6 7 8
bag. (kg/s) 33.87 32.40 32.04 31.85 31.73 31.66 31.60 31.56 31.53
vap. (kg/s) 75.59 83.03 86.11 87.84 88.92 89.69 90.24 90.68 91.01
TAli. (C) 118.79 204.12 229.67 242.46 250.14 255.24 258.89 261.63 263.76
Pel. (MW) 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00
exe 26.26 27.44 27.76 27.92 28.02 28.09 28.14 28.17 28.21
Bagasse consumption fixed to 35 kg / s (65 bar and 480 C) - Group II
Scenarios Basis II B1 B2 B3 B4 B5 B6 B7 B8
Reg. - 1 2 3 4 5 6 7 8
bag. (kg/s) 35.00 35.00 35.00 35.00 35.00 35.00 35.00 35.00 35.00
vap. kg/s) 78.11 89.68 94.08 96.52 98.07 99.15 99.95 100.56 101.04
TAli. (C) 118.79 204.12 229.67 242.46 250.14 255.24 258.89 261.63 263.76
Pel. (MW) 52.41 55.75 56.63 57.09 57.38 57.57 57.71 57.81 57.90
exe 26.10 27.07 27.33 27.46 27.55 27.60 27.64 27.67 27.70
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November, 07-10th, 2016, Vitria, ES, Brazil

4.1 Exegertic efficiency and Increase on Efficiency for Regenerative scenarios in Groups I and II.

The graphs of exergetic efficiency and it increase show that increasing the number of regenerators is reduced the
irreversibility level in the system, since it raises the average temperature of heat addition (Badr et al., 1990). Something
worth noting in Fig. 5 is the impact of the first regenerator; they operate a larger addition of heat to the feed water, obeying
the ratio proposed in Eq. (1) and considerations of the case study.

29
Exergetic Efficiency (%)

28

27
Regeneratives I
26
Regeneratives II

25 Basis I

Basis II
24
1 2 3 4 5 6 7 8
Regenerators
Figure 4. Variation of exegertic efficiency for regenerative scenarios in Groups I and II.

Regeneratives I - Group I Regeneratives II - Group II

5,0 4,0
Increase in Exergetic Efficiency

4,0
3,0

3,0
2,0
(%)

2,0
1,0
1,0

0,0 0,0
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Regenerators Regenerators
Figure 5. Variation of increasing efficiency for regenerative scenarios in Groups I and II.

The temperature in both groups start at 42% of saturation at a pressure of 65 bar and after adding one (1) regenerator
to the regenerating cycle, already reach 73% of this same parameter. Five (5) regenerators reach 91%, remembering that
the maximum value of eight (8) regenerators is 94% of the saturation temperature of the boiler feed. According Badr et
al. (1990), the reduction of this heat-sensitive amount to be added to the working fluid at the beginning of the generation
causes noticeably reduce on the level of irreversibility in the system.
Note that setting a net power at a predetermined value, makes that the exergetic efficiency has higher growth relative
to the bagasse fixed consumption situation. These differences reflect the assumptions imposed in the case study. It is
noted that there was a growth of 20% and 29% in steam generation for Groups I and II, respectively. Group I hold a less
increase of this parameter, since the efficiency increments translate into reduced energy demand. Group II is configured
to consume a bagasse constant rate and this fact causes the increases in efficiencies from becoming a generation of steam;
increasing the flow it is invariably accompanied by an increase of the irreversibilities associated with the flow of the
working fluid.
The Fig. 5 shows that with respect to the base case (Basis I) the Regenerative A1 allows to obtain an increase of 4.52
% in the exergetic efficiency when one regenerator is added, for two regenerators (Regenerative A2) this increase is
1.14%. When four or more regenerators are added to cycle (Regenerative A4,5,6,7,8) the efficiency gains are negligible (~
0.37%). For the Basis II, the results show that when one regenerator is added (Regenerative B 1) the increase in the
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November 07-10th, 2016, Vitria, ES, Brazil

efficiency is 3.72%, after the four regenerator (Regenerative B 4) the gains are negligible, less than 0.31%. This occurs
because the boiler feed water temperature approaches to its saturation temperature.

4.2 Expected differences between Group I and II: Bagasse surplus and Electric Power Generated

The case study was divided into two distinct groups aimed, in addition to optimizing the improvement scenarios, the
ability to assess in what ways the increase in efficiency would manifest. The first group took over the horizon to expand
the surplus bagasse which currently already has a certain value and does not apply exclusively as fuel. The second takes
the most common scenario in which it aims to consume all the available bagasse to generate larger electric surplus to be
sold.
10
9
8
Surplus Bagasse (%)

7
6
5
4
3 Regeneratives I

2 Basis I
1
1 2 3 4 5 6 7 8
Regenerators
Figure 6. Variation of surplus bagasse for regenerative scenarios of Group I.

58
57
Electric Power ( MW)

56
55
54
53
52 Regeneratives II

51
Basis II
50
1 2 3 4 5 6 7 8
Regenerators
Figure 7: Variation in net power output for regenerative scenarios of Group II

The charts above clearly expose differences between groups and lead to a different assessment of the impacts
generated by regeneration in improvement scenarios. The electrical power for the behavior outlined for the Group II and
the surplus bagasse for Group I reflect only the exergetic efficiency profiles treated in section 4.3.1.2 of this same work.
The values of bagasse consumption evolved from 33.87 kg / s (Basis I) to 31.53 kg / s on the A8, which represented an
increase in the surplus bagasse of 6.92% for the Group I. Power electric started from 52.41 MW (Basis II) and came to
57.90 MW in B8, which mean an increase of 10.48%. The impact of the first regenerator is more evident, which has also
been detailed in previous section, such that A5 and B5 have scenarios 94.22% and 93.99% of the effect generated eight
regenerators for Groups I and II respectively.

5. CONCLUSION

Considering the trend of increasing the bagasse value and the interconnection of the energy matrix that allows the sale
of surplus, this work justified as a meaningful assessment to the sugar-alcohol sector.
It was clear that the inclusion of regeneration in plants of this sector is favorable, since it peaked at 6.92% surplus
bagasse for Group I and, similarly, an increase of 10.48% in the electrical power to the group II. These results are
configured as parameters for the regeneration feasibility analysis; now bagasse, now the sale of surplus electrical and
increase the revenue.
Proceedings of ENCIT 2016 16th Brazilian Congress of Thermal Sciences and Engineering
Copyright 2012 by ABCM November, 07-10th, 2016, Vitria, ES, Brazil

It is worth noting the impact generated by the first regenerators was superior, making it necessary an economic
evaluation to determine an optimal number. Finally, there was obtained an increase in the exergetic efficiency of 7.27%
for the first group and 6.00% for the second group.

6. ACKNOWLEDGMENTS

For economic funding, the Foundation for Research of the State of Minas Gerais - FAPEMIG, National Council for
Scientific and Technological Development - CNPq and the higher level of personal development coordination - CAPES.

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8. RESPONSIBILITY NOTICE

The authors are the only responsible for the printed material included in this paper.