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Kasabonika Cogeneration Project
Group 1
1. Nay Min Lwin (8823904)
2. Carlos Salazar (8853222)
3. Shaik, Shamveel
4. Cherukuri, Sai
5. Bhandari, Divyang Roopsingh
6. Chauhan, Jainishkumar Vijaybhai
7. Jetly, Virat
8. Verma, Karan
9. Prajapati, Yash Rakeshkumar
10. Vasani, Madhav
11. Christie, Marlon
12. Raniya, Aftab Ajit
13. Patel, Mohammadakram
14. Patel, Neel Mauleshbhai
15. Rohit, Niyati Ishvarbhai
Applied Energy Management- Renewable Energy, Conestoga College
ERGY8005: Cogeneration
Professor: Jim Smith
August 09, 2023
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Table of Contents
1. Introduction …………………………………………………………………………...3
2. What is cogeneration?........................................................................................3
3. Community Details..............................................................................................4
4. Electricity Needs..................................................................................................6
5. Generator Consideration ....................................................................................8
6. Fuel Source.........................................................................................................8
7. Electricity generation...........................................................................................8
8. Equipment Description.......................................................................................11
9. Heat Recovery and Distribution……………………………………...……………..14
10. System Operation..............................................................................................17
11. Cost Estimation.................................................................................................18
12. Operations and Maintenance (O&M) Costs.......................................................18
13. Environmental Impact........................................................................................19
14. Conclusion.........................................................................................................19
15. References........................................................................................................20
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1. Introduction
There are many Remote Communities in Canada that are not connected to the
grid and depend on local generators for electrical energy supply. These communities'
main electrical energy source is diesel generators due to their reliability, and no natural
pipelines are available for the gas turbine generator option. Fuel transportation is winter
road or by air because most of these communities have no road access. This project is
the Conceptual Cogeneration System design overview aimed at community
development in Kasabonika, Ontario, Canada. This project endeavours to address the
pressing need for sustainable energy solutions by creating a cogeneration system that
seamlessly integrates the community's electricity, heating, and cooling requirements.
This project aims to design a robust system that meets the community's energy needs
and minimizes environmental impact. This project will outline the technical aspects of
the cogeneration system, from the flow sheet layout to equipment specifications.
Additionally, the report will delve into the operational strategies for different seasons,
ensuring the system's adaptability to varying climatic conditions.
2. What is cogeneration?
Cogeneration, also known as Combined Heat and Power (CHP), is a highly
efficient energy generation process that produces both electricity and usable heat from
a single fuel source. This approach maximizes energy efficiency by capturing and
utilizing the heat that is typically wasted in traditional power generation. Cogeneration
systems are often used in various industries and communities to meet their electricity,
heating, and sometimes cooling needs while reducing overall energy consumption and
greenhouse gas emissions.
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Figure 1: Efficiency in the Cogeneration System
Note: (From RETScreen)
3. Community Details
Kasabonika Lake First Nation is an important community within the Oji-Cree First
Nations band, located in a remote and northern part of Ontario, Canada. Below are
some key details about Kasabonika Lake First Nation:

Community: Kasabonika Lake First Nation

Location: It is located about 570 kilometers directly north of Thunder Bay, Ontario

Land base: The First Nation's land base is approximately 10,806.5 hectares

Population: The community has a population of 1000 people

Number of households: 230

Transportation: No road access, transportation rely on winter road or by air
(Northern Policy Institute - Living Off-the-Grid in Northern Ontario, n.d.),
(Native Ministries International, 2020)
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Figure 2: Location of Kasabonika Lake First Nation
Note: (From Google map)
Figure 3: Kasabonika Lake First Nation
Note: (From Google map)
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4. Electricity Needs
Calculating the electricity needs of an off-grid community involves considering
various factors such as population size, energy consumption patterns, and the types of
appliances and facilities present. This can vary widely based on factors like lifestyle,
climate, and local industry. Generally, the estimated total Annual Electricity
Consumption can be calculated as follows:
Daily Energy Usage per household (kWh) = Total Power consumption per household
(kW) × Daily Usage (hours)
Total Annual Electricity Consumption (kWh) = Daily Energy Usage (kWh) × Days in a
year (365 days)
The most important data that need to consider for electricity demand are climate
data and peak load data. Based on that data, the generator size can be decided. The
climate data generated by RETScreen is below in Figure 4. Based on the historical data
analysis for Kasabonika Lake First Nation electricity demand, the electricity needs will
be estimated as below:

Summer electricity needs: 175 kW (minimum)

Winter electricity need: 879 kW (maximum)

Estimated annual energy consumption 4,200,000 kWh (assume each person
consumes 4,200 kWh annually)
(David Curtis. NORTHERN MICRO-GRID PROJECT. (n.d))
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Figure 4: Kasabonika Lake First Nation Climate data
Note: (From RETScreen)
Figure 5: Kasabonika Lake First Nation Electricity Annual Load
Note: David Curtis. NORTHERN MICRO-GRID PROJECT. (n.d)
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5. Generator Consideration
The community has no grid transmission line; thus electrical power supply is
solely dependent on a diesel generator station (DGS). The project will consist of three
diesel engines with generators, each with 600 Volt AC and 60 Hz frequency. This
system is known as genset. Kasabonika’s electricity demand varies throughout the year
due to spring, summer, fall and winter climate. To meet the varying demand throughout
the year and better redundancy, the gensets rated at 400 kW, 600 kW, and 1000 kW
will be considered. The DGS rating is determined by the remaining capacity when the
largest unit is non-operational, resulting in a rating of 1000 kW. Based on power
demand analysis, the highest peak load occurs in winter at 879 kW. And the lowest
peak load in summer is 175 kW. Programmable logic controllers (PLCs) choose the
optimal genset to meet demand and maximize efficiency in the DGS.
6. Fuel Source
The generator system requires a steady diesel fuel supply to continue the
combustion process and generate electricity. The estimated annual fuel required to
meet Kasabonika’s energy demands will be 1,200,000 L. Fuel storage tanks are
typically on-site to ensure an uninterrupted fuel supply. The DGS facility is equipped
with a pair of fuel tanks capacity of 95,000 litres for fuel storage. An adjacent fuel farm
owned by Kasabonika Lake First Nation provides 400,000 L to the DGS. The
transportation of fuel to fill the tanks is facilitated by using winter roads. The additional
fuel needed by the DGS, in addition to what is transported via winter road, is supplied
via air transportation throughout the entire year.
7. Electricity Generation
A diesel generator system generates electricity for the Kasabonika community
through a process that involves converting the energy stored in diesel fuel into electrical
energy. The process involve as below:
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Diesel Combustion: Diesel fuel is injected into the generator's internal combustion
engine. Within the engine, the diesel fuel ignites due to the high temperature generated
by compression. This combustion process releases a significant amount of heat energy.
Mechanical Energy Conversion: The heat energy generated from the combustion of
diesel fuel causes the air inside the engine's cylinders to expand rapidly. This expansion
creates high-pressure gases that drive the engine's pistons in a controlled manner. The
reciprocating motion of the pistons is converted into rotational motion by the crankshaft.
Rotational Motion: The rotational motion of the crankshaft is used to turn the rotor of
an alternator (generator). The alternator consists of coils of wire and a magnetic field.
As the rotor spins, it induces an electric current in the coils through electromagnetic
induction.
Generation of Alternating Current (AC): The electric current generated in the coils is
in the form of alternating current (AC). AC is the standard type of electrical current used
for most power distribution systems.
Voltage Regulation: The generator system includes voltage regulation mechanisms to
ensure that the generated AC voltage remains stable and within acceptable limits.
Distribution: The generated AC electricity is then distributed through power lines to the
community's homes, businesses, and other facilities. Transformers are used to step up
or step down the voltage for efficient distribution and to match the community's power
demand. (Team, 2023)
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Figure 6: The Main Parts of the Diesel Generator
Note: (From: Team, 2023)
Figure 7: The Kasabonika’s electricity distribution system
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8. Equipment Description
Generators
Generator No. 1: 1000 kW Cummins Diesel Generator (600V Three Phase 60Hz)
Technical specifications:

Model: WP-C1000GF

Hz: 60 Hz

Power factor: 0.8 P.F

Standby: 1000 kW

Prime Power: 900 kW

Powered by a top-tier engine, alternator, and control panel

Relay Brand: Top-of-the-line Siemens APT

Micro Brand: LS

Wire Pipes: PA Corrugated pipes

Battery Brand: Camel-DF
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Generator No. 2: 600 kW Cummins Diesel Generator (600V Three Phase 60Hz)
Technical specifications:

Model: ST-C550GF

Voltages: 110 / 220 V (Single Phase), 208 V (Three Phase), 240 / 480 V (Three
Phase), 575 V (Three Phase), 600 V (Three Phase)

Frequency: 60 Hz

Power factor: 0.8 P.F

Standby: 600 kW

Prime power: 550 kW

Powered by a top-tier engine, alternator, and control panel

Relay Brand: Top of the line Siemens APT

Micro Brand: LS

Wire Pipes: PA Corrugated pipes

Battery Brand: Camel-DF
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Generator No. 3: 500 kW Prime Power Volvo Diesel Generator (600V Three Phase
60Hz)
Technical specifications:

Model: ST-V500GF

Hz: 60 Hz

Power factor: 0.8 P.F

Standby: 512 kW

Prime Power: 500 kW

Powered by a top-tier engine, alternator, and control panel

Relay Brand: Top-of-the-line Siemens APT

Micro Brand: LS

Wire Pipes: PA Corrugated pipes

Battery Brand: Camel-DF
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9. Heat Recovery and Distribution
The process of heat recovery from a diesel engine generator for using hot water
in Kasabonika involves several steps to capture the excess heat generated by the
generator and transfer it to a water heating system (Baidya et al., 2019). The process
will involve below:
Heat Exchanger Installation: A heat exchanger of the type of Heat Recovery Silencer
Radial is installed in the exhaust system of the diesel engine generator. This heat
exchanger is designed to efficiently transfer heat from the hot exhaust gases to another
fluid, usually water or a heat transfer fluid. (Hossain, n.d.)
Heat Exchanger Specifications:
Engine Exhaust Application
Capacity: 200kW to 7MW
Entering Gas Temps: 300°F to 1,300°F
Heat Sink Types: engine jacket water, process water, boiler water, or ethylene glycol
Features
-
Full exhaust gas bypass assembly
-
Modulating damper actuator (pneumatic or electric)
-
Sound attenuation
-
Stainless steel interior lining
-
Internal heating surface expansion design
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No joint welds within the heating surface in contact with the exhaust gas
stream
-
10 gauge hard shell seal welded exterior
-
Ease of tube replacement requiring no overhead cranes or special rigging
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Fluid Circulation: A separate closed-loop system is set up, consisting of a pump,
pipes, and the heat exchanger. The fluid, often water mixed with an antifreeze solution,
circulates through the heat exchanger.
Heat Transfer: As the exhaust gases from the generator flow through the heat
exchanger, they transfer their heat to the circulating fluid. This raises the temperature of
the fluid significantly.
Hot Water Storage: The heated fluid is then directed to a hot water storage tank in the
water distribution and hot water storage station. This storage tank holds the heated
water for later use.
Domestic Hot Water System: The hot water from the storage tank is integrated into
the residential hot water system. When residents turn on the hot water taps or use
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appliances that require hot water, the pre-heated water from the storage tank is mixed
with cold water to achieve the desired temperature.
Temperature Control: The system may include controls to ensure that the hot water
temperature is appropriate for domestic use and to prevent overheating.
Backup Heating: In cases where the recovered heat is not sufficient to meet the entire
hot water demand, a conventional water heating system can serve as a backup.
Efficiency and Maintenance: The system should be designed and maintained to
ensure efficient heat transfer and optimal operation. Regular maintenance of the heat
exchanger, fluid circulation system, and controls is essential.
Figure 8: Heat recovery system
Note: From (Yousefi et al., 2017)
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Figure 9: Hot water distribution system
10. System Operation
The three genset operations rated 400 kW, 600 kW and 1000 kW respectively to
meet the varying demand throughout the year (Figure 10). As Kasabonika’s community
power supply solely relies on the genset, power redundancy is important. If the largest
genset (1000 kW) is out of service, the other two gensets (400 kW and 600 kW) can
generate a stable power supply to the community. To get better efficiency, the
programmable logic controller (PLC) is used to control the gensets based on power
demand.
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Figure 10: Kasabonika Lake First Nation electricity demand
Note: Claudio CañizaresDepartment. (2016, October 18)
11. Cost Estimation
Item
Description
Price
1
Generator No. 1: 1000 kW Cummins Diesel Generator (600V Three Phase
60Hz)
$
343,659.00
2
Generator No. 2: 600 kW Cummins Diesel Generator (600V Three Phase
60Hz)
$
206,196.00
3
Generator No. 3: 500 kW Prime Power Volvo Diesel Generator (600V
Three Phase 60Hz)
$
164,957.00
4
Heat Recovery Silencer Radial - HRSR for Generator 1
$
6,780.00
5
Heat Recovery Silencer Radial - HRSR for Generator 2
$
6,780.00
6
Heat Recovery Silencer Radial - HRSR for Generator 3
$
6,780.00
7
Construction (foundations and civil work)
$
35,741.00
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Piping and Electric Wiring
$
22,055.00
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Installation Cost
$
71,482.00
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Commissioning Costs
$
107,222.00
TOTAL INITIAL COSTS
$
971,652.00
12. Operations and Maintenance (O&M) Costs
Item
Description
Price
1
Maintenance Cost per year
$
2
Fuel Costs per year $0.40/KWh
$ 1,680,000.00
TOTAL O&M COSTS PER YEAR
$ 1,700,871.00
20,871.00
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13. Environmental Impact
Diesel engine generators have significant environmental impacts, emitting
pollutants like nitrogen oxides, sulphur dioxide, particulate matter, and greenhouse
gases. These emissions contribute to air pollution, climate change, respiratory issues,
etc. Diesel generators also produce noise, contribute to water, and land pollution, and
rely on finite fossil fuels. The Kasabonika’s community Genset consumed a total of 1.2
million litres of diesel fuel annually, leading to the release of approximately 3,434 tonnes
of CO2 equivalent emissions. (David Curtis. NORTHERN MICRO-GRID PROJECT.
(n.d))
14. Conclusion
In summary, the Conceptual Cogeneration System designed for Kasabonika,
Ontario, represents a significant stride towards sustainable energy solutions for remote
communities. By seamlessly integrating electricity, heating, and cooling needs, this
innovative system not only addresses energy demands but also demonstrates a
commitment to environmental responsibility. Its ability to generate both electricity and
heat from a single fuel source while considering the unique challenges of the
Kasabonika Lake First Nation community showcases its efficiency and adaptability.
Although challenges such as diesel-related environmental impacts persist, the project's
emphasis on heat recovery and collaboration sets a precedent for a more sustainable
energy future, highlighting the potential for responsible energy management in off-grid
communities.
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References

Native Ministries international. (2020, July 11). Default Site.
https://data.nativemi.org/tribal-directory/Details/kasabonika-lake-first-nation-1598773

Claudio CañizaresDepartment. (2016, October 18). Electrical Energy Needs for
Canadian Remote Communities, from
http://gten.ca/downloads/2016/presentations/Energy-needs-for-Canadian-remotecommunities.pdf

Northern Policy Institute - Living Off-the-Grid in Northern Ontario. (n.d.).
https://www.northernpolicy.ca/article/living-offthegrid-in-northern-ontario-1916.asp

David Curtis. NORTHERN MICRO-GRID PROJECT. (n.d)
https://www.osti.gov/etdeweb/servlets/purl/21390264

Hossain, S. N. (n.d.). Waste Heat Recovery From the Exhaust of a Diesel Generator
Using Shell and Tube Heat Exchanger. ASME.
https://asmedigitalcollection.asme.org/IMECE/proceedingsabstract/IMECE2013/56284/V06AT07A080/261561

Baidya, D., De Brito, M. a. R., Sasmito, A. P., Scoble, M. J., & Ghoreishi-Madiseh, S. A.
(2019). Recovering waste heat from diesel generator exhaust; an opportunity for
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combined heat and power generation in remote Canadian mines. Journal of Cleaner
Production, 225, 785–805. https://doi.org/10.1016/j.jclepro.2019.03.340

Yousefi, M., Hooshyar, D., Kim, J. H., Rosen, M. A., & Lim, H. (2017). Optimum waste
heat recovery from diesel engines: Thermo-economic assessment of nanofluid-based
systems using a robust evolutionary approach. Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 233(1), 65–
82. https://doi.org/10.1177/0954408917743373

Team, L. (2023, June 18). Working principle of diesel Generator + Diagram | Linquip.
Industrial Manufacturing Blog | linquip. https://www.linquip.com/blog/workingprinciple-of-diesel-generator/?amp=1