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TRANSCRIPT
SmallScaleCogenera-on
March10,2016
BuildingEnergy2016Presenta5on
Today’sagenda
Cogenera-on/CHPOverview
WhatDoIDoNext?–Study?
TechnologiesAvailabletoMarket
Incen-ves/RebatesandCredits
StateIncen-vesandRenewableAMributes
Resiliency/CaseStudyDiscussion
Introduc-ons
Ques-onsandAnswers
Cogenera-onOverview
u Alsocommonlycalled“combinedheatandpower”(CHP)
u Putsimply,togenerateelectricity(and/ormechanicalenergy)andthermalenergyinasingle,integratedsystemtomaximizetotaloverallefficiency
u Thiscontrastswithcommonprac5ceinthiscountrywhereelectricityisgeneratedatacentralpowerplant,andon-sitehea5ngandcoolingequipmentisusedtomeetnon-electricenergyrequirements
u ThethermalenergyrecoveredinaCHPsystemcanbeusedforhea5ngorcoolingbuildings.BecauseCHPcapturestheheatthatwouldbeotherwiseberejectedintradi5onalseparategenera5onofelectricormechanicalenergy,thetotalefficiencyoftheseintegratedsystemsismuchgreaterthanfromseparatesystems.(Ontheorderof40%-50%moreefficient)
Cogenera-onOverview
u Thethermalenergyoutputfromaprimemover(Microturbine,Reciproca5ngEngine,GasTurbine,FuelCell,Etc.)ismostefficientlyusedifitcanbedelivereddirectlyintoasteamorhotwatersystem.Thisdeliversthehighestoverallsystemefficiencyandresultsinthelargestoverallvalueproposi5ontoendusers
u Thethermaloutputfromthesesystemscanalsobeusedtoprovidecoolingthroughabsorp5onchillers,however,thefinancialbenefitfromthesetypeprojectsoZenarelowerthannon-coolingprojectsduetotheaddedinfrastructurecostsneededonthesetypejobs(i.e.chiller,towers,pumps,etc.unlesstheyalreadyexiston-site)
u ThethermalenergyrecoveryfromCHPprojectsisoneoftheprimarycashflowgeneratorsthatcreatesthevaluetotheowneranddrivesROI
Cogenera-onOverview
70%-85%Efficient30%-35%
Efficient
LineLosses
EfficientTransformer
Losses
Efficient
70%-85%SystemEfficiency
Cogenera-onOverview
FuelInput(Nat.Gas,LFG,DigesterGas)
ExhaustHeat
GenerateSteamasBy-product(HRSG)
PowerOutput
Process(Sterilizers,Laundry,Etc.)
Water/BuildingHeat
BP/LPTurbines
Facility/End-User
Engine
He
at
HotWaterHeatRecoveryforDomes-c,Space,Pooland/orProcessHea-ng
JacketWaterLubeOilIntercooler
Cogenera-onOverview
Use for Thermal Energy Distributed Generation Technologies
I.C. Engine
Double-Effect Absorption Water-Cooled Chiller
Micro-turbine
Solid Oxide Fuel Cell
Commercial Phosphoric Acid Fuel Cell
Single-Effect Absorption Chiller Residential
PEM Fuel Cell
Desiccant Technology
Gas-turbine
180ºF
360ºF
800ºF
600ºF
Heat Recovery Steam Generator, ORC’s
Cogenera-onOverview
Benefits
Ø EnergyandOpera5onalCostSavingsØ ImprovedPowerReliabilityØ AddedHea5ng/CoolingSystemRedundancyØ ControlofCustomer’sU5lityFuture
Ø DesigninFutureSiteExpansionØ SocietalBenefits:ReducedTotalEmissions,
ReducedStressonPowerGrid.Ø BeneficialGrants/Incen5ves
FeaturesØ Generatepoweronsiteatacostthatis
lowerthancanbepurchased
Ø U5lizeexhaustheattoproducesteamforspacehea5ng,processloadsandspacecooling
Ø U5lizehotwaterwasteheatfordomes5chotwater,condensateandspacehea5ng,processloads,absorp5oncooling,etc.
Ø Op5mizethesizeofthesystembymatchingtheelectricandheatprofilesofthefacility
Cogenera-onOverview
Ingeneral,themarketforCHPincludes:Ø Hospitals,NursingHomes
Ø Colleges&Universi5es
Ø WasteWaterTreatmentPlants
Ø Manufacturing
Ø Pharmaceu5cals&ChemicalCompaniesØ Pulp/PaperMills
Ø LargeMixedUseDevelopments(Office&Residen5alMix)
Cogenera-onOverview
Barrierstoentry:Ø EnvironmentalPermijng
Ø U5lityInterconnec5onRequirements
Ø U5lityRateStructure(BackupDemandCharges,Ratchets,etc.)
Ø LackofRebatesandIncen5ves
Ø LackofBenefitforEnvironmentalBenefitsofCHP(REC’s)
Ø Deprecia5onschedulesforCHPInvestmentsVaryDependingonOwnershipandMayNotReflecttheTrueEconomicLifeoftheEquipment
TechnologySummary
Ø Combus5onTurbines–NaturalGas/DieselFuel/LandfillGasØ (IncludingMicroturbines)
Ø Reciproca5ngEngines-NaturalGas/DieselFuel/LandfillGas
Ø FuelCells–Natural/LandfillGas
Ø SteamTurbine/CombinedCyclePlant–BoilerscanoperateonNaturalGas/LandfillGas/Biomass/FuelOil,Coal,WoodChips,etc.
TechnologySummary
Ø Natural/LandfillGas,JetFuel&DieselFuelØ FueltoElectricEfficiencies–21%-40%Ø SizeRange–30kW–100’sofMWØ HighGradeWasteHeatUsedtoMakeSteamThroughHRSGØ TurbinesCanBeRecuperatedandNon-RecuperatedØ HRSGCanbeDuctFiredtoCreateMoreSteamVeryEfficientlyØ HandfulofManufacturerswithLongHistoryØ HighUp5mePercentageØ LongTimeBetweenServiceIntervalsØ MajorOverhaulRequired~5Years
Combus-onTurbines
(RecuperatorPreheatsCompressedAirBeforeCombus5ontoIncreaseElectricalEfficiency)
TechnologySummary
Ø HighPressureGasRequirements(OZenRequireGasCompression)Ø NoiseMustbeConsideredØ EmissionsVariesGreatlyBetweenManufacturers(5ppm–50ppmNOX)Ø PerformanceDegradeswithOutdoorAirTemperatureØ PerformanceDegradeswithCleanlinessofCompressor/TurbineBladesØ OverallNetEfficienciesCanReach>80%
Combus-onTurbines(Con-nued)
TechnologySummary
Combus-onTurbines(Con-nued)–TypicalLayout
Combus5onTurbine HeatRecoverySteamGenerator
ExhaustBypass
EmissionsControl
(CO,NOX)
DuctBurnerDiverterValve
TechnologySummary
Ø AsOATRises,kWOutputDropsandExhaustTemperatureIncreasesCombus-onTurbines(Con-nued)–PerformanceVSOAT
Note:>34%DecreaseinOutputfrom0oFOAT
and100oFOAT
TechnologySummary
Ø AsOATRises,kWOutputDropsandElectricalEfficiencyDecreasesCombus-onTurbines(Con-nued)–PerformanceVSOAT``
TechnologySummary
Ø AsOATRises,kWOutputDropsCombus-onTurbines(Con-nued)-Microturbine
TechnologySummary
Ø Capstone(30kW,60kW,200kWPackages(CanBeCombined–1MW)Ø GE(>25MW–1500MW)Ø KawasakiGasTurbinesAmericas(600kW–18MW)Ø OpraTurbines(1.8MW)Ø PWPowerSystems(30MW–140MW)Ø Siemens(4MW–400MW)Ø SolarTurbines(1.2MW–22MW)–DivisionofCaterpillar
Combus-onTurbines(Con-nued)-Manufacturers
TechnologySummary
Ø TurbineWasteHeatBoilersAreUsedtoCaptureExhaustEnergyfromTurbinestoGenerateSteam(HRSG)orHighTemperatureHotWaterØ RentechØ EnergyRecoveryInterna5onalØ DeltakØ BabcockPowerØ Cain
Combus-onTurbines(Con-nued)
TechnologySummary
Combus-onTurbines(Con-nued)Ø Size/Scaleof4.5MWCHPPlant,30klb/hrHRSG,700TonAbsorber
Bldg.Footprint~2500Sq.Ft.
TechnologySummary
Combus-onTurbines(Con-nued)-Ø Size/Scaleof4.5MWUnit
TurbineSize10’-5”x36’-6”
TechnologySummary
Combus-onTurbines(Con-nued)Ø LubeOilCooler&Combus5onAirInletfor4.5MWUnit
TechnologySummary
Combus-onTurbines(Con-nued)Ø DuctBurner,GasMeterandScannerBlower
TechnologySummary
Combus-onTurbines(Con-nued)Ø Size/Scaleof1.0MWCHPPlant,ChilledWaterandHotWaterHR
• 320TonsofCooling
• Upto3,000
MBHHotWater
TechnologySummary
TriCombus-onTurbines(Con-nued)Ø Size/Scaleof1.0MWCHPPlant 65kWTurbine(typ.)
GasCompressor(typ.)
Absorp5onChiller/Heater(typ.)
ApproximateSize25’x90’
TechnologySummary
Combus-onTurbines(Con-nued)Ø Size/Scaleof1.0MWCHPPlant
TechnologySummary
Combus-onTurbines(Con-nued)Ø MicroturbineOp5ons
TechnologySummary
Combus-onTurbines(Con-nued)Ø MicroturbineOp5onsØ HotWater/SteamVSHW/CHW
MicroturbinetoHRSG
Microturbine(s)toChiller/HotWaterHeater
200kWTurbine(75–80psiginletgaspressure)
TechnologySummary
Ø Natural/Landfill/BioGas&DieselFuelØ FueltoElectricEfficiencies–25%-49%Ø SizeRange(60kW–15MW)Ø HighGradeWasteHeatUsedtoMakeSteamThroughHRSGfromExhaustØ LowGradeWasteHeatfromJacketWater,LubeOilandInter/AZercoolerØ HandfulofManufacturerswithLongHistoryØ GoodUp5mePercentage(>92%)Ø ShorterDura5onBetweenServiceIntervalsØ MaintenanceDaily/Weekly/MonthlyØ MajorOverhaulsDependonEngineSpeed
(720,900,1200,1800RPM)
Reciproca-ngEngines
TechnologySummary
Ø LowPressureGasRequirementsØ QuickIni5alStartuptoFullLoadØ Noise/Vibra5onMustbeConsideredØ EmissionsVariesGreatlyBetweenManufacturersØ LeanBurnVersusRichBurnOp5onsDependingonApplica5onØ PerformanceDoesNotDegradewithOutdoorAirTemperatureØ OverallNetEfficienciesCanReach>80%IfaHomeCanBeFoundforLow
GradeHeat(HotWater)
Reciproca-ngEngines(Con-nued)
TechnologySummary
Ø Aegis(75kW)Ø Caterpillar(85kW–4MW)Ø Cummins(300kW–2MW)Ø Gauscor(150kW–900kW)Ø Jenbacher(250kW–9.5MW)Ø Kawasaki(5MW–7.5MW)Ø MAN(68kW–580kW)Ø Schmit(100kW–500kW)Ø Tecogen(65kW–100kW)
Reciproca-ngEngines(Con-nued)
Note:SmallerEnginesTypicallyAreUsedOnlytoHeatHotWaterandNottoProvideSteam
TechnologySummary
ExampleofReciproca5ngEngineMaintenanceAc5vi5es
Ø CheckOilLevel/Pressure(Daily)Ø CheckBateryAcidLevels(Monthly)Ø GreasingofGeneratorBearings(Every1,000Hours)Ø SparkPlugReplacement(1,400Hourson1800RPMEngine,4,000HoursonSlowerSpeedEngines)Ø CheckValveClearance(Every2,000Hours)Ø Oil/OilFilterReplacement(Every2,000Hours)Ø CheckAirFilters,VerifyIgni5onTiming(~4,000Hours)Ø Recondi5onCylinderHeads,ChangeHighVoltageWires(~8,000hours)Ø ReplacementofGeneratorBearings,Pistons,CylinderLinings(20,000Hours)Ø TurboReplacement/Refurbishment,ChangeConnec5ngRods(~20,000hours)Ø EngineOverhaulIncludingCylinderBlock,CrankshaZ,CamshaZ(48,000-60,000hours)
Reciproca-ngEngines(Con-nued)
TechnologySummary
SimplifiedSystemSchema-c
650kWEngine
FuelIn
ExhaustOut~750oF
ExhaustToAtmosphere~325oF
850lb/hr125psigsteam
200oFHotWater
180oFHotWater
1,800MBHHotWaterToHostSite
WasteHeatRadiator
120oF125MBHIntercoolerHotWater
TechnologySummary
Reciproca-ngEngines(Con-nued)Ø Size/Scaleof670kWCHPPlant,840lb/hrHRSG,1,747MBHHW
TechnologySummary
Reciproca-ngEngines(Con-nued)Ø Size/Scaleof3,000kWCHPPlant,4,150lb/hrHRSG,4,416MBHHW
TechnologySummary
Reciproca-ngEngines(Con-nued)Ø Size/Scaleof3,000kWCHPPlant,4,150lb/hrHRSG,4,416MBHHW
TechnologySummary
Ø Natural/BioGasØ ElectrochemicalProcess(NoCombus5on)Ø MoltenCarbonate,PhosphoricAcid,SolidOxideØ FueltoElectricEfficiencies–40%-47%Ø SizeRange(400kW–Mul5MWViaParallelingUnits)Ø SmallScaleUnitsHeatCanProvideBoth200oFand120oFHotWaterØ LargerUnits(<1.4MW)ProduceSteamasWellas200oFand120oFWaterØ LimitedofManufacturers(Bloom,Doosan,FCE)Ø HighQualityPower(DCtoACConversion)Ø GoodUp5mePercentage(>92%)Ø ReducedOutputwithServiceLife
FuelCells
TechnologySummary
Ø ClassIRenewable–AssistswithRebates/Incen5vesandRenewable/AlternateEnergyCredits(highercredit/mWh)
Ø FederalTaxCredits(30%InvestmentTaxCredit)Ø VirtuallyEmissionsFreeØ LimitedWaterUsageRequiredØ HighMaterialCostsØ GasMustbeCleanedtoMeetCertainSpecifica5onsifBiogasisUsed.
ThisCanGetExpensiveØ HighMaintenanceCosts–StackLife~5YearsDuringWhichTime
ElectricalOutputDegradesandHeatOutputIncreases(10%Degrada5on)Ø TypicallyMoreExpensiveThanOtherTechnologies(UseIncen5ves/
Rebates,REC’stoHelpBringCostIn-LineWithOtherOfferings)
FuelCells
TechnologySummary
DoosanFuelCellExample–400kW
400kWtoHostSite42%ElectricalEff.
640,000BTU/HR(Upto250oF)
3,515SCFH
880,000BTU/HR(Upto140oF)
65dBA@10meters
TechnologySummary
FuelCellEnergyExample–2.800MW
2800kWtoHostSite47%ElectricalEff.(LHV)FuelIn10,860
SCFH(LHV)15–20psig
4,433,000BTU/H@250oF7,460,000BTU/HR@120oF
72dBA@10feet
ApproximateFootprint–44’Wx70’Wx26’H
~700oFExhausttoHRSG(~3,000lb/hr)
9GPMWatertoPackage4.5GPMWatertoDrain
WhatDoIDoNext?
Ø Thefirststepistypicallytoundertakeafeasibilitystudy.Thesestudiesareperformedbyqualifiedengineeringteamswithyearsofexperienceinthedesign,construc5onandopera5onofCHPplants
Ø Thesestudiestypicallyinclude:Ø SiteSurveyofExis5ngSystemsandEquipment(FuelType,HW,Steam,CHWLoads,etc.)Ø ReviewofExis5ngElectricalandFuelDeliveryInfrastructure(GasPressure,FuelOilTanks)Ø DetailedInterviewswithOpera5onsStafftoUnderstandExis5ngSystemOpera5onsØ DetailedReviewofU5lityData(Tariffs,IntervalData,Chiller/BoilerLogs)
Ø Iden5fyHourtoHour,DaytoNightandWeekdaytoWeekendChangesinLoad
Ø ReviewofExis5ngAirPermijngØ ReviewofPlanningandZoningRequirements(Si5ng,Acous5cs,etc)Ø DiscussionsRegardingMasterPlanning(FutureSiteNeeds)Ø Reliability/RedundancyRequirementsØ Opera5onalRequirementsofNewSystem(GridParallel,IslandMode–ExtendedOutage)Ø Inves5ga5onIntoIncen5ves/RebatesandREC’s/AEC’sØ DiscussionsWithU5lityCompanyRegardingHighLevelInterconnec5onConcepts
WhatDoIDoNext?
Ø Thesestudiestypicallyinclude:Ø DevelopmentofAlterna5vesandDetailedScenarioModeling–DifferentPrimemoversØ ReviewWithDecisionMakersandTuneConceptsØ Crea5onConceptualDrawingsØ DevelopmentofProbableCostEs5matesFromPreviousProjectWork,MajorEquipment
CostEs5matesandByWorkingWithContractorsExperiencedinCHPInstalla5onsØ ReviewFinancing/Construc5onAlterna5veswithCustomerØ DevelopmentofFinancialModelsBasedonCustomerFeedbackforU5lityRates
(Exis5ngCommodityContracts,Escala5onRatesAssumed,etc),SiteGrowthEs5matesandFinancingOp5onsChosen
Ø ModelingAlsoIncludesRebates/Incen5ves,REC’s,ProbableEs5matesofCost,U5lityCostSavings,MaintenanceCosts,Construc5onInterest,etc.
Ø IllustrateSensi5vityAnalysisBasedonKeyVariablesØ DiscussNextSteps(Schema5c/DesignDevelopmentPackagetoVerifyPricing)
FeasibilityStudy(Con-nued)
WhatDoIDoNext?
FeasibilityStudy(Con-nued)–DataExample
WhatDoIDoNext?
FeasibilityStudy(Con-nued)–Rebates/Incen-vesØ DSIREWebsite:WWW.DSIREUSA.ORG
WhatDoIDoNext?
FeasibilityStudy(Con-nued)–Rebates/Incen-vesØ MassSave:Between$750/kWand$1200perKwDependingonCapacity&Efficiencyhtp://www.masssave.com/business/eligible-equipment/combined-heat-and-power
Ø Maine–upto$1Mperprojecthtp://www.efficiencymaine.com/opportuni5es/program-opportunity-no5ce/Ø NewYork–NYSERDA–upto$2.5Mperprojecthtp://www.nyserda.ny.gov/All-Programs/Programs/Combined-Heat-and-Power-Program.aspx
Ø Connec5cut–upto$450/kWplusfinancingop5onshtp://www.energizect.com/your-business/solu5ons-list/Combined-Heat-Power
WhatDoIDoNext?
Ø DesignShouldBeBasedonFailureAnalysisØ EmergencyRentals–Con5ngency–CHPisanEconomicEnginebut
DependingOnSite/Process,RentalsorBackupDieselGensetsMaybeAppropriate
Ø Availability&EfficiencyGuaranteesØ EquipmentwithLocalSupportandTrackRecordØ ServiceAgreementsandCri5calOn-SiteSparesØ HireOperatorswithExperienceOpera5ngHighAvailabilityPlants
FeasibilityStudy(Con-nued)–OtherImportantItemstoConsider
EBDHistory/BackgroundofCHPProjects
Par-alListofEBDProjects
Customer SystemDescrip-onDanburyHospital 4.5MWGasTurbine
SikorskyAircraZ 10MWGasTurbine
Prat&Whitney 7.5MWGasTurbine
FairfieldUniversity 4.5MWGasTurbine
DataCenter 1MWMicroTurbine
NorwalkHospital 3MWReciproca5ngEngine
WesleyanUniversity 650kWReciproca5ngEngine
IndustrialFacilityinRhodeIsland 5MW&7.5MWReciproca5ngEngines
IndustrialFacilityinFlorida 22.5MWGasTurbine
Q&A