chp for emission control
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CHP for Emission Control. In Partnership with the US DOE. Governors’ Ethanol Coalition Meeting June 22, 2004 Madison Wisconsin. Presented By: John J. Cuttica Midwest CHP Application Center www. CHPCenterMW .org. Presentation Outline. FEW Breakout Sessions Why CHP IN Ethanol Plants - PowerPoint PPT PresentationTRANSCRIPT
Presented By: John J. Cuttica Midwest CHP Application Center
www.CHPCenterMW.org
Presented By: John J. Cuttica Midwest CHP Application Center
www.CHPCenterMW.org
CHP for Emission Control
CHP for Emission Control
Governors’ Ethanol Coalition MeetingJune 22, 2004
Madison Wisconsin
Governors’ Ethanol Coalition MeetingJune 22, 2004
Madison Wisconsin
In Partnership with the US DOE
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UIC
In Partnership with the US DOE
Presentation Outline Presentation Outline • FEW Breakout Sessions
• Why CHP IN Ethanol Plants
• CHP, The Concept
• CHP, The Business Case
• CHP For Emission Control
• Further Assistance
• FEW Breakout Sessions
• Why CHP IN Ethanol Plants
• CHP, The Concept
• CHP, The Business Case
• CHP For Emission Control
• Further Assistance
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UIC
In Partnership with the US DOE
FEW Breakout SessionsFEW Breakout Sessions• Cogeneration (1): Thursday 8:30 to 10:00am
– 4 papers being presented
• Cogeneration (2): Thursday 10:15 to 11:45 am
– Panel Discussion
» US Energy Partners - Russell, Kansas Plant
» Adkins Energy – Lena, Illinois Plant
» Northeast Missouri Grain – City of Macon Missouri
» EME Engineering Company
» US Environmental Protection Agency
• Cogeneration (1): Thursday 8:30 to 10:00am– 4 papers being presented
• Cogeneration (2): Thursday 10:15 to 11:45 am
– Panel Discussion
» US Energy Partners - Russell, Kansas Plant
» Adkins Energy – Lena, Illinois Plant
» Northeast Missouri Grain – City of Macon Missouri
» EME Engineering Company
» US Environmental Protection Agency
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UIC
In Partnership with the US DOE
Why CHP Is a Good FitWhy CHP Is a Good Fit
• Energy Is The Second Largest Cost Of Production for Dry Mill Ethanol Plants
• Electric And Steam Demands Are Large And Coincident
• Electric And Steam Profiles Are Relatively Flat
• Both Thermal And Electric Reliability Are Very Important
• Energy Is The Second Largest Cost Of Production for Dry Mill Ethanol Plants
• Electric And Steam Demands Are Large And Coincident
• Electric And Steam Profiles Are Relatively Flat
• Both Thermal And Electric Reliability Are Very Important
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UIC
In Partnership with the US DOE
Why CHP Is a Good FitWhy CHP Is a Good Fit
• Operating Hours Are Continuous – 24/7
• Ability To Utilize Fuels Other Than Natural Gas
• $aves Energy And Reduces Energy Costs
• Hedge Against Unstable Energy Prices
• Potential for Emissions Control (VOC Destruction)
• Operating Hours Are Continuous – 24/7
• Ability To Utilize Fuels Other Than Natural Gas
• $aves Energy And Reduces Energy Costs
• Hedge Against Unstable Energy Prices
• Potential for Emissions Control (VOC Destruction)
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UIC
In Partnership with the US DOE
What is CHP?What is CHP?• Integrated Energy Supply System
• Located At or Near a Building or Facility
• Provides All or a Portion of the Electrical Load
• Utilizes the Thermal Energy– Process Heat– Heating– Cooling– Drying
• Integrated Energy Supply System
• Located At or Near a Building or Facility
• Provides All or a Portion of the Electrical Load
• Utilizes the Thermal Energy– Process Heat– Heating– Cooling– Drying
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UIC
In Partnership with the US DOE
Benefits Of CHPBenefits Of CHPHigh Efficiency, On-Site Generation Means …High Efficiency, On-Site Generation Means …
•CompetitivenessCompetitiveness•Lower Energy CostsLower Energy Costs•Better ReliabilityBetter Reliability•Better Power QualityBetter Power Quality
•EnvironmentalEnvironmental•Lower Emissions Lower Emissions (including CO(including CO22 ) )•Conserve Natural Conserve Natural ResourcesResources
•CompetitivenessCompetitiveness•Lower Energy CostsLower Energy Costs•Better ReliabilityBetter Reliability•Better Power QualityBetter Power Quality
•EnvironmentalEnvironmental•Lower Emissions Lower Emissions (including CO(including CO22 ) )•Conserve Natural Conserve Natural ResourcesResources
• SynergiesSynergies• Potential Generation AssetPotential Generation Asset• Especially Municipal/Co-opsEspecially Municipal/Co-ops
• Support Grid InfrastructureSupport Grid Infrastructure–Fewer T&D ConstraintsFewer T&D Constraints–Defer Costly Grid UpgradesDefer Costly Grid Upgrades
• Facilitates Deployment of Facilitates Deployment of New Clean Energy New Clean Energy TechnologiesTechnologies
• SynergiesSynergies• Potential Generation AssetPotential Generation Asset• Especially Municipal/Co-opsEspecially Municipal/Co-ops
• Support Grid InfrastructureSupport Grid Infrastructure–Fewer T&D ConstraintsFewer T&D Constraints–Defer Costly Grid UpgradesDefer Costly Grid Upgrades
• Facilitates Deployment of Facilitates Deployment of New Clean Energy New Clean Energy TechnologiesTechnologies
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UIC
In Partnership with the US DOE
Gas Turbine CHPGas Turbine CHP
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UIC
In Partnership with the US DOE
Gas Turbine/Supplemental Firing CHP
Gas Turbine/Supplemental Firing CHP
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UIC
In Partnership with the US DOE
Boiler/Steam Turbine CHPBoiler/Steam Turbine CHP
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UIC
In Partnership with the US DOE
CHP System Cost and PerformanceCHP System Cost and PerformanceGas Turbine Gas Turbine
w/Duct FiringBoiler/Steam
Turbine
Capacity, MW 1 - 15 1 - 15 0.5 - 5
Electrical Efficiency, % (HHV) 22 – 32 12 - 17 6 - 10
Steam Output, Btu/kWh 4,500 – 6,700 12,000 – 20,000 35,000 – 40,000
Overall Efficiency, % (HHV) 65 - 70 80 - 85 75 - 85
Power to Steam Ratio 0.4 – 0.6 0.17 – 0.27 0.08 – 0.12
Installed Costs, $/kW 1,800 - 900 2,000 – 1,000 350 – 900*
Non-fuel O&M Costs, $/kWh 0.006 – 0.01 0.006 – 0.01 <0.004
* Incremental costs of steam turbine generator and supporting systems only
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UIC
In Partnership with the US DOE
CHP TechnologiesCHP Technologies
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UIC
In Partnership with the US DOE
–Gas TurbinesGas Turbines–Gas TurbinesGas Turbines
Reliable CHP TechnologiesReliable CHP Technologies
• Electric Generation Equipment• Electric Generation Equipment
–Reciprocating Reciprocating EnginesEngines
–Reciprocating Reciprocating EnginesEngines– Steam Turbines– Steam Turbines
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UIC
In Partnership with the US DOE
• Heat Recovery Systems– Steam and Hot Water– Exhaust Gases
• Heat Recovery Systems– Steam and Hot Water– Exhaust Gases
Reliable CHP TechnologiesReliable CHP Technologies
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UIC
In Partnership with the US DOE
Other ComponentsOther Components• Grid Interconnect:
– Isolation Switch– Switchgear– Protection Relays
– Synchronizing Equipment
• Installation:– Equipment Footprint– Floor Loading– Proximity To HVAC Equipment– Number of Electrical Feeds
• Grid Interconnect:– Isolation Switch– Switchgear– Protection Relays
– Synchronizing Equipment
• Installation:– Equipment Footprint– Floor Loading– Proximity To HVAC Equipment– Number of Electrical Feeds
» PowerPower» FrequencyFrequency
» CurrentCurrent» VoltageVoltage
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UIC
In Partnership with the US DOE
CHP Is A Low Technical RiskCHP Is A Low Technical Risk• Utilize Proven Technologies
• Employ Standard Design Practices
• Incorporate Good Maintenance Practices
• Utilize Proven Technologies
• Employ Standard Design Practices
• Incorporate Good Maintenance Practices
CHP Business CaseCHP Business Case
Analysis Done By:Bruce Hedman
Energy & Environmental Analysis, IncUnder
US EPA CHP Partnership Program
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UIC
In Partnership with the US DOE
Plant Operating AssumptionsPlant Operating AssumptionsPlant Capacity, mmgal/yr 50
Operating Hours 8760
Electric Use, kWh/gal 0.96
Annual Electric Use, MWh 48,180
Baseload Electric Demand, MW 5.5
Steam Use, lb/gal 19.3
Steam Use, lbs/hr 110,000
Annual Steam Use, mmlbs 963,600
Boiler Fuel Use, Btu/lb 24,125
Annual Boiler Fuel Use, mmBtu 1,206,300
Annual Drier Fuel Use, mmBtu 605,000
Electric Costs, $/kWh 0.07
Gas Costs, $/mmBtu 6.00
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UIC
In Partnership with the US DOE
The Value EquationThe Value Equation
- Reduced purchased electricity costs
+ Increased fuel costs
+ Increased O&M costs
+ Increased capital expenditure
- Displaced capital?
- Reliability, other operational savings?
- Overall Savings
- Reduced purchased electricity costs
+ Increased fuel costs
+ Increased O&M costs
+ Increased capital expenditure
- Displaced capital?
- Reliability, other operational savings?
- Overall Savings
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UIC
In Partnership with the US DOE
Gas Turbine CHP System AssumptionsGas Turbine CHP System AssumptionsGas Turbine
Capacity, MW 5.2
Run Hours 8500
Gas Turbine Fuel, mmBtu/hr 67.2
Duct Burner Fuel, mmBtu/hr 0
Steam Output, lb/hr 28,600
Power to Steam Ratio 0.62
O&M Costs, $/kWh 0.008
Capital Costs
Turbine Genset, $/kW 415
HRSG, $/kW 100
Interconnect, $/kW 60
Misc Equipment, $kW 80
Engineering, installation, etc, $/kW
390
Total Installed Cost, $/kW 1,045
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UIC
In Partnership with the US DOE
Gas Turbine CHP – Financial Results
Gas Turbine CHP – Financial Results
W/O CHP W/ CHP
Purchased Electricity, 1000 $ 3,372.6 278.6
Boiler Fuel, 1000 $ 7,227.0 5,423.4
CHP Fuel, 1000 $ 0 3,344.8
Energy Costs*, 1000 $ 10,599.6 9,046.8
O&M Costs, 1000 $ 0 353.6
Standby Charges, 1000 $ ($3/kW) 0 187.2
Total Operating Costs, 1000 $ 10,599.6 9,587.5
Operating Savings = $1,012,100
* Does not include DDGS drier fuel
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UIC
In Partnership with the US DOE
Gas Turbine CHP – PaybackGas Turbine CHP – Payback
Capital Costs = $5,434,000 Payback = 5.4 yrs
Capital Costs = $4,980,000 Payback = 4.9 yrs
CHP System $5,434,000 - Boiler credit $ 450,000 $4,984,000
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UIC
In Partnership with the US DOE
Sensitivity to Electric & Natural Gas PricesSensitivity to Electric & Natural Gas PricesGas Turbine CHPGas Turbine CHP
Sensitivity to Electric & Natural Gas PricesSensitivity to Electric & Natural Gas PricesGas Turbine CHPGas Turbine CHP
0
2
4
6
8
5 6 7 8 9 10
Electricty Price, cents/kWh
Sim
ple
Pa
yb
ac
k,
yrs
$4 $5 $6 $7 $8
Natural Gas Price, $/mmBtuNatural Gas Price, $/mmBtu
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UIC
In Partnership with the US DOE
Payback – Various CHP OptionsPayback – Various CHP OptionsCHP System Type
Capital Cost - $000
Operating Savings - $000
Simple Payback – Yrs.
Boiler Credit - $000
Capital Cost (2) - $000
Simple Payback (2) – Yrs.
Gas Turbine
5,434 1,012 5.4 450 4,984 4.9
Gas Turbine W/Duct Burner
6,266 1,476 4.2 900 5,366 3.6
Boiler / Steam Turbine
2,175 1,390 1.6
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UIC
In Partnership with the US DOE
Integrate VOC Destruction With CHP(Techniques Presently Under Evaluation)Integrate VOC Destruction With CHP(Techniques Presently Under Evaluation)
• Ingest VOC into the Turbine
– Technical Challenge With Ethanol Dryer VOC Stream
• Destruction Through the Turbine Exhaust
– Less of Technical Challenge, More of a Cost Effictiveness Issue
• Ingest VOC into the Turbine
– Technical Challenge With Ethanol Dryer VOC Stream
• Destruction Through the Turbine Exhaust
– Less of Technical Challenge, More of a Cost Effictiveness Issue
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UIC
In Partnership with the US DOE
Integrate VOC Destruction With CHPIntegrate VOC Destruction With CHP• VOC Stream Destroyed In Plant Boiler
– Presently Being Explored By Ethanol Industry
– Adding Steam Turbine Small Incremental Cost
• Destroy VOC in T/O (recuperated / non-recuperated)– Recover Heat From non-recuperated T/O
and Use in Steam Turbine
• VOC Stream Destroyed In Plant Boiler– Presently Being Explored By Ethanol
Industry
– Adding Steam Turbine Small Incremental Cost
• Destroy VOC in T/O (recuperated / non-recuperated)– Recover Heat From non-recuperated T/O
and Use in Steam Turbine
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UIC
In Partnership with the US DOE
Gas Turbine/VOC Destruction CHPGas Turbine/VOC Destruction CHP
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UIC
In Partnership with the US DOE
Thermal Oxidizer/Steam Turbine CHPThermal Oxidizer/Steam Turbine CHP
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UIC
In Partnership with the US DOE
Integrate VOC Destruction With CHP(Next Steps)
Integrate VOC Destruction With CHP(Next Steps)
• Multi State Pre-Proposal Submitted Under STAC Science RFP (Illinois, Kansas, Minnesota)
• Presently Seeking Other Funding Sources to Evaluate & Test the Various Options
• Multi State Pre-Proposal Submitted Under STAC Science RFP (Illinois, Kansas, Minnesota)
• Presently Seeking Other Funding Sources to Evaluate & Test the Various Options
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UIC
In Partnership with the US DOE
CHP – Further AssistanceCHP – Further Assistance• US EPA Combined Heat & Power Partnership
– Launched in 2001
– 138 Partners – 851 MW of Projects Assisted
– Voluntary Public-Private Partnership To Help Get CHP Projects Installed
– Education, Networking, Resources, Technical Assistance, Recognition
• Contact Luis Troche @ 202/343-9442
WWW.epa.gov/chp
• US EPA Combined Heat & Power Partnership
– Launched in 2001
– 138 Partners – 851 MW of Projects Assisted
– Voluntary Public-Private Partnership To Help Get CHP Projects Installed
– Education, Networking, Resources, Technical Assistance, Recognition
• Contact Luis Troche @ 202/343-9442
WWW.epa.gov/chp
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UIC
In Partnership with the US DOE
CHP – Further AssistanceCHP – Further Assistance• US DOE Sponsored Application Centers
• Midwest CHP Application Center– Serves 8 State Midwest Region
– Information, Education, Technical Assistance
– Contact: John Cuttica 312/996-4382
WWW.chpcentermw.org
• Five Additional Centers Throughout the US
• US DOE Sponsored Application Centers
• Midwest CHP Application Center– Serves 8 State Midwest Region
– Information, Education, Technical Assistance
– Contact: John Cuttica 312/996-4382
WWW.chpcentermw.org
• Five Additional Centers Throughout the US