Combined Heat and Power Opportunities in Southern Illinois

Graeme Miller

Assistant Director

US DOE Midwest CHP Technical Assistance Partnership

• DOE CHP Technical Assistance Partnerships

• CHP Concepts and Benefits

– CHP Configurations and Technologies

– CHP Market Sectors

• CHP Project Profiles

• Available Utility Incentives

• Next Steps in Evaluating CHP

Agenda

• End User Engagement

Partner with strategic End Users to advance technical solutions using

CHP as a cost effective and resilient way to ensure American

competitiveness, utilize local fuels and enhance energy security. CHP

TAPs offer fact-based, non-biased engineering support to

manufacturing, commercial, institutional and federal facilities and

campuses.

• Stakeholder Engagement

Engage with strategic Stakeholders, including regulators, utilities, and

policy makers, to identify and reduce the barriers to using CHP to

advance regional efficiency, promote energy independence and

enhance the nation’s resilient grid. CHP TAPs provide fact-based, non-

biased education to advance sound CHP programs and policies.

• Technical Services

As leading experts in CHP (as well as microgrids, heat to power, and

district energy) the CHP TAPs work with sites to screen for CHP

opportunities as well as provide advanced services to maximize the

economic impact and reduce the risk of CHP from initial CHP screening

to installation.

www.energy.gov/chp

3

DOE CHP Deployment Program Contactswww.energy.gov/CHPTAP

Tarla T. Toomer, Ph.D.CHP Deployment ManagerOffice of Energy Efficiency and Renewable EnergyU.S. Department of EnergyTarla.Toomer@ee.doe.gov

Patti GarlandDOE CHP TAP Coordinator [contractor]Office of Energy Efficiency and Renewable EnergyU.S. Department of EnergyPatricia.Garland@ee.doe.gov

Ted BronsonDOE CHP TAP Coordinator [contractor]Office of Energy Efficiency and Renewable EnergyU.S. Department of Energytbronson@peaonline.com

DOE CHP Technical Assistance Partnerships (CHP TAPs)

Two-thirds of the fuel used to generate

power in the US is lost as heat

Conversion Losses66.6%

Energy Utilization in the Utility Sector

Source: https://flowcharts.llnl.gov/content/assets/images/charts/Energy/Energy_2015_United-States.png

CHP: A Key Part of Our Energy Future

Form of Distributed Generation (DG)

An integrated system

Located at or near a building / facility

Provides at least a portion of the electrical load and

Uses thermal energy for:

o Space Heating / Cooling

o Process Heating / Cooling

o Dehumidification

CHP provides efficient, clean, reliable, affordable energy –

today and for the future.

Source: www.energy.gov/chp

Fuel 100 units

CHP75% efficiency

Total Efficiency~ 75%

Fuel

Fuel

30 units

Power Plant32% efficiency(Including T&D)

Onsite Boiler80% efficiency

45 units

Electricity

Heat

Total Efficiency~ 50%

94 units

56 units

30 to 55% less greenhouse gas emissions

CHP Recaptures Heat of Generation, Increasing

Energy Efficiency, and Reducing GHGs

Common CHP Technologies

50 kW 100 kW 1 MW 10 MW 20 MW

Fuel Cells

Gas TurbinesMicroturbines

Reciprocating Engines

Steam Turbines

CHP System Schematic

Prime MoverReciprocating EnginesCombustion Turbines

MicroturbinesSteam Turbines

Fuel CellsORC turbine

ElectricityOn-Site Consumption

Sold to Utility

FuelNatural Gas

Propane

BiogasLandfill Gas

CoalSteam

Waste ProductsOthers

Generator

Heat Exchanger

ThermalSteam

Hot WaterSpace Heating

Process HeatingSpace Cooling

Process CoolingRefrigeration

Dehumidification

Critical Infrastructure and Resiliency Benefits

of CHP“Critical infrastructure” refers to those assets, systems, and networks that, if incapacitated, would have a substantial negative impact on national security, national economic security, or national public health and safety.”

Patriot Act of 2001 Section 1016 (e)

Applications:

Hospitals and healthcare centers

Water / wastewater treatment plants

Police, fire, and public safety

Centers of refuge (often schools or universities)

Military/National Security

Food distribution facilities

Telecom and data centers

CHP (if properly configured):

Offers the opportunity to improve Critical Infrastructure (CI) resiliency

Can continue to operate, providing uninterrupted supply of electricity and heating/cooling to the host facility

What Are the Benefits of CHP?

• CHP is more efficient than separate generation of electricity and heating/cooling

• Higher efficiency translates to lower operating costs (but requires capital investment)

• Higher efficiency reduces emissions of pollutants

• CHP can also increase energy reliability and enhance power quality

• On-site electric generation can reduce grid congestion and avoid distribution costs.

CHP Is Used Nationwide In Several Types of

Buildings/Facilities

81.3 GW installed at more than 4,400 sites

Saves 1.8 quads of fuel each year

Avoids 241 M metric tons of CO2 each year

Source: DOE CHP Installation Database (U.S. installations as of Dec. 31, 2017) Slide prepared on 7-3-18

CHP Today in the United States

• 81.3 GW of installed CHP at more than 4,400 industrial and commercial facilities

• 8% of U.S. Electric Generating Capacity; 14% of Manufacturing

• Avoids more than 1.8 quadrillion Btus of fuel consumption annually

• Avoids 241 million metric tons of CO2

compared to separate production

Slide prepared on 7-3-18

Existing CHP Capacity

CHP Today in Illinois

Source: Doe CHP Database, 2019

CHP Prime Mover CHP Capacity (kW) CHP InstallationsBackpressure Steam Turbine 3,000 1

Boiler/Steam Turbine 679,637 17

Combined Cycle 260,100 4

Combustion Turbine 140,640 15

Reciprocating Engine 134,891 82

Grand Total 1,218,268 119

Market Sector in Illinois CHP Capacity (kW) CHP Installations Agriculture 22,160 7

Chemicals 45,900 7

Colleges/Univ. 132,517 13

Fabricated Metals 7,750 3

Food Processing 512,175 15

General Gov't. 6,300 1

Hospitals/Healthcare 23,220 6

Machinery 89,810 6

Misc 3,301 12

Nursing Home 4,750 5

Office Building 7,469 5

Primary Metals 81,012 3

Pulp and Paper 6,500 2

Refining 214,000 4

Research Facilities 8,300 1

Schools 11,705 16

Stone/Clay/Glass 14,100 1

Transportation Equipment 9,240 1

Wastewater Treatment 18,065 12

Grand Total 1,218,274 120

• CHP systems are often categorized based on the type of prime mover that drives the system. There are five predominant prime mover technologies used for CHP systems:

– Reciprocating engines

– Gas turbines

– Microturbines

– Boiler/steam turbines

– Fuel cells

• Three CHP configurations (described on following slides)

• Reciprocating engine or turbine with heat recovery

• Boiler / steam turbine

• Fuel cell

These two configurations offer good potential for incorporation into packaged CHP systems

Configurations

• Gas or liquid fuel is combusted in a prime mover, such as a reciprocating engine, microturbine, or gas turbine

• The prime mover is connected to a generator that produces electricity

• Energy normally lost in the prime mover’s hot exhaust and cooling system is recovered to provide useful thermal energy for the site

Reciprocating Engine or Turbine with Heat Recovery

• Fuel is burned in a boiler to produce high pressure steam that is sent to a backpressure or extraction steam turbine

• The steam turbine is connected to an electric generator that produces electricity

• Low pressure steam exits the turbine and provides useful thermal energy for the site

Boiler / Steam Turbine

Two types of electric generators are used with reciprocating engines and turbines to produce alternating current (AC) electricity: induction and synchronous.

Induction

• Requires grid power (external

power source)

• When grid goes down,

CHP system goes down

• Contributes to poor power factor

• Less complicated and less costly to

interconnect compared to

synchronous

• Preferred by utilities

Synchronous

• Does not need grid to operate (self

excited)

• CHP system can continue to operate

through grid outage

• Can assist in power factor correction

• More complicated and more costly to

interconnect compared to induction

(safety considerations)

• Preferred by CHP customers

Designing for ReliabilityTwo Generator Types

• Induction– Requires external power

source to operate

– When grid goes down, generator goes down

– Less Complicated and Costly to Interconnect

• Synchronous– Self Excited (Does not

need grid to operate)

– Generator can operate thru Grid outages

– More Complicated and Costly to Interconnect

Uninterrupted Operation Requirements

• Black start capability– Allows the system to start up

independently from the grid

• Generators capable of grid-independent operation– The system must be able to operate

without grid power signal

• Ample Carrying Capacity– System size must match critical loads

• Parallel utility interconnection and switch gear controls– The system must be able to disconnect

from the grid, support critical loads, and reconnect after an event

19

• Size Range: 10 kW to 10 MW

• Characteristics

– Thermal can produce hot water, low pressure steam, and chilled water (through absorption chiller)

– High part-load operation efficiency

– Fast start-up

– Minimal auxiliary power requirements for black start.

• Example Applications:

– universities, hospitals, water treatment facilities, industrial facilities, commercial buildings, and multi-family

dwellings

• Size Range: 1 MW to 300 MW

• Characteristics

– Produces high quality, high temperature thermal that can include high pressure steam for industrial processes, and chilled water (with absorption chiller)

– Available in a wide range of capacities and configurations

– Best efficiency when operated at full load (part-load efficiency is often much lower than full load efficiency)

• Example Applications:

– hospitals, universities, chemical plants, refineries, food processing, paper, military bases

• Size Range: 30 kW to 330 kW

(modular packages exceeding 1 MW)

• Characteristics

– Thermal can produce hot water,

steam, and chilled water (through

absorption chiller)

– Compact size and light weight

– Inverter based generation can

improve power quality

• Example Applications:

– multifamily housing, hotels, nursing

homes, waste water treatment,

gas & oil production

• Size Range: 100 kW to over 250 MW

• Characteristics

– Requires a boiler or other steam source

– Can be mated to boilers firing a variety of gaseous, liquid or solid fuels (e.g., coal and biomass fuels such wood, waste products, and pellets).

– Mature technology with very high durability and reliability

– Can operated over a wide range of steam pressures

– Backpressure steam turbines can be used to produce power by replacing pressure reducing valves (PRVs) in existing steam systems

• Example Applications:

– Industrial applications, district heating and cooling systems, forest products, paper mills, chemicals, food processing, PRVs

• Heat Exchangers

– Recover exhaust gas from prime mover

– Transfers exhaust gas into useful heat (steam, hot water) for downstream applications

– Heat Recovery Steam Generators (HRSG) the most common

• Heat-Driven Chillers

– Absorption Chiller

• Use heat to chill water

• Chemical process (not mechanical)

– Steam Turbine Centrifugal Chiller

Image Source: University of Calgary

Image Source: DOE - EERE

• Absorption chillers are heat operated refrigeration

machines that operate on chemical and physical

reactions to transfer heat. The absorption cycle

substitutes a physiochemical process for the

mechanical compressor used in common refrigeration

systems.

• Absorption chillers can be driven with hot water,

steam, or prime mover exhaust.

• Absorption chillers are available in sizes from 5 to 3,000

refrigeration tons. This capacity correlates to a CHP

electric output of approximately 50 to 10,000 kW.

• For 40°F and higher chilling fluid temperatures (e.g.,

building air conditioning), a common refrigerant

solution mixture is water (refrigerant) and lithium

bromide (absorbent). For chilling fluid temperatures

below 40°F (e.g., cold storage), a common refrigerant

solution mixture is ammonia (refrigerant) and water

(absorbent).

A 200-ton single-stage absorption chiller integrated with three 600 kW reciprocating engines that also provide hot water for process and space heating. The system is located at a metal fabrication facility in Fitchburg, Massachusetts. Photo courtesy of Northeast CHP Technical Assistance Partnership (CHP TAP).

CharacteristicTechnology

Reciprocating Engine

Gas Turbine Microturbine Fuel Cell Steam Turbine

Size Range 10 kW – 10 MW 1 – 300 MW 30 kW – 330 kW (larger modular units available)

5 kW – 1.4 MW (larger modular units available)

100 kW – 250 MW

Electric Efficiency (HHV)

30% – 42% 24% – 36% 25% – 29% 38% – 42% 5% – 7%

Overall CHP Efficiency (HHV)

77% – 83% 65% – 71% 64% – 72% 62% – 75% 80%

Total Installed Cost ($/kW) [3]

$1,400 – $2,900 $1,300 – $3,300 $2,500 – $3,200 $4,600 –$10,000$670 – $1,100

[4]

O&M Cost (¢/kWh) 0.9-2.4 0.9-1.3 0.8-1.6 3.6-4.5 0.6-1.0

Power to Heat Ratio 0.6 – 1.2 0.6 – 1.0 0.5 – 0.8 1.3 – 1.6 0.07 – 0.10

Thermal Output (Btu/kWh)

2,900 --6,100 3,400 --6,000 4,400 --6,400 2,200 --2,600 30,000 --50,000

Notes: 1) Unless noted otherwise, information based on U.S. Department of Energy, CHP Technology Fact Sheet Series, 2016, 2017.

2) All performance and cost characteristics are typical values and are not intended to represent a specific product.

3) Costs will vary depending on site specific conditions and regional variations.4) Costs shown are for a steam turbine only, and do not include costs for a boiler, fuel handling equipment, steam loop, and controls.

Comparison of CHP Characteristics [1, 2]

CharacteristicTechnology

Reciprocating Engine

Gas Turbine Microturbine Fuel Cell Steam Turbine

Fuel Pressure (psig) [1]

1-75100-500 (may require fuel compressor)

50-140 (may require fuel compressor)

0.5-45 n/a

Part Load Efficiency

Good at both part-load and

full-load

Better at full-load

Better at full-load

Better at full-load

Good at both part-load and full-load

Type of Thermal Output

LP steam, hot water, space

heating, chilled water

LP-HP steam, hot water,

process heating, chilled

water

LP steam, hot water, chilled

water

LP steam, hot water, chilled

water

LP-HP steam, hot water, chilled water

FuelCan be operated with a wide range of gas and liquid fuels. For CHP, the most common fuel is

natural gas.

Hydrogen, natural gas,

propane, methanol

Steam turbines for CHP are used primarily where a solid fuel (e.g., coal or biomass) is

used in a boiler. [2]

Notes: 1) Adapted from Catalog of CHP Technologies, U.S. Environmental Protection Agency Combined Heat and Power Partnership, 2015.

2) Backpressure steam turbines can be used to produce power by replacing pressure reducing valves (PRVs) in existing steam systems.

Characteristic

Technology

Reciprocating Engine

Gas Turbine Microturbine Fuel Cell Steam Turbine

Emissions

CHP technologies are capable of meeting or exceeding air quality regulations throughout the United States, including states such as California that have demanding limits for NOx, CO, and VOC emissions. To achieve compliance, a CHP technology may need to integrate an exhaust treatment

technology such as an oxidation catalyst or a selective catalytic reduction system.

Other

Reciprocating engines start quickly and

operate on typical natural gas

delivery pressures.

Gas turbines and microturbines have low engine-out emissions and require no cooling. A fuel gas

compressor may be required to deliver the specified inlet gas

pressure.

Fuel cells are quiet, have low emissions, and produce high

quality power.

Steam turbines require a boiler or other steam

source.

Attractive CHP Markets

Industrial

• Chemical

manufacturing

• Ethanol

• Food processing

• Natural gas

pipelines

• Petrochemicals

• Pharmaceuticals

• Pulp and paper

• Refining

• Rubber and

plastics

Commercial

• Data centers

• Hotels and

casinos

• Multi-family

housing

• Laundries

• Apartments

• Office buildings

• Refrigerated

warehouses

• Restaurants

• Supermarkets

• Green buildings

Institutional

• Hospitals

• Schools (K – 12)

• Universities &

colleges

• Wastewater

treatment

• Residential

confinement

Agricultural

• Concentrated

animal feeding

operations

• Dairies

• Wood waste

(biomass)

Biogas CHP

• Biogas is a mixture of gases produced by the breakdown of organic matter

in an oxygen free environment.

• Wastewater Treatment Plants

• Livestock Farms

• Biogas is primarily comprised of methane (CH4) and carbon dioxide (CO2)

and may have small amounts of hydrogen sulphide (H 2S), moisture and

siloxanes.

• Technology Required:

• Anaerobic Digester

• Gas Conditioning Equipment (Depends on gas makeup)

• CHP Prime Mover and Heat Recovery

• Most Common: Recip Engines, Microturbines

• Co-Digesting additional organic material may help increase biogas

production

Biogas CHP

A typical WWTP processes 100 gal/day of wastewater for each person they serve

Each million gallons per day (MGD) of wastewater flow can produce enough biogas in an anaerobic digester to produce 30 kW of electric capacity

Project Snapshot:A Resilient Manufacturing Plant

SC Johnson Waxdale Plant

Racine, WI

Application/Industry: Manufacturing

Capacity: 6.4 MW

Prime Mover: Gas turbine

Fuel Type: Landfill gas and natural gas

Thermal Use: Space & process heating

Installation Year: 2003

Energy Savings: Unknown

Highlights: The SC Johnson Waxdale Plant (producer of such

household products as Glade®, Windex®, Pledge®, ScrubbingBubbles®, Shout®, Raid® and OFF!®) installed a 3.2 MW

combustion turbine CHP system in 2003 fueled by landfill gasfrom a nearby landfill. The company added a second 3.2 MW

unit in 2005 fueled by natural gas. The two units provide baseload electricity for the 2.2 million ft2 manufacturing facility while

providing up to 40,000 lbs/hr of high quality steam for heatingand manufacturing processes. The control systems isolate the

CHP system from the utility grid during outages and enable theplant to keep its critical operations up and running.

Source: http://www.midwestchptap.org/profiles/ProjectProfiles/SCJohnsonWaxdalePlant.pdf

Slide prepared 6/2017

32

Project Snapshot:Targeting Net-Zero

Downers Grove Sanitary District

Downers Grove, IL

Application/Industry: Wastewater Treatment

Capacity: 280 kW

Prime Mover: Reciprocating engine

Fuel Type: Biomass

Thermal Use: Heat for the digestion process

Installation Year: 2014

Highlights: Waste grease from nearby

restaurants helps power the CHP system, which

offsets about 50% of the wastewater treatment

plant’s energy consumption.

Source: http://www.midwestchptap.org/profiles/ProjectProfiles/DownersGrove.pdf

Slide prepared 6/2017

Project Snapshot:Cow Power (5 Cows = 1 kW)

Hunter Haven Farms

Pearl City, IL

Application/Industry: Dairy Farm

Capacity: 260 kW

Prime Mover: Caterpillar engines (2)

Fuel Type: Anaerobic digester biogas

Thermal Use: Heating the digester

Installation Year: 2008

Energy Savings: Unknown

Highlights: Hunter Havens Farm owns and operates

24/7 a 260 kW anaerobic digester and biogas-fired

combined heat and power (CHP) system. The system

produces electricity for the site and to sell to the local

utility. The recovered heat is used to maintain the

temperature of the digester, heat farm buildings, and

provide the farm with hot water. The system can

manage the waste for up to 1,200 dairy cows.

Source: http://www.midwestchptap.org/profiles/ProjectProfiles/HunterHavenFarms.pdf

Slide prepared 6/2017

34

Available Incentives

• Incentive – $0.12/kWh and $1.20/therm for eligible

electricity and natural gas savings, under Custom

Program

• Electric cap at $500,000, natural gas cap at $100,000

• Feasibility Studies – up to 50% of costs or 25% of annual savings identified, capped at $20k

Ameren Illinois CHP Incentives

(https://www.ameren.com/illinois/energy-efficiency)

How to Implement a CHP Project with

the Help of the CHP TAP

CHP TAP Role: Technical Assistance

• High level assessment to

determine if site shows

potential for a CHP

project

– Qualitative Analysis• Energy Consumption & Costs

• Estimated Energy Savings & Payback

• CHP System Sizing

– Quantitative Analysis• Understanding project drivers

• Understanding site peculiarities

DOE TAP CHP Screening Analysis

Annual Energy Consumption

Base Case CHP Case

Purchased Electricty, kWh 88,250,160 5,534,150

Generated Electricity, kWh 0 82,716,010

On-site Thermal, MMBtu 426,000 18,872

CHP Thermal, MMBtu 0 407,128

Boiler Fuel, MMBtu 532,500 23,590

CHP Fuel, MMBtu 0 969,845

Total Fuel, MMBtu 532,500 993,435

Annual Operating Costs

Purchased Electricity, $ $7,060,013 $1,104,460

Standby Power, $ $0 $0

On-site Thermal Fuel, $ $3,195,000 $141,539

CHP Fuel, $ $0 $5,819,071

Incremental O&M, $ $0 $744,444

Total Operating Costs, $ $10,255,013 $7,809,514

Simple Payback

Annual Operating Savings, $ $2,445,499

Total Installed Costs, $/kW $1,400

Total Installed Costs, $/k $12,990,000

Simple Payback, Years 5.3

Operating Costs to Generate

Fuel Costs, $/kWh $0.070

Thermal Credit, $/kWh ($0.037)

Incremental O&M, $/kWh $0.009

Total Operating Costs to Generate, $/kWh $0.042

Finding the Best Candidates:

Some or All of These Characteristics

• Consistent source of organic matter to produce biogas

• High and constant thermal load

• Favorable spark spread

• Need for high reliability

• Concern over future electricity prices

• Interest in reducing environmental impact• Existing central plant

• Planned facility expansion or new construction; or equipment replacement within the next 3-5 years

CHP Project Resources

Good Primer Report DOE CHP Technologies

Fact Sheet Series

www.eere.energy.gov/chpwww.energy.gov/chp-technologies

CHP Project Resources

DOE Project Profile Database

energy.gov/chp-projects

EPA dCHPP (CHP Policies and

Incentives Database

www.epa.gov/chpdchpp-chp-

policies-and-incentives-database

CHP Project Resources

DOE CHP Installation Database

(List of all known

CHP systems in U.S.)

Low-Cost CHP Screening and

Other Technical Assistance from

the CHP TAP

energy.gov/chp-installs

energy.gov/CHPTAP

o Proven technologies are commercially

available and cover a full range of sizes and

applications

o Ameren Illinois offers both electric and

natural gas energy efficiency incentives for

CHP in Illinois

o There are available resources to help your facility evaluate CHP

o Contact Midwest CHP TAP for assistance if:

o Interested in having a Qualification Screening performed to determine if there is an opportunity for CHP at your site

o If you already have an existing CHP plant and interested in expanding it

o Need an unbiased 3rd Party Review of a proposal

46

Questions?

47

BUSINESS PROGRAM ENERGY ADVISORS1. Chad WhiteheadChad.Whitehead@gdsassociates.com309.620.6333

2. Steven SmithSteven.L.Smith@leidos.com309.212.5831

3. Rod RhoadsRod.Rhoads@gdsassociates.com217.649.8897

4. Mark SteinmetzMark.Steinmetz@gdsassociates.com217.670.9606

5. Michael HarrisonMichael.Harrison@leidos.com309.212.1490

6. Mike ThompsonMichael.E.Thompson@leidos.com309.213.0336

7. Larry ErwinLawrence.F.Erwin@leidos.com309.838.2340

Ameren Illinois Business Program Energy Advisors

Call 1.866.800.0747

to request a consultation with an Energy Advisor

Thank You

Graeme Miller

Assistant Director

(312) 996-3711

gmille7@uic.edu

Cliff Haefke

Director

(312) 355-3476

chaefk1@uic.edu