recycling waste heat – chp as an alternative
DESCRIPTION
Recycling Waste Heat – CHP as an alternative. Wednesday, March 2, 2005 Waste Heat to Power Generation Workshop University of California - Irvine. Patti W. Garland Oak Ridge National Laboratory for U.S. Department of Energy. Combined Heat and Power. - PowerPoint PPT PresentationTRANSCRIPT
Recycling Waste Heat – CHP as an alternative
Patti W. GarlandOak Ridge National Laboratoryfor U.S. Department of Energy
Wednesday, March 2, 2005Waste Heat to Power Generation Workshop University of California - Irvine
Combined Heat and Power
• CHP is the generation of electricity and heat sequentially from the same energy input.– Electricity primarily used on-site, but some can
be sold back to grid. Grid can serve as back-up or swing provider.
– Thermal energy used for heating/cooling or dehumidification or for process applications.
– CHP uses all technologies and all fuels.
• The “waste” heat can be recycled to drive thermally activated technologies
Advantages of CHP
• CHP is more efficient than separate generation of electricity and heat.
• Higher efficiency translates to lower operating cost, but requires capital investment.
• On-site electric generation reduces grid congestion and avoids distribution costs.
• Higher efficiency reduces emissions of pollutants.
• Increased reliability and power quality can also add significant value.
Typical CHP Systems
Gas Turbine or Engine/Heat Recovery Unit:Steam Boiler/Steam Turbine:
Raise CHP Awareness Eliminate Regulatory and Institutional Barriers Develop CHP Markets and Technologies
Our CHP activities are guided by the actions identified in the National CHP Roadmap as those items required of us to meet the CHP Goal
U.S. DOE CHP Vision and Technology Roadmap
By 2010, double the amount of CHP capacity in the United States
1998, 46GW 2010, 92GW
Where Are We??
0
10
20
30
40
50
60
70
Industrial Commercial Other
1995
2000
2004
Our Progress to Date — 2004
WE ARE HERE
80GW81
46
92
Installed CHP in 2004
• 81,000 MW at 2,866 sites
• Average capacity is 28 MW
• Median capacity is 2.0 MW
• 64% of installed capacity is in systems greater than 100 MW
• 2% of installed capacity is in systems smaller than 5 MW
Existing CHP Represents 8% of the Nation’s Electric Generating Capacity
Source: Energy and Environmental Analysis
Other Mfg8%
Metals5%
Refining13%
Food Processing
8%Chemicals
34%
Paper15%
Other Industrial
6%
Comm'l/inst11%
• Existing CHP Capacity (2004): 81,000 MW
Source: Energy and Environmental Analysis
CHP Uses a Wide Range of Fuels….
• Existing CHP Capacity (2004): 81,000 MW
Natural Gas69%
Coal14%
Oil2%
Wood/Biomass
3%
Waste10%
Other2%
Source: Energy and Environmental Analysis
…and a Wide Range of Technologies
• Existing CHP Capacity (2004): 81,000 MW
Boiler/Steam Turbine
31%
CombinedCycle48%
GasTurbine
19%
RecipEngine
2%
Other< 1%
DE Activities Directly Supporting the Advancement of the CHP Goal
• Improved Generation and Heat Utilization
• Integrated Energy Systems
• End Use Applications
• CHP Outreach and Market Development
Improved Generation and Heat Utilization
2000
2001
Cost competitive with the market
<<.15 lbs/ MWh NOx
2010
$900-$1,200/kW17-30% Efficiency.35 lbs/MWh NOx
Cost competitive with the market
40% Efficiency .15 lbs/MWh NOx
Cost competitive with the market
50% Efficiency 0.15 lbs/MWh NOx
Gas Turbines
Reciprocating Engines
Microturbines
199229% efficiency+2 lbs/MWh NOx
$600/kW38% Efficiency0.15 lbs/MWh NOx
$400/kW
2007
2000$300-$400/kW25-40% Efficiency2-3 lbs/MWh NOx
2007
Fuel Cells, Photovoltaics, Wind, HydropowerOthers
• Integrated Energy Systems for CHP– combinations of dissimilar subsystems designed or
assembled so they work together with higher efficiency and/or lower cost than they would operate individually
• Overcome regulatory, institutional, and market barriers – Packaged systems—“plug and play”– Modular components factory tested and integrated
easing field installation
• Develop model integrated energy systems having 70% efficiency with at least 4 year payback that are easily replicable
Integrated Energy Systems (IES)
Seven Packaged Systems (IES) ProjectsFour Up and Running in 2004
• Honeywell Laboratories – Fort Bragg, NC– 5 MW turbine generator integrated with 1,200 RT
waste-heat driven absorption chiller • Burns and McDonnell – Austin Energy
– 5.2 MW turbine generator integrated with 2,500 RT waste heat fired absorption cooling with greater than 70% efficiency
• UTRC– A&P Supermarket, New York– Combination of off the shelf components for
packaged system—PureComfortTM now commercially available
– 4, 5, or 6 Capstone 60 Microturbines coupled with 110 to 155 RT Carrier absorption chillers. Also considering refrigeration, desiccants, and thermal storage systems
• Gas Technology Institute – Engine generator (290 kW to 770 kW) integrated
with absorption chiller. Testing underway at GTI.
Residential Integrated Energy Systems
• Four Micro-CHP projects awarded in FY04– Heating and Power
• ECR International – Water based Rankine Cycle, 3kW electric, 40 kW thermal
• TIAX – 2kW Stirling Engine based system with space heat and hot water
– Cooling Heating and Power• AMTI – 4.7 kW IC Engine, space heat, hot water and
thermally activated desiccant system coupled with conventional AC
• UTRC – Micro CHP equipment assessment and evaluation for optimized residential systems
Ft. Bragg
Verizon
Current IES Projects Target Commercial / Institutional Market Sectors
200 Market St.Austin EnergyButler Hospital*Eastern Maine*Metropolitan Hospital*United Nursing Home*Ramapo College*University of MarylandGas Technology Institute
Pepperell High School*
Cinemark
Quality Inn HiltonRitz Carlton*Sheraton*W. Hotel – NYC*Raley’s *HEBA&PIngersol Rand
*FY04 Solicitation Awards
Healthcare Sector
Butler Hospital (Providence, RI)UTC Pure Comfort System ( 4 – C60 microturbines) with 110-ton absorption chillerPartners: UTC Power, Carrier Corporation, Witham & Associates, New England Gas, CDH Energy
Eastern Maine Medical Center (Bangor, ME) Gas Turbine (4.4 MW) to generate 24,000 lb/hr of steam and drive a 500-ton absorption chiller. Partners: Solar Turbines, Cianbro Corp., Vanderweil Engineers, Univ. of Maine, IDEA
Metropolitan Hospital (Grand Rapids, MI)Novi Energy Reciprocating engines (2 MW) with an absorption chiller.Partners: Inland Detroit Diesel, GE Jenbacher, Honeywell, Stanley Consultants, Workstage, and NTH Consultants.
Educational Facilities
Pepperell High School (Floyd County, GA) SEMCO Reciprocating engine (200 kW) coupled with four, integrated active desiccant HVAC systemsPartners: C&M Engineering, Floyd County Schools, and Hess Microgen
Ramapo College (Mahwah, NJ)GTIReciprocating engines (1.6 MW) to generate steam and operate an absorption chiller.Partners: Preventive Maintenance Services, CDH Energy Corp., Public Service Electric and Gas, Attainment Technologies, Monsen Engineering, Ramapo College of New Jersey
Hotels and Supermarkets
Ritz Carton Hotel, San Francisco, CAGTIUTC Pure Comfort System (4 C-60 microturbines) and 110 ton absorption chiller.Partners: UTC Power, Pacific Gas & Electric, Carrier Commercial Systems
Sheraton Hotel Complex (Rancho Mirage, CA)Energy Concepts CompanyReciprocating engine (200 kW) + a microturbine (250 kW) and absorption chillers. Partners: Shenandoah Springs Village, Desert Power Partners, and Ingersoll-Rand.
Raley’s Supermarket (Loomis, CA)TIAX LLC Reciprocating engine (280 kW) with absorption cooling Partners are Hess Microgen
Utilities
Basin Electric (Flasher, ND)Gas Technology InstitutePipeline Compressor stationGas Turbine with an Organic Rankine Cycle
Provides power quality improvements to local hospital in remote location
Site: Site: Los Angeles, CALos Angeles, CA
Product: Product: Chrome plating shop Chrome plating shop
Utility: Utility: Southern California Gas CompanySouthern California Gas Company
Power Gen.:Power Gen.: Four 30 kW Capstone micro-turbinesFour 30 kW Capstone micro-turbines
Heat Rec.:Heat Rec.: Hot water for plating tank heating and Hot water for plating tank heating and exhaust is re-used for sludge dryingexhaust is re-used for sludge drying
Operation:Operation: base loadedbase loaded
Status:Status: Data collection started June 2002Data collection started June 2002
Comments:Comments: Other plating companies interested in this configuration. Customer Other plating companies interested in this configuration. Customer is pursuing use of absorption chiller with system.is pursuing use of absorption chiller with system.
DEMONSTRATION
Higgins Brick FactoryChino Hills, CA
Cons. Utility: SoCal Gas
Power Gen.: Three 80 kW Bowman micro-turbines
Heat Rec.: Indirect heat exchange to pre-heat kiln comb. air
Operation: Three base loaded turbines 24/7
Status: System commissioning in-progress
Comments: Demonstrates waste heat recovery for process heating. Operation scheduled to begin in Summer 04
Simmax Energy is planning to provide energy services to the plant
ORNL and University of Maryland Collaborate on Integrating CHP Systems into a Commercial Building
University of Maryland,College Park
Integration Test Center and User Facility at ORNL
CHP Outreach and Market Development Activities
• Raising CHP Awareness– Regional Initiatives and CHP Application Centers (SEP)– Annual CHP Roadmap Meeting and Policy Day– Participation in trade shows, meetings and educational activities for
targeted audiences• Eliminating Regulatory and Institutional Barriers
– Air regulations, environmental permitting• Research on emissions permitting, Environmental permitting screening tool,
Review of environmental models, Develop Regulatory Requirements Database for Electric Generators
– Interconnection requirements• Utility interconnection practices
– Site permitting, tax treatment • Analyze cost and financing of DG/CHP, Review of DG siting procedures
– Costly standby and backup power charges • Electric rate primer, Review of States’ CHP activities
• Developing Markets (Targeted Markets Identified)– Baseline CHP installations– Assess technical and economic potential– Identify the value proposition
Click on any state to access state specific information on DG permitting issues,
or click on the state name in the drop box below:
Please Note:
The information for this database was obtained through a combination of interviews with state permitting officials and review of state permitting regulations. This database is a work in progress. Please check back frequently for updates. This work is being done for the U.S. Department of Energy and Oak Ridge National Laboratory. While the information is believed to be accurate, always verify information with appropriate regulatory agencies. This site is best viewed with Microsoft's Internet Explorer
6.0
Regulatory Requirements Database for Electric Generators
Specific Issues:EMISSIONS REGULATIONS
STATE ENVIRONMENTAL REGULATIONS
SITING REGULATIONS
EXIT FEES
STANDBY RATES
BUILDING, ZONING,AND FIRE CODES
AMMONIA ISSUES
REPORTING REQUIREMENTS
ECONOMIC INCENTIVES
http://www.eea-inc.com/rrdb/DGRegProject/index.html
The Opportunity for Alternative CHP Fuels
• High natural gas prices have decreased spark spreads and reduced CHP market potential
• Proposed solutions focus on increasing natural gas supply or reducing demand, neither will likely help much in the short run
• Renewable portfolio standards, public benefit funding, and other renewable incentives are spurring investment in biomass fueled projects
Natural Gas Prices Have Risen and Are Expected to Stay High
Source: EIA and NYMEX
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4
6
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10
12
14
Jan-
97
Oct-97
Jul-9
8
Apr-9
9
Jan-
00
Oct-00
Jul-0
1
Apr-0
2
Jan-
03
Oct-03
Jul-0
4
Apr-0
5
Jan-
06
Oct-06
$/M
CF
US City Gate Price
US Wellhead Price
NYMEX Henry Hub Price (Future)
California
Alternative Solution: Develop Other, Cost-Effective Fuels
• Anaerobic Digester Gas• Biomass Gas• Black Liquor • Blast Furnace Gas • Coalbed Methane• Coke Oven Gas• Crop Residues • Food Processing Waste• Industrial VOC's
• Landfill Gas
• Municipal Solid Waste
• Orimulsion
• Petroleum Coke
• Sludge Waste
• Textile Waste
• Tire-Derived Fuel
• Wellhead Gas
• Wood
• Wood Waste
• Opportunity Fuel: any fuel that has the potential to be used for economically-viable power generation, but is not traditionally used for this purpose
• Opportunity fuels include:
Processing Technology Key to Use of Opportunity Fuels
Steam Turbine
BiomassGas
LandfillGas
DigesterGas
Ethanol
Dry Waste
Crop Residues
Food Processing Waste
Municipal Solid Waste*
Wood and Wood Waste
Moist Waste
Sludge Waste
Farm Waste
Food Processing Waste
Black Liquor
CombustionTurbine
Recip Engine
Fuel Cell
*Municipal Solid Waste may require drying
Gasifier
Fermenter
Landfill
Boiler
AnaerobicDigester
Dryer
Blendedw/ Diesel Recip Engine
Fuel Cell
Source: Resource Dynamics
Why are Opportunity Fuels Not Used More Often?
• Availability of fuel source often inconsistent in volume and in quality, resulting in variations in fuel volume, BTU content, and contaminants
• Often requires changes (adding $) to generating equipment or purchasing processing equipment (digester, filtration, gasifier)
• Site where fuel is located has little thermal and/or electric demand
• Costs to transport fuel to ideal site can kill projects
• Producing/processing fuel can be labor intensive
• Technology not yet commercialized for small-scale use in U.S.
Opportunity Fuel Performance Chart: Selecting the Top Candidates
Opportunity Fuel Availability Heating Value
Fuel Cost
Equipment Cost
Emissions / Environment
DER/CHP Potential Rating Limitations
Anaerobic Digester Gas 5.0 Need anaerobic digester
Biomass Gas 4.0 Gasifiers extremely expensive
Black Liquor 3.0 Most BL already used up by mills
Blast Furnace Gas 2.0 Limited availability, low Btu
Coalbed Methane 5.0 Coal mines - lack CHP demand
Coke Oven Gas 3.0 Availability - most already used
Crop Residues 3.0 Difficulty in gathering/transport
Food Processing Waste 4.0 Limited market, broad category
Ethanol 4.0 Currently only used for vehicles
Industrial VOC’s 2.0 Must be used w/ NG turbine
Landfill Gas 4.5 Landfills – little demand for CHP
MSW / RDF 3.0 Low heating value, contaminants
Orimulsion 2.5 Orimulsion not available in U.S.
Petroleum Coke 3.5 Many contaminants; large apps
Sludge Waste 2.5 Low heating value, contaminants
Textile Waste 3.0 Must be cofired; larger apps
Tire-Derived Fuel 4.0 Best suited for large apps
Wellhead Gas 4.5 Oil / gas wells – no CHP demand
Wood (Forest Residues) 4.0 Fuel can be expensive
Wood Waste 4.5 Waste may have contaminants
Key: = excellent / not an issue, = average / could become an issue, = poor / major issue
DOE CHP Vision/Technology Roadmap
REGIONAL RECOMMENDATIONS:
1) Raise CHP Awareness - Create new and support existing CHP awareness efforts by Regional and State Groups
2) Conduct a coordinated outreach campaign to educate architects, building designers, and local building and other code officials about CHP
3) Provide SWAT team technical assistances to those interested in installing CHP Systems
Regional Application Centers
Mid Atlanticwww.chpcenterma.org
Midwestwww.chpcentermw.org
Pacificwww.chpcenterpr.org
Northwestwww.chpcenternw.org
Northeastwww.northeastchp.org
Intermountainwww.IntermountainCHP.org
The regional application centers will promote combined heating and power (CHP) technology and practices, serve as a central repository and clearinghouse of CHP information, and identify and help implement regional CHP projects.
Gulf Coast
Southeastern
RAC Services Offered
• Education and Outreach– Websites (Available & Updated) – Focused Training and Educational Courses– Workshops / Conferences – Regulatory Interactions
• Project Support– Site Evaluations (Screening)– Application Analysis (Tech / Financial)– Technical Assistance
• Other Activities
Industrial Assessment Centers• Strengthen interface between IAC and RAC – increase small industrial market
• Training on CHP for IACs
• Incorporate CHP into IAC assessment recommendations where appropriate, conversely encourage RACs to recommend IAC assessments where appropriate
• Introduce engineering students to CHP – broaden the workforce
•Within Standard Industrial Codes (SIC) 20-39. •Gross annual sales below $100 million. •Fewer than 500 employees at the plant site. •Annual energy bills from $100,000 to $2 million. •No professional in-house staff to perform assessment.
The IAC program enables small/medium-sized manufacturers to have comprehensive energy, waste and productivity assessments performed at no cost. Recommendations from these assessments have averaged $55,000 in potential annual savings for each manufacturer.
Team Work for Success
DOE
- DE
EPA
Nat Lab
sVA
FEMP
RACs
HUD
Initiatives
States
USCHPA
Tech Dev.
Mark
ets
Polic
y
Tools
Fuels
For more information: www.eere.energy.gov/de