Recycling Waste Heat – CHP as an alternative : Recycling Waste Heat – CHP as an alternative Patti W. Garland
Oak Ridge National Laboratory
for U.S. Department of Energy
Wednesday, March 2, 2005
Waste Heat to Power Generation Workshop
University of California - Irvine
Combined Heat and Power : 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 : 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 : Typical CHP Systems Gas Turbine or Engine/Heat Recovery Unit: Steam Boiler/Steam Turbine:
U.S. DOE CHP Vision and Technology Roadmap : Raise CHP Awareness
Eliminate Regulatory and Institutional Barriers
Develop CHP Markets and Technologies 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?? : Where Are We?? Our Progress to Date — 2004
Installed CHP in 2004 : 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 : Existing CHP Represents 8% of the Nation’s Electric Generating Capacity Source: Energy and Environmental Analysis Existing CHP Capacity (2004): 81,000 MW
CHP Uses a Wide Range of Fuels…. : Source: Energy and Environmental Analysis CHP Uses a Wide Range of Fuels…. Existing CHP Capacity (2004): 81,000 MW Natural Gas
69% Coal
14% Oil
2% Wood/
Biomass
3% Waste
10% Other
2%
…and a Wide Range of Technologies : Source: Energy and Environmental Analysis …and a Wide Range of Technologies Existing CHP Capacity (2004): 81,000 MW Boiler/
Steam Turbine
31% Combined
Cycle
48% Gas
Turbine
19% Recip
Engine
2% Other
< 1%
DE Activities Directly Supporting the Advancement of the CHP Goal : 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 : Improved Generation and Heat Utilization 2000 2001 Cost competitive with the market
<<.15 lbs/ MWh NOx
2010 $900-$1,200/kW
17-30% 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 1992 29% efficiency
+2 lbs/MWh NOx
$600/kW 38% Efficiency
0.15 lbs/MWh NOx
$400/kW 2007 2000 $300-$400/kW
25-40% Efficiency
2-3 lbs/MWh NOx 2007
Fuel Cells,
Photovoltaics,
Wind,
Hydropower
Others
Integrated Energy Systems (IES) : 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) Projects Four Up and Running in 2004 : Seven Packaged Systems (IES) Projects Four 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 : 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
Slide16 : Ft. Bragg Verizon Current IES Projects Target
Commercial / Institutional Market Sectors 200 Market St.
Austin Energy Butler Hospital*
Eastern Maine*
Metropolitan Hospital*
United Nursing Home* Ramapo College*
University of Maryland
Gas Technology Institute Pepperell High School* Cinemark Quality Inn
Hilton
Ritz Carlton*
Sheraton*
W. Hotel – NYC* Raley’s *
HEB
A&P
Ingersol Rand *FY04 Solicitation Awards
Healthcare Sector : Healthcare Sector
Butler Hospital (Providence, RI)
UTC Pure Comfort System ( 4 – C60 microturbines) with 110-ton absorption chiller
Partners: 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 : Educational Facilities Pepperell High School (Floyd County, GA)
SEMCO
Reciprocating engine (200 kW) coupled with four, integrated active desiccant HVAC systems
Partners: C&M Engineering, Floyd County Schools, and Hess Microgen
Ramapo College (Mahwah, NJ)
GTI
Reciprocating 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 : Hotels and Supermarkets Ritz Carton Hotel, San Francisco, CA
GTI
UTC 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 Company
Reciprocating 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 : Utilities Basin Electric (Flasher, ND)
Gas Technology Institute
Pipeline Compressor station
Gas Turbine with an Organic Rankine Cycle
Provides power quality improvements to local hospital in remote location
Slide21 :
Site: Los Angeles, CA
Product: Chrome plating shop
Utility: Southern California Gas Company
Power Gen.: Four 30 kW Capstone micro-turbines
Heat Rec.: Hot water for plating tank heating and exhaust is re-used for sludge drying
Operation: base loaded
Status: Data collection started June 2002
Comments: Other plating companies interested in this configuration. Customer is pursuing use of absorption chiller with system. DEMONSTRATION
Higgins Brick Factory Chino Hills, CA : Higgins Brick Factory Chino 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 : 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 : Integration Test Center and User Facility at ORNL
CHP Outreach and Market Development Activities : 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
Regulatory Requirements Database for Electric Generators :
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 http://www.eea-inc.com/rrdb/DGRegProject/index.html
The Opportunity for Alternative CHP Fuels : 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 : Natural Gas Prices Have Risen and Are Expected to Stay High Source: EIA and NYMEX
Alternative Solution: Develop Other, Cost-Effective Fuels : 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 : Processing Technology Key to Use of Opportunity Fuels Source: Resource Dynamics
Why are Opportunity Fuels Not Used More Often? : 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 Performance Chart: Selecting the Top Candidates
DOE CHP Vision/Technology Roadmap : DOE CHP Vision/Technology Roadmap REGIONAL RECOMMENDATIONS:
Raise CHP Awareness - Create new and support existing CHP awareness efforts by Regional and State Groups
Conduct a coordinated outreach campaign to educate architects, building designers, and local building and other code officials about CHP
Provide SWAT team technical assistances to those interested in installing CHP Systems
Slide35 : Regional Application Centers Mid Atlantic
www.chpcenterma.org Midwest
www.chpcentermw.org Pacific
www.chpcenterpr.org Northwest
www.chpcenternw.org Northeast
www.northeastchp.org Intermountain
www.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 : 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 : 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.
Slide38 : Team Work for Success For more information: www.eere.energy.gov/de