Michael Burke - Director of Process Engineering, Enerfab, Inc.

Michael Burke - Director of Process Engineering, Enerfab, Inc.

Kentucky Association of Manufacturers
Energy Conference
May 14, 2014
Case Study – Executing a 200
kW Combined Heat and Power
Project
Michael Burke, Andrew Koenig and Mark
Linsberg
Case Study Overview
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Project Summary
Combined Heat and Power (CHP) Background
Concept Development
CHP Development Resources
Project Timeline
Project Site
System Design
Equipment
Construction
Completed System
Lessons Learned
Questions
Project Summary
• 6 Cylinder 1800 RPM
Natural gas reciprocating
engine
• Energy Input 2,100,000
Btu/hour
• Electrical Output 200 kW
• Usable hot water output
1,000,000 Btu/hour
• Installed at manufacturing
facility in Cincinnati, Ohio
• Projected 3.5 year payback
Combined Heat and Power (CHP)
• Also referred to as “Co-Generation”
• Combined Heat and Power (CHP) is an efficient and
reliable approach to generating electrical and thermal
energy from one fuel source.
• By recovering the waste heat from electricity
production and using it in a facility, fuel utilization
efficiencies are greatly increased. 85% - 90% for CHP
versus 55% - 60% for conventional generation.
• CHP is not a specific technology but an application of
technologies to meet an energy users needs.
Efficiency Advantage of CHP
Typical CHP System Flow
Concept Development
• 2008 – Ohio SB 221 Enacted – Set Alternative Energy,
Renewable Energy and Energy Efficiency Goals
• July 2012 – Ohio SB 315 – CHP can be used to meet SB
221 Energy Efficiency Goals
• August 2012 Presidential Executive Order – Set Goal 40
gigawatts of new CHP by 2020
• Experience developing, installing and operating a 360
kW packaged natural gas distributed generation unit
• Brighton fabrication facility interested in reducing energy
costs
• Abundance of natural gas from US shale plays
North American Shale Plays
CHP Development Resources
• DSIRE – Database of State Incentives for
Renewables and Efficiency – www.dsireusa.org
• EPA Combined Heat and Power Partnership –
www.epa.gov/chp
• USDOE Midwest Clean Energy Application
Center – www.midwestcleanenergy.org
Project Timeline
October 2012 – Developed CHP Project Concept
November 2012 – Presented Concept to Executives
December 2012 – Received approval to proceed with
facility energy audit
March 2013 – Completed energy audit supports 210
kW CHP System – Project funding approved
April 2013 – Located and acquired packaged CHP
unit – began final design, permitting and utility
interconnection processes
May 2013 – Located and acquired auxiliary equipment
Project Timeline - Continued
June 2013 – Completed design, obtained building
permit, started construction
July 2013 – Completed interconnection
agreement, completed civil construction
August 2013 – Received air permit, completed
mechanical construction
September 2013 – Completed electrical
construction and System Commissioning
December 2013 – Ribbon cutting event with
proclamation from Ohio Governor
Project Site
System Design – Electric Load
System Design – Thermal Load
• Acid Passivation Process in Plant
• 1,000,000 Btu water heater used to maintain
tank temperature.
Project ROI
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Facility Electric Cost - $0.095/kWh
Facility Gas Cost - $5.00 / MMBtu
Minimum Electrical Requirement – 200 KW/h
Thermal Demand – 900,000 Btu/h
Annual Operating Hours – 8,000 hrs
Project Installed Cost - $300,000
Simple Payback – 3.5 yrs
Equipment – 210 KW CHP Unit
CHP Unit Specifications
GridFox 210 Technical Information
GridFox 210 Emissions
Unit Weight
16,060 lbs
NOx
0.15 g/bhp-hr
Engine
Liebherr TBG 926
CO
0.60 g/bhp-hr
Generator
Stamford HC 434 E
NMCH
0.15 g/bhp-hr
Speed
1800 rpm
Exhaust Flow
1,750 lbs/hr
Fuel
Natural Gas
Noise Level
70 dBA
Voltage / Frequency
480 volts / 60 hz
Electric Power 100% Load
210 kW / 252 kVA
Energy Input 100% Load
2,100,000 Btu/hr
Engine Power 100% Load
295 bhp
Hot water out Temperature
185 Deg. F
Usable Hot Water Thermal Output
1,100,000 Btu/hr
Hot water return Temperature
158 Deg. F
Exhaust Gas Temperature
248 Deg. F
Inlet Gas Pressure
0.29 - 0.725 psi
Equipment - Auxiliary
Equipment - Auxiliary
Project Construction
Project Construction – Cont.
Project Construction – Cont.
Completed System
Completed System – Cont.
Project Takeaways
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Size the CHP system to match the heating load
Do not base project economics on selling electricity back to the utility
unless there are attractive net metering tariffs
Select equipment suppliers capable of providing field and technical
support
The CHP project team needs to understand electric supply contracts,
gas supply contracts, utility interconnection, air permitting, local
permitting, available incentives, project financing, project economics, plc
control systems and civil, mechanical and electrical design and
construction
Be prepared to educate internal and external stakeholders about CHP
benefits and limitations
Verify existing contracts for electricity allow CHP installation
Start the interconnection design and application process as soon as
possible
Questions?
Enerfab
4955 Spring Grove Avenue
Cincinnati, Ohio 45232
513-482-7616
www.enerfab.com
Michael Burke – [email protected]
Andrew Koenig – [email protected]