OPET CHP/DH WP 2 Task 2b. Small and Micro Scale CHP. Successful implemented projects in Slovakia May Deliverable

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1 OPET CHP/DH WP 2 Task 2b. Small and Micro Scale CHP Successful implemented projects in Slovakia May 2004 Deliverable Energy Centre Bratislava Ambrova 35, Bratislava, , SLOVAKIA Tel: Fax: office@ecb.sk European Commission (Directorate-General for Energy and Transport) Contract no. NNE5/2002/52: OPET CHP/DH Cluster

2 Case Study - SLOVAKIA Author(s): Ing. Samuel Piecka, Valer Klukan Organisation: Energy Centre Bratislava Address: Ambrova 35 Tel.: Fax: office@ecb.sk Web: The project "OPET CHP/DH Cluster" has obtained financial support from the European Commission (Directorate-General for Energy and Transport) under the contract no. NNE5/2002/52 for Community Activities in the Field of the specific programme for RTD and demonstration on "Energy, Environment and Sustainable Development - Part B: Energy programme" The responsibility for the content on this publication lies solely with the authors. The content does not necessarily represent the opinion of the European Community and the Community is not responsible for any use that might be made of data appearing herein

3 CASE STUDY 1 Hotel Európa, Komárno CHP unit Quantity Introduction into service TEDOM Plus 22 A Address: Contact Person: Hotel Európa Ing. Pavol Boroš M.R.Štefánika 1 Phone: Komárno Slovakia Parametres of CHP unit Operating parametres Electric output 22 kw Production of electricity p.a. 160 MWh Heat output 45,4 kw Production of heat p.a GJ Gas consumption 8,2 m 3 / hour Gas consumption p.a. 59,600 m 3 Short description of project: Project was realised by MEE (Energy efficiency management) method. Previous steam source was replaced by warm water source. Except CHP unit there was installed also Viessmann Paromat Simplex boiler with specific output of 225kW, made with internal warm water circle, equipped with measuring and regulation system. CHP unit is working on maximal performance in summer time during VT, in winter time 24 hours per day. Boiler is additional source of heat in time from October till March

4 Savings per year Gross payback SKK 3,98 years Hotel Európa in Komárno has 80 beds, 6 one bed rooms and 74 places in 2 bed rooms. To hotel belongs also restaurant with 140 places, coffee-bar with 80 places, 2 saloons (20 places each) and night bar with 60 places. Hotel disposes also with subterranean parking places for 16 cars and summer terrace for 140 guests. Laundry is also included. Professional orientation of hotel management directs mostly into travelling, so most important topic when investing is improving quality of offered services. Heat production and electricity purchasing is necessary condition of well working hotel, but those investments are not visible for guests, so they can not evaluate them. Energetic and energy costs are usually taken just trough electricity and gas bills. Normally, there is just common reconstruction of boiler house that is connected just with higher efficiency. There is missing synergy effect of more technological actions. Usually there are not technical and economical analyses before realisation that may help investor to get better base for decision taking. Lowest investment does not mean lowest operating costs. Next problem is, that boiler house supplier has no motivation to take care about optimal operation after get paid. For optimal operation is necessary continuous monitoring of all activities and adapting all operations to current conditions. That requests regular checking and practical knowledge. Because of problems above, management of hotel Európa took strategic decision that gives services, reconstruction and optimalization of power engineering to energy services company manager of energy efficiency MEE. In economical strong countries is this type of services common. Manager of hotel is educated in technics so he was able to evaluate submitted project and its realisation and he was also able provide all the staff with deep information about boiler house. Base for dealings about form and content of cooperation was request of hotel manager for not increasing costs (costs can not be higher than were before realisation). After deep analyse of electricity and heat consumption in period of 3 years were made basic conditions for contract by manager of MEE. The process of optimalization of energy source in hotel Európa started after contract signing. Hotel Európa has its own heat source that contains of 3 steam boilers. 2 were connected, third is cold reserve. Heat was used for warm water heating trough heat exchangers and for preparing of warm household water that is accumulated in 2 pieces of accumulating boilers (2 x 2,5 m3 ). Average consumption in boiler house was about x 1000 m3 gas annually. Maximal efficiency of boiler house was estimated on 80%. That means that it has made about 1750 GJ of heat p.a. Hotel took electricity from distribution network in tariff B5 with technical maximum 66kW. Year consumption of electrical work was over kwh

5 In boiler house was installed system of measuring and regulation from Siemens that provided boiler house with warm water medium optimal performance. There was no time for making boiler house more efficient and lower costs. Total liquidation of antecedent technology was because of amount of investments and also economical payback impossible. There was founded compromise that was based on creating warm water circuit non regulated water with heat output 45,5 kw and electrical output 22 kw. CHP unit is designed to cover own electricity consumption of hotel and heat production in normal charging. Because of that, it is not able to cover all demand in months when is requested higher output. Steam boiler utilisation is not possible because of total efficiency aspect. So there was added warm water boiler Viessmann Promat Simplex with output 225 kw into internal warm water circuit. In case of surplus, there is also emergency cooler. Previous steam boilers are still working; one of them was connected through exchanger gas/water into internal warm water circuit parallel with equipment named above. It is an emergency heat source in case of dropout. Previous system of regulation and measuring was renewed. After project preparation and getting building permission, all reconstruction took just 2 months. Operation of hotel was not affected during this time except 3 hour electricity switch off because of connecting CHP unit. Time of switch off was consulted with manager of hotel. MEE provided project with financing, its building and operating. He will own all system all agreed time and after that time, he will transfer it to hotel in accordance with agreed conditions. During this time, he will support hotel with heat and electricity. That model will help with reconstruction without increasing costs and also there will be no administrative problems for hotel management. Hotel did not have to invest any additional money into reconstruction and also get promise of not increasing costs for energies. There is deal between hotel management and MEE management about every year measuring and calculating of operating costs. If real costs are lower than guaranteed values that are hotel paying for energies, difference will be divided between both sides in accordance to agreed system. It means, that hotel will pay for energies less from second year without any investments. Assets MEE for hotel Európa: Modernisation of power engineering without investments Promise of not increasing energy costs Real saving from second year because of CHP unit - 4 -

6 CASE STUDY 2 The city of Dolný Kubín has been significantly enlarged during last decades. Therefore the district heating within the city has been developed. Current system of DH is in ownership of the municipality and it is operated through the city company TEHOS ltd. From the first moment big attention was given to preparation of the heat supply strategy. The detailed heat supply study has been elaborated and step by step is implemented. Regarding to this study TEHOS has decided to start combined heat and power in the smallest boiler house, where the cogeneration unit TEDOM Premi 22 has been installed. Modernization in Dolný Kubín The boiler house in Obrancov Mieru Street is from all four the smallest one, which are operating under TEHOS ltd. The boiler house originally equipped with two hot water gas boilers with total specific output of 3.4 MW produces heat and DHW and supplies in the surroundings 105 flats with total useful heating area of 6,330 m 2, nursery, several shops, offices and hostel of Business College. The real heat consumption during the last years in above mentioned buildings were in average 12,500 GJ, but the calculated consumption was less than 11,500 GJ. The main reason was bad technical condition of the outer distribution network and the lower operation efficiency of the boiler house in the summer period, when the boilers were operating only for DHW preparation. Due to this fact the TEHOS ltd. has decided for comprehensive investment in order to minimize the heat losses in outer distribution network of heating water and DHW. Further objective was rational heat production especially in this boiler house. The main intents: exchange of outer distribution network for for-isolated pipes in the circuit within this boiler house - 5 -

7 replacement of 4 pipe network was with 2 pipe network installation of heat exchange station on demand sites The total length of the reconstructed heat water distribution net was 345 m. The boiler Viessman Vitoplex 10 with lower specific output of 285 kw was added into the boiler house in order to improve overall efficiency of the heat production and DHW production. The CHP unit was installed in order to decrease the heat production cost. The original total specific output of the boiler house was 3,400 kw (2x1700kW) after implementation of the project it was only 2,030 kw, one boiler of 1,700 kw has remained as the cold reserve. Having regard to high volume of the whole investment costs the TEHOS ltd has decide to accept the proposal of INTECH Slovakia to apply the method of energy efficiency management (MEE) for the CHP part of the project. The MEE method is based on achievement of energy savings without direct financial investments from the site of owners or operators of heat source. The necessary investment is provided by the company offering the Energy efficiency management. Technical solution The cogeneration unit is parallel connected with the boilers, and the operation of the CHP unit is continuous with priority according to other boilers. The other boilers are starting according to the requirements of heating system. The starting order of the boilers is specified. The production of electricity form CHP unit is in parallel operation with public energy network. The CHP unit is equipped with asynchronous generator; it means that it could be in operation only when the power supply of the boiler house from the public network is ok. In the CHP unit there are installed electrical protections in order to control and record the differences between the CHP parameters and public network parameters. If these parameters exceed the specified values the CHP unit is automatically shut down. This function completely fills the requirements of the distribution companies and provides protection against negative effects from the distribution network. In the boiler house 9,000 kwh of electric power was consumed. Additional 2800 kwh had to be purchased to cover the demand in the time when the CHP is shut down, due to the revision of the unit. The overall supply of the electric energy from CHP into the public network was more than 28,800 kwh. The whole investment will be repaid from the electricity sales

8 CASE STUDY 3 GAS ENGINE CHP IN ENERGY INDUSTRY SLOVENSKÝ PLYNÁRENSKÝ PRIEMYSEL, A.S. Operator: Address: Sector: Slovenský plynárenský priemysel, a.s. Mlynské nivy 44/a, 82511, Bratislava Energy Case Study Background Slovenský plynárenský priemysel a.s. (Slovak Gas Industry) is a state owned utility responsible for transfer of natural gas from Russia and also acts as national distributor of natural gas. The company started with direct support of CHP projects in the mid 1990s, as it established together with the German Ruhrgas the joint venture INTERKVET (KVET = Combined production of electricity and heat). Since then, SPP has also entered several larger project enterprises aimed to implementation of CHP projects in the municipal area. Expected changes: With respect to deregulation of energy markets in the Slovak Republic, the government plans to privatise the company. The change of ownership may imply also changes in the organisation of the company business. The CHP plant is located at the headquarters of SPP, and this case study was included as the first example of a tri-generation CHP in the Slovak Republic. Characteristic of site: Minimum thermal demand: 0,45 MWh Minimum electric demand: 0,312 MW e Maximum thermal demand: 3 x 0,450 MWh Maximum electric demand: 3x 0,312 MW e In 2000, the total electricity demand represented 3400 MWh e, of which 3373 MWh e was supplied by the CHP plant MWh e was sold to the power network operated by ZSE

9 The reasons for investing in CHP were economic operation and environmental standards. The strategic issues of importance were: reference site for CHP - as SPP intends to act as one of main agents in encouraging the increasing use of CHP reduced energy costs secure energy supplies environmental targets CHP expertise Technical description of installation The CHP plant at the headquarters of SPP consists of 3 engine/generator sets of type TBG 310, with heat exchangers for utilization of thermal energy in the intercooler and exhaust gases manufactured by Waukesha, Dresser Group, U.S. and supplied by Motorgas s. r.o., Czech Republic. The CHP plant unit was installed within the existing gas and heat distribution system in the boiler house and is connected also to the cooling system; the main cooling components include an absorption cooler supplied by TRANE, cooling output 2x294kW, filled with LiBr- H 2 O, as well as 1 central emergency radiator water/air cooler with ventilator for removing surplus heat and 3 radiator water/air coolers with ventilators for cooling of the absorber and condenser. The CHP plant is operated by the company INTERKVET a joint venture which was set up by SPP and Ruhrgas. The power generated by the CHP plant is partly consumed by SPP a.s. and the remaining part is supplied to the energy grid operated by ZSE. During the heating period, the heat produced by the CHP plant is partly used for preparation of warm water and heating of the SPP headquarters, partly supplied to the Benzinol Company, which is located in the neighbourhood of the SPP area. In the summer period, the CHP is used for preparation of warm water as well as for cooling of the SPP administration complex. Factors which influenced the design were: heat to power ratio, temperature of heat, which is favourable for absorption coolers opportunity to export power or heat balances of heat and power consumption Plant capacity, outputs and efficiency Parameter Units Capacity Rated electrical output MW e 3 x Rated heat output MW t 3 x Fuel input (natural gas) MWh pa Electricity outputs MWh pa Heat outputs MWh pa Electrical efficiency: % Heat efficiency: % Table 1 Technical data of the project in Slovenský plynárenský priemysel, a.s. Plant Availability - 8 -

10 The CHP plant is available during the whole year, except during planned shut downs for routine maintenance i.e hours per year. Annual operation full load equivalent: 5876 hours/year. Economic description of installation Investment costs: (mill. EURO) CHP technology 0.63 construction + connections others Table 2 Investment costs of the project in Slovenský plynárenský priemysel, a.s. Operating costs: Fuel costs mill. EURO 0.14 /year Operational costs EURO/ kwh e Electricity tariff for buying EURO/kWh e 0.097/0.02 Electricity tariff for selling EURO/ kwh e 0.033/0.03 Tariff for heat sales EURO/kWh t Table 3 Operating costs of the project in Slovenský plynárenský priemysel, a.s. Incomes, savings and payback period Savings from power thousand EURO 96.8 Income from power thousand EURO/year Income from heat thousand 200 EURO/year Net income/savings from CHP thousand operation EURO/year Payback period years 3.9 Table 4 Incomes, savings and payback period of the project in Slovenský plynárenský priemysel, a.s. Source of finance: own source - 9 -