INTRODUCTION POWER GENERATION FROM LANDFILL GAS AT KENTUCKY PLANT

Transcription

1 INTRODUCTION POWER GENERATION FROM LANDFILL GAS AT KENTUCKY PLANT 1

2 OUR PRODUCTS Avalon Hybrid Avalon ES 350 Camry Camry Camry Hybrid 2

3 OUR PLANT TOYOTA MOTOR MANUFACTURING, KY GR 1,350 acre (546 hectare) site 830 acres (336 hectare) developed AR TEST TRACK Avalon ES 350 Camry TEAM SERVICES 1 TOYOTA CROSS DOCK UNIT K DIE CON P T2 W ASSY A3 A2 R T1 A1 TLS UTIL N 3

4 CHANGES TMMK is CHANGING 1. New products Lexus, October Reborn Replace aging plant and equipment, through Toyota - North America Reorganization Production Engineering Office and Lab located at TMMK, April

5 ENERGY GROWTH TMMK Energy Load Growth mw 120 Plan TMMK 2014 LEXUS 2015 REBORN PAINT 1 RETIREONE TOYOTA 2019 PH 1 & 2 Electricity usage will increase over 20% 5

6 OUR CO2 FOOTPRINT 600, ,000 TMMK METRIC TONS CO2 ANNUALLY 520K PAINT 1 RETIRE ONE TOYOTA PHASE 2 507K METRIC TONS 400, , , , K REBORN Bodyweld Plastics Powertrain Paint & 1 Toyota ONE TOYOTA REBORN LEXUS BASE CO2 is increasing ~ 20% 6

7 OUR CHALLENGE Toyota 2050 Challenge 7

8 OUR CHALLENGE Toyota 2050 Challenge 8

9 OUR IDEAS TO REDUCE CO2 How to reduce our CO2 footprint? ITEM Solar Array Wind Turbine Combined Heat Process Electricity from Landfill Gas CO2 GENERATION COST FEASIBILITY Zero Cost / KW high Only 30% effective in KY Zero Cost / KW high Only 35% effective in KY Lower CO2 Lower CO2 Minimize release of CO2 from landfill Higher energy usage to generate Fixed cost contract for 20 yrs Location remote from hot water process Landfill has 1MW of gas that will grow over time to 10 MW Install system to generate electricity from landfill gas 9

10 OUR PROJECT 1. Municipal Solid Waste breaks down naturally in landfills, creating landfill gas ( 50% methane) 2. A network of wells collects and prepares the landfill gas 3. Landfill gas is used to fuel generators, producing renewable electricity 4. Electricity is transmitted through underground lines to TMMK 5. Renewable electricity created from the landfill will be used to power the production of 10,000 vehicles per year Landfill greenhouse gas emissions will be cut by an estimated 95 %, which adds up to better air quality for the local community It s just one more way we re driving KY s future 10

11 OUR PROJECT N 1. Landscape between TMMK and Landfill is: a. All privately owned b. Includes public roads, railroads and streams c. Very hilly and rocky 11

12 CONSTRUCTION COSTS PROBLEM: Original construction bids were very high Let us Value Engineer the project VE ITEM DESCRIPTION BENEFIT SAVINGS Cable manufacture Cable rating Boring bit General contractor Put cable in conduit at the factory Use 35kV rated cable Use air hammer vs. traditional drill bit TMMK serve as general contractor for project One pull for conduit & one for cable becomes one pull for both 3 cables instead of 6 Smaller bore hole (7 vs 12 ) Can expand to 10MW 600 /day vs. 200 /day (300% improvement in output) 75% reduction in water Reduce sub contractor markup through direct negotiation $.55M $.7M $1.8M $.45M Total VE $3.5M 12

13 TRANSMISSION WIRE VALUE ENG ORIGINAL IDEA: a. 12 bore hole b. 6 conduits pulled c. 15kV wire rating d. 3 wires pulled now (5MW capacity) e. 3 wires pulled future (5 MW capacity) VALUE ENGINEERING: a. 7 bore hole b. 3 conduits & wire pulled now c. 35kV wire rating d. Wire in conduit from factory (10 MW capacity) 13

14 INSTALLING WIRE (6.5 miles 10km) PROBLEM: Ground is hilly and rocky so not easy to dig. Homeowners will not like their property disturbed. Let us bore the path for the conduit & wire BORING WIRE CONNECTION DIRECTIONAL BORING MACHINE 1. Very little disturbance to the owners land 2. Simplified overall construction of installing the wire 14

15 COMPLETE EQUIPMENT AT LANDFILL 1 MW GENERATOR 480 V, 3PH SUPPORT SHOP/ OFFICE 3 MW TRANSFORMER 480 V, 3PH TO 13,200 V, 3PH LANDFILL GAS VACUUM / PRESSURIZATION SKID 15

16 OUR CO2 FOOTPRINT REDUCTION METRIC TONS 600, , , , , ,000 TMMK METRIC TONS CO2 408K LFG = 1 MW 400K REBORN Bodyweld Plastics Powertrain Paint & 1 Toyota LFG = 2 MW LFG = 3 MW LFG = 5 MW LANDFILL ONE TOYOTA REBORN LEXUS (507K) 469K CO2 is decreasing ~ 5% 16

17 REFLECTION 1. This is first application of Landfill Gas at a Toyota plant in the world 2. This is the first private to private Landfill Gas project in the Commonwealth of Kentucky 17

18 THANK YOU ANY QUESTIONS? 18