CHP Technologies Update CHP Operators Workshop Iowa Economic Development Authority (IEDA) November 6, 2014 Cliff Haefke
Energy Resources Center (ERC) o o o o o Located within the College of Engineering at the University of Illinois at Chicago (UIC) Founded in 1973 as a fast response team capable of extending technical expertise, advice, and professional assistance to various organizations. ERC is an interdisciplinary public service, research, and special projects organization that works to improve energy efficiency and the environment. Expertise areas include energy efficiency, distributed generation, utilities billing management, and biofuels and bioenergy. www.erc.uic.edu 2
Presentation Sources o Websites and Published Resources U.S. DOE EERE U.S. EPA CHP Partnership Catalog of CHP Technologies http://www.epa.gov/chp/technologies.html o Input from CHP Industry Manufacturers and Equipment Representatives 3
Agenda o Power Generation Technologies Reciprocating Engines, Gas Turbines, Steam Turbines, Microturbines, Fuel Cells, Organic Rankine Cycle o Thermally Activated Technologies (Heat Recovery), Absorption Chillers, Desiccant Systems o Ancillary Equipment Controls, System Operations Software, Biogas Conditioning 4
CHP Technology Components Fuel Prime Mover Generator Electricity Natural Gas Propane Biogas Landfill Gas Coal Steam Waste Products Others Reciprocating Engines Combustion Turbines Microturbines Steam Turbines Fuel Cells Heat Exchanger Synchronous Induction Inverter Controls On-Site Consumption Sold to Utility Thermal Steam Hot Water Space Heating Process Heating Space Cooling Process Cooling Dehumidification 5
CHP Installation Summary Status o Five (5) prime mover technologies comprise 97% of CHP projects today and 99% of installed CHP capacity 6 Source: Catalog of CHP Technologies
Comparing CHP and Separate Heat and Power (SHP) Efficiencies 7 Source: Catalog of CHP Technologies
Summary of Existing Prime Mover Technologies: Advantages & Disadvantages 8 Source: Catalog of CHP Technologies
Recent U.S. DOE Research and Development o Advanced Reciprocating Engine Systems (ARES) o Packaged Systems o High Value Applications o Fuel-Flexible CHP o Demonstrations For more information: http://www.energy.gov/eere/amo/chp-rd-project-descriptions#packagedchp 9
1. Power Generation Technologies
1A. Power Generation Technologies Engines o Increased Electric Power Efficiency Range of 27-49% depending on capacity and engine design (lean burn, rich burn) Most engines use turbochargers (>300 kw) Improved materials (allow higher temperatures, higher speeds, higher power densities, longer equipment life) o Increased Fuel Flexibility From only natural gas to include biogas, liquid fuels, and others o Reduced Emissions (without after treatment) 11 Improved combustion (including pre-combustion chambers) Electronic controls Source: Catalog of CHP Technologies
1A. Power Generation Technologies o NOx levels as low as 1.8 lb/mwh and CO emissions of 8.1 lb/mwh before exhaust gas treatment o Adding selective catalytic reduction (SCR) and CO oxidation catalyst can allow lean burn recip. engines to meet California South Coast emissions standards of 0.07 lb/mwh for NOx and 1.0 lb/mwh for CO o Public private R&D partnerships Engines (additional notes) Advanced Reciprocating Internal Combustion Engine (ARICE) funded by California Energy Commission (CEC) Advanced Reciprocating Engine System (ARES) funded by DOE Active for 10 years and produced commercialized Phase I and Phase II engines Phase III aiming to reach overall engine efficiency goals of 0.1 g/bhp NOx emissions, 50% BTE efficiency, 80+% CHP efficiency, maintenance costs of $0.01 /kwh while maintaining competitive costs 12 Source: Catalog of CHP Technologies
1B. Power Generation Technologies o Increased Efficiency Range of 24-37% efficiency Combined Cycle (CC) efficiency up to 61% o Reduced Emissions Combustion Turbines Less than 10 ppm of NOx without after treatment Diluent injection, lean premixed combustion, After treatment technologies: Selective Catalytic Reduction (SCR), CO oxidation catalysts, catalytic combustion, catalytic absorption systems o Improved Part-Load Flexibility o Improved Fuel Use Flexibility 13
1B. Power Generation Technologies o Turbine Inlet Cooling (TIC) 14 Combustion Turbines (cont.) TIC prevents loss of generation capacity up to 30% and reduction in generation efficiency up to 10% Existing technologies included direct evaporative (e.g. wetted media and fogging) and chiller systems Now indirect evaporative and hybrid systems (combination of two technologies, evaporative + chiller, indirect + direct) are available Use of thermal energy storage has significantly increased opportunity for TIC improving peak generation capacity and overall turbine economics Source: www.turbineinletcooling.org
1B. Power Generation Technologies Combustion Turbines (additional notes) o Public private partnerships have advanced gas turbine technology, other improvements include: Increased reliability, availability, and maintainability Development of the recuperated 4.6 MW Solar Mercury gas turbine with low emissions and electrical efficiency of 37.5% (LHV) compared to unrecuperated gas turbine of similar size having electric efficiency of 28.5% (note: recuperated equals less available thermal energy) o Large gas turbine research focused on improving CC efficiency to a goal of 65% (LHV), reducing emission even further, integrating gas turbines with clean coal gasification and carbon capture o Smaller gas turbine research focused on improving performance, enhancing fuel flexibility, reducing emissions, reducing life cycle costs, and integration with improved thermal utilization technologies 15
1C. Power Generation Technologies Steam Turbines o o o o o o Efficiency range of 5-48% (depending on capacity and technology) Range of smaller capacity has reduced from 500 kw to 100 kw Electronic controls have replaced pneumatic controls Installed cost has come down Focus on renewable markets is stimulating demand for small and medium turbines U.S. DOE funding collaborative research and development of improved ultra-supercritical (USC) steam turbines with goals of: Capable of 55-60% efficiencies Based on boiler tube materials that can withstand pressures of up to 5,000 psi and temperatures of 1,400 F Prototype targeted for commercial testing by 2025 16
1D. Power Generation Technologies o Availability of capacity range has increased from 35-75 kw to 30-330 kw achieving better operation economics: Higher efficiencies Microturbines Lower capital and maintenance costs o Packaged systems available up to 1 MW o Designed to meet state and federal emissions regulations o Fuel flexibility has increased from just natural gas to include sour gas, biogas, and liquid petroleum fluids o Developments under way for a 370 kw machine w/ 42% eff. 17
1E. Power Generation Technologies o Under development for over 40 years as an emerging power source o Many different sizes are commercially available today, decrease in costs over past years, installed costs > $4,600/kW o Four primary types for fuel cells: Phosphoric acid (PAFC) Molten carbonate (MCFC) Solid oxide (SOFC) Fuel Cells Proton exchange membrane (PEMFC) 18
1F. Power Generation Technologies Organic Rankine Cycle (ORC) o Similar to steam Rankine cycle but uses an organic fluid instead of steam o Generates electric power from low-level waste heat source, as low as 250 o F and as high as 750 o F (>750 o F steam turbines show better economics) o Net power output when using exhaust gases from a reciprocating engine is about 7% of the rated capacity of the engine o Net power output when using gas turbine exhaust gases is about 20% of the rated capacity of the turbine 19
2. Thermally Activated Technologies
2A. Thermally Activated Technologies (Heat Recovery) Heat Recovery Steam Generators (HRSG) 21 o o o o New horizontal flow, once-through vertical-tube Benson technology Replaces the high-pressure drum with thin-walled components Improves dependability, increases cycling load performance with minimal impact on frequent start-up/shut-down cycles on lifetime and O&M costs Improves rapid start-up capability Engine Heat Recovery o o Replacing copper with aluminum tubes with corrosion-resistant protective coating Reduce installed cost by ~10% (Al costs 1/3 of Cu cost and also weighs only 30% of copper weight per pound) Source 1: www.modernpowersystems.com Source 2: equipment rep
2B. Thermally Activated Technologies Absorption Chillers Brief History of North American Chiller Marketplace o 1960 s the advent of single stage absorbers o 1970 s the advent of two stage absorbers o 1980 s direct fired chillers (Japan) o 2000 exhaust driven absorbers (Asia) o 2010 resurgence in Marketplace due to Natural Gas and CHP. 22 Source: Thermax
2B. Thermally Activated Technologies o Can cool a fluid to as low as 32 o F compared to previous limits of 40-44 o F o Prevent crystallization of LiBr at cooling water temperatures as low as 50 o F o Can use water temperature as low as 160 o F o Use more effective corrosion inhibitor (Lithium Molybdate instead of Lithium Nitrate and Lithium Chromate) o Use of auto purging Absorption Chillers (cont.) 23
2B. Thermally Activated Technologies Absorption Chillers (cont.) o Cooling potential on engine ratings Engine Size (kw) Cooling Capacity* on Exhaust + Jacket Water (ton) 300 100 ~ 110 500 175 ~ 200 1,000 300 ~ 350 1,500 425 ~ 500 2,000 525 ~ 600 * Indicative and may vary as per engine waste heat parameters 24 Source: Thermax
2B. Thermally Activated Technologies Absorption Chillers (cont.) o OEM COP comparison of absorption chillers o Efficiencies need to be weighed against installed cost and complexity COP Comparison Triple Effect- ExGas Double Effect- ExGas Multi-Energy-ExGas + Jacket Water Single Effect - Jacket Water 0.0 0.5 1.0 1.5 2.0 25 Source: Thermax
2B. Thermally Activated Technologies Absorption Chillers (cont.) o Example: Comparing Cooling Capacity Potential and Cost from a 1 MW Reciprocating Engine Chiller Configuration Cooling Capacity (TR) Cooling Capacity (%) Price (%) Single Effect Hot Water Chiller 230 100 100 Double Effect Ex Gas Chiller + Single Effect Hot Water Chiller Multi-Energy Chiller Single Chiller on Ex Gas + Jacket Hot Water Combined Triple Effect Ex Gas + Single Effect Hot Water Chiller 300 130 115 300 130 106 345 150 132 Source: Thermax 26 Source: Thermax
2C. Thermally Activated Technologies Desiccant Dehumidifiers o Can be regenerated by low level heat source as low as 115 F (from condenser cooling) o Annual sales have increased ten folds: 100s to 1000s o Prices have come down more than 40% over the last ten years primarily due to increased production o Commercially available desiccant systems: 27 1. Desiccant cooling systems using direct and indirect evaporative cooling, but providing no dehumidification 2. Gas-fired desiccant, with mechanical cooling for dehumidification with cooling 3. Small commercial liquid desiccant, for dehumidification and cooling 4. Condenser-heat-reactivated desiccant for ventilation dehumidification, at neutral temperature Source: ASHRAE Presentation 2009 (Lew Harriman)
3. Ancillary Equipment
3A. Ancillary Equipment Controls and System Operations Software o Multi-function controllers o Operations software using client data and market conditions to establish plans for operation based on real time load modeling, building systems, and other factors 29 Customize yearly planning and budgeting Integrated solutions with other equipment Project generator usage, fuel usage, maintenance Day ahead decision making capabilities on when to run generator Real time price triggers on when to run generators Manage electric and natural gas budget and improve risk management Execution of plans may be accomplished by direct supervisory control to the clients process systems or by automatic notification systems
3B. Ancillary Equipment Biogas Conditioning o Biogas conditioning and proper maintenance is essential for extending life of equipment o H 2 S, moisture, and siloxane removal is important Siloxanes in biogas from wastewater treatment and landfills More recent treatment options include re-generable siloxane treatment, biological H2S removal systems, media based H 2 S/siloxane combination removal systems o Industry has gained valuable experience 30
US DOE CHP Technical Assistance Partnerships (TAPs) o U.S. DOE CHP Technical Assistance Partnerships (TAPs) originally established in 2001 by U.S. DOE and ORNL to support DOE CHP Challenge (formally known as RACs and CEACs) o Today the 7 TAPs promote the use of CHP, District Energy, and Waste Heat to Power Technologies o Strategy: provide a technology outreach program to end users, policy, utility, and industry stakeholders focused on: Market analysis & evaluation Education & outreach Technical assistance o Midwest Website: www.midwestchptap.org 31
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DOE CHP TAP Technical Development Assistance Screening and Preliminary Analysis Feasibility Analysis Investment Grade Analysis Procurement, Operations, Maintenance, Commissioning Quick screening questions with spreadsheet payback calculator. Uses available site information. Estimate: savings, Installation costs, simple paybacks, equipment sizing and type. 3 rd Party review of Engineering Analysis. Review equipment sizing and choices. Review specifications and bids, Limited operational analysis Advanced Manufacturing Office (AMO) 33 manufacturing.energy.gov
Questions Cliff Haefke (312) 355-3476 chaefk1@uic.edu www.erc.uic.edu