Recycling Waste Heat – CHP
as an alternative
Wednesday, March 2, 2005
Waste Heat to Power Generation Workshop
University of California - Irvine
Patti W. Garland
Oak Ridge National Laboratory
for U.S. Department of Energy
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
• 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
Steam Boiler/Steam Turbine:
Gas Turbine or Engine/Heat Recovery Unit:
U.S. DOE CHP Vision and
Technology Roadmap
By 2010, double the amount of CHP capacity in the United States
1998, 46GW
2010, 92GW
Our CHP activities are
guided by the actions
identified in the
National CHP
Roadmap as those
items required of us to
meet the CHP Goal
 Raise CHP Awareness
 Eliminate Regulatory and Institutional Barriers
 Develop CHP Markets and Technologies
Where Are We??
70
60
50
40
1995
2000
2004
30
20
10
92
0
Industrial Commercial
Other
WE ARE HERE
80
81
GW
46
Our Progress to Date — 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 Capacity (2004): 81,000 MW
Other Mfg
8%
Other
Industrial
6%
Comm'l/inst
11%
Metals
5%
Food
Processing
8%
Refining
13%
Chemicals
34%
Paper
15%
Source: Energy and Environmental Analysis
CHP Uses a Wide Range of Fuels….
• Existing CHP Capacity (2004): 81,000 MW
Wood/
Biomass
3%
Waste
10%
Other
2%
Oil
2%
Coal
14%
Natural Gas
69%
Source: Energy and Environmental Analysis
…and a Wide Range of Technologies
• Existing CHP Capacity (2004): 81,000 MW
Gas
Turbine
19%
Recip
Engine
2%
Other
< 1%
Boiler/
Steam Turbine
31%
Combined
Cycle
48%
Source: Energy and Environmental Analysis
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
2000
$900-$1,200/kW
17-30% Efficiency
.35 lbs/MWh NOx
Fuel Cells,
Photovoltaics,
Wind,
Hydropower
Others
1992
29% efficiency
+2 lbs/MWh NOx
$600/kW
2001
Microturbines
2007
Cost competitive with
the market
40% Efficiency
.15 lbs/MWh NOx
Gas
Turbines
38% Efficiency
0.15 lbs/MWh NOx
$400/kW
2010
Cost competitive with
the market
<<.15 lbs/ MWh NOx
2000
$300-$400/kW
25-40% Efficiency
2-3 lbs/MWh NOx
Reciprocating
Engines
2007
Cost competitive with
the market
50% Efficiency
 0.15 lbs/MWh NOx
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
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
• 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
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*
Ft. Bragg
Cinemark
Quality Inn
Hilton
Ritz Carlton*
Sheraton*
W. Hotel – NYC*
Raley’s *
HEB
A&P
Ingersol Rand
Verizon
*FY04 Solicitation Awards
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
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
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
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
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
DEMONSTRATION
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.
Higgins Brick Factory
Chino Hills, CA
Cons. Utility:
Power Gen.:
Heat Rec.:
Operation:
Status:
Comments:
SoCal Gas
Three 80 kW Bowman micro-turbines
Indirect heat exchange to pre-heat kiln comb. air
Three base loaded turbines 24/7
System commissioning in-progress
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
University of Maryland,
College Park
Integration Test Center and User Facility at ORNL
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:
Specific Issues:
EMISSIONS
REGULATIONS
STATE ENVIRONMENTAL
REGULATIONS
SITING REGULATIONS
EXIT FEES
STANDBY RATES
BUILDING, ZONING,
AND FIRE CODES
AMMONIA ISSUES
REPORTING
REQUIREMENTS
ECONOMIC INCENTIVES
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
http://www.eea-inc.com/rrdb/DGRegProject/index.html
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
14
US City Gate Price
12
US Wellhead Price
NYMEX Henry Hub Price (Future)
$/MCF
10
California
8
6
4
2
Source: EIA and NYMEX
6
O
ct
-0
-0
6
Ja
n
r-0
5
4
Ap
3
l-0
Ju
O
ct
-0
-0
3
Ja
n
r-0
2
1
Ap
0
l-0
Ju
O
ct
-0
-0
0
Ja
n
r-9
9
8
Ap
l-9
Ju
7
O
ct
-9
Ja
n
-9
7
0
Alternative Solution: Develop Other,
Cost-Effective Fuels
• 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:
• 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
Processing Technology Key to Use of
Opportunity Fuels
Steam Turbine
Dry Waste
Boiler
Crop Residues
Fuel Cell
Ethanol
Food Processing Waste
Municipal Solid Waste*
Fermenter
Wood and Wood Waste
Landfill
Gas
Blended
w/ Diesel
Recip Engine
Landfill
Biomass
Gas
Dryer
Gasifier
Recip Engine
Fuel Cell
Moist Waste
Sludge Waste
Farm Waste
Food Processing Waste
Black Liquor
Source: Resource Dynamics
Combustion
Turbine
Digester
Gas
Anaerobic
Digester
*Municipal Solid Waste may require drying
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
Availability
Heating
Value
Fuel
Cost
Equipment
Cost
Emissions /
Environment
DER/CHP
Potential
Rating
Limitations
Anaerobic Digester Gas
5.0
Need anaerobic digester
Biomass Gas
4.0
Gasifiers extremely expensive
Black Liquor
3.0
Most BL already used up by mills
Blast Furnace Gas
2.0
Limited availability, low Btu
Coalbed Methane
5.0
Coal mines - lack CHP demand
Coke Oven Gas
3.0
Availability - most already used
Crop Residues
3.0
Difficulty in gathering/transport
Food Processing Waste
4.0
Limited market, broad category
Ethanol
4.0
Currently only used for vehicles
Industrial VOC’s
2.0
Must be used w/ NG turbine
Landfill Gas
4.5
Landfills – little demand for CHP
MSW / RDF
3.0
Low heating value, contaminants
Orimulsion
2.5
Orimulsion not available in U.S.
Petroleum Coke
3.5
Many contaminants; large apps
Sludge Waste
2.5
Low heating value, contaminants
Textile Waste
3.0
Must be cofired; larger apps
Tire-Derived Fuel
4.0
Best suited for large apps
Wellhead Gas
4.5
Oil / gas wells – no CHP demand
Wood (Forest Residues)
4.0
Fuel can be expensive
Wood Waste
4.5
Waste may have contaminants
Key:
= excellent / not an issue,
= average / could become an issue,
= poor / major issue
DOE CHP Vision/Technology Roadmap
REGIONAL RECOMMENDATIONS:
1) Raise CHP Awareness - Create new
and support existing CHP awareness
efforts by Regional and State Groups
2) Conduct a coordinated outreach
campaign to educate architects,
building designers, and local building
and other code officials about CHP
3) Provide SWAT team technical
assistances to those interested in
installing CHP Systems
Regional Application Centers
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.
Northwest
www.chpcenternw.org
Midwest
www.chpcentermw.org
Northeast
www.northeastchp.org
Pacific
www.chpcenterpr.org
Mid Atlantic
www.chpcenterma.org
Intermountain
www.IntermountainCHP.org
Gulf Coast
Southeastern
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
• 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
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.
•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.
Tools
Team Work for Success
For more information: www.eere.energy.gov/de