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CHP Technologies Update
CHP Operators Workshop
Iowa Economic Development Authority (IEDA)
November 6, 2014
Cliff Haefke
Energy Resources Center (ERC)
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o Located within the College of Engineering at the University of Illinois at Chicago
(UIC)
o Founded in 1973 as a “fast response” team capable of extending technical
expertise, advice, and professional assistance to various organizations.
o ERC is an interdisciplinary public service, research, and special projects
organization that works to improve energy efficiency and the environment.
o Expertise areas include energy efficiency, distributed generation, utilities billing
management, and biofuels and bioenergy.
o www.erc.uic.edu
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
Presentation Sources
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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
Agenda
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CHP Technology Components
Prime Mover
Reciprocating Engines
Combustion Turbines
Microturbines
Steam Turbines
Fuel Cells
Electricity
On-Site Consumption
Sold to Utility
Fuel
Natural Gas
Propane
Biogas
Landfill Gas
Coal
Steam
Waste Products
Others
Generator
Synchronous
Induction
Inverter
Heat
Exchanger
Thermal
Steam
Hot Water
Space Heating
Process Heating
Space Cooling
Process Cooling
Dehumidification
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Controls
o Five (5) prime mover technologies comprise 97% of CHP
projects today and 99% of installed CHP capacity
CHP Installation Summary Status
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Source:
Catalog of
CHP
Technologies
Comparing CHP and Separate
Heat and Power (SHP) Efficiencies
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Source:
Catalog of
CHP
Technologies
Summary of Existing Prime Mover
Technologies: Advantages & Disadvantages
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Source:
Catalog of
CHP
Technologies
o Advanced Reciprocating Engine Systems (ARES)
o Packaged Systems
o High Value Applications
o Fuel-Flexible CHP
o Demonstrations
Recent U.S. DOE Research
and Development
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For more information:
http://www.energy.gov/eere/amo/chp-rd-project-descriptions#packagedchp
1. Power Generation
Technologies
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)
– Improved combustion (including pre-combustion chambers)
– Electronic controls
1A. Power Generation Technologies
Engines
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Source:
Catalog of
CHP
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
– 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
1A. Power Generation Technologies
Engines (additional notes)
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Source:
Catalog of
CHP
Technologies
o Increased Efficiency
– Range of 24-37% efficiency
– Combined Cycle (CC) efficiency up to 61%
o Reduced Emissions
– 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
1B. Power Generation Technologies
Combustion Turbines
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o Turbine Inlet Cooling (TIC)
– 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
1B. Power Generation Technologies
Combustion Turbines (cont.)
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Source: www.turbineinletcooling.org
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
1B. Power Generation Technologies
Combustion Turbines (additional notes)
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o Efficiency range of 5-48% (depending on capacity and technology)
o Range of smaller capacity has reduced from 500 kW to 100 kW
o Electronic controls have replaced pneumatic controls
o Installed cost has come down
o Focus on renewable markets is stimulating demand for small and
medium turbines
o 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
1C. Power Generation Technologies
Steam Turbines
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o Availability of capacity range has increased from 35-75 kW to
30-330 kW achieving better operation economics:
– Higher efficiencies
– 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.
1D. Power Generation Technologies
Microturbines
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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)
– Proton exchange membrane (PEMFC)
1E. Power Generation Technologies
Fuel Cells
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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 250oF and as high as 750oF (>750oF 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
1F. Power Generation Technologies
Organic Rankine Cycle (ORC)
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2. Thermally Activated
Technologies
2A. Thermally Activated Technologies
(Heat Recovery)
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Heat Recovery Steam Generators (HRSG)
o New horizontal flow, once-through vertical-tube Benson technology
o Replaces the high-pressure drum with thin-walled components
o Improves dependability, increases cycling load performance with
minimal impact on frequent start-up/shut-down cycles on lifetime and
O&M costs
o Improves rapid start-up capability
Engine Heat Recovery
o Replacing copper with aluminum tubes with corrosion-resistant
protective coating
o 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
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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. Source: Thermax
o Can cool a fluid to as low as 32oF compared to previous
limits of 40-44oF
o Prevent crystallization of LiBr at cooling water
temperatures as low as 50oF
o Can use water temperature as low as 160oF
o Use more effective corrosion inhibitor (Lithium Molybdate
instead of Lithium Nitrate and Lithium Chromate)
o Use of auto purging
2B. Thermally Activated Technologies
Absorption Chillers (cont.)
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2B. Thermally Activated Technologies
Absorption Chillers (cont.)
24 Source: Thermax
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
2B. Thermally Activated Technologies
Absorption Chillers (cont.)
25 Source: Thermax
o OEM COP comparison of absorption chillers
o Efficiencies need to be weighed against installed cost and complexity
0.0 0.5 1.0 1.5 2.0
Single Effect - Jacket Water
Multi-Energy-ExGas + Jacket Water
Double Effect- ExGas
Triple Effect- ExGas
COP Comparison
2B. Thermally Activated Technologies
Absorption Chillers (cont.)
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Source:
Thermax
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 300 130 115
Multi-Energy Chiller – Single Chiller on Ex Gas +
Jacket Hot Water Combined 300 130 106
Triple Effect Ex Gas +
Single Effect Hot Water Chiller 345 150 132
Source: Thermax
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:
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
2C. Thermally Activated Technologies
Desiccant Dehumidifiers
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Source:
ASHRAE Presentation 2009
(Lew Harriman)
3. Ancillary Equipment
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
– 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
3A. Ancillary Equipment Controls and System Operations Software
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o Biogas conditioning and proper maintenance is
essential for extending life of equipment
o H2S, 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 H2S/siloxane combination removal systems
o Industry has gained valuable experience
3B. Ancillary Equipment
Biogas Conditioning
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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
US DOE CHP Technical
Assistance Partnerships (TAPs)
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Advanced Manufacturing Office (AMO) manufacturing.energy.gov 33
Screening and Preliminary
Analysis
Feasibility Analysis
Investment Grade Analysis
Procurement, Operations,
Maintenance, Commissioning
Uses available site
information.
Estimate: savings,
Installation costs,
simple paybacks,
equipment sizing
and type.
Quick screening
questions with
spreadsheet
payback
calculator.
3rd Party review of
Engineering
Analysis.
Review equipment
sizing and choices.
Review
specifications and
bids,
Limited operational
analysis
DOE CHP TAP Technical
Development Assistance
