Compressor Station Heat Recovery

Dennis Cousino, P.E. - Zero Stage, Inc.

9/7/2010

Why Recover Compressor Station Heat using the ZSI

Technology?1.Increased Capacity

As much as a 30% improvement in station horsepower & PL flow during peak seasons

2.Increased EfficiencyUp to a 50% improvement in Btu/IGHP heat

rate

3.Improved EmissionsAs much as a 50% reduction in tons-per-year

emissions

How Do You Make Recovery of Compressor Station Heat

Payback?Conventional methods of compressor station heat recovery require the installation of electrical generation, with it’s associated complexity and cost.

This electricity needs to be sold to recover value from the investment.

Most pipeline operators don’t want to get involved in another “business”, generating & selling electricity.

Way too many “GEARS” for most

mid-stream companies!

What is the Zero Stage Solution?

Instead of using the recovered energy to generate electricity, our Solution puts this power into improving the capacity, efficiency & emissions of your pipeline system.

Your Gas

Turbine

Heat Recovery & ZSI Boost System

Your Compressor

Returning value for your investment,

in your base business!

The Zero Stage Recovered Energy Solution

Recovered energy from the turbine exhaust improves the density of the inlet air to the gas turbine, making the engine more powerful, more efficient & reducing emissions.

Fuel Energy

Exhaust Energy

Pipeline Energy

A simpler Solution, with fewer “Gears”, to go wrong!

The Zero Stage Front End – Installed & Running

A Conventional 1980 Solar Saturn Compressor Set

Same Compressor, w/ZSI Inlet Boost System, Exhaust Heat Recovery will

be Added in the Next Phase

Let the Zero Stage Engineering Team evaluate your station.

Chances are, there are significant economic benefits to

be found in applying heat recovery & ZSI boost technology

to your pipeline system!

Zero Stage, Inc. 918-605-6702

Gas turbine emission reduction & resultant performance enhancement thru inlet air density modification

Advanced technology for reducing emissions from stationary engines used in; Compressor Drives Power Generation

thru inlet air pressurization and intercooling.

Emissions Reduction Value

The ZSI system allows the existing engine to operate continuously at the point of lowest emissions, at any power level.

The reduction is thru inlet air density modification, using external air pressurization and inter-cooling.

Increased mass flow improves combustion & mixing efficiency, which lowers CO emissions.

Increased mass flow & reduced fuel use lowers combustion temperature, reducing thermal NOx.

Improved engine performance & efficiency, and horsepower substitution reduces GHG emissions

Lower Emissions by Design Point Matching & Horsepower Substitution

Every engine has a design point at which the combustion process is optimized. Most of the time, the plant location & changing ambient conditions keep the engine from operating at this point.

ZSI has developed a system that keeps the combustion optimized for operation at the lowest emissions level, at any site location, ambient temperature and power level.

Boost fan HP adds to the cycle power, with no emission component, just like electrical driven compression.

R&D testing of the ZSI system shows that running at this point reduces the tons per year as much as 40% from uncontrolled conditions.

Associated Performance Improvement

During emission limiting operation, the ZSI system can increase site rated HP of your existing gas turbine as much as 50%, up to the OEM limit, every day, in any ambient condition, at any site.

Additional unit capacity results in the ability to shutdown other stations to match demand, with associated emissions & fuel reductions.

Improved Efficiency

The ZSI technology increases the engine efficiency as much as 5%, every running hour, resulting in a significant reduction in fuel, CO and GHG emissions.

In a heat recovery application of the ZSI system, the engine-compressor, or engine-generator, will operate with combined cycle efficiency, showing as much as a 30% improvement over the simple cycle, pre-ZSI, conditions. This improvement comes without the cost of adding a second compressor or generator to the plant.

Improved Engine Longevity

Operation of the ZSI modified system will result in lower combustion temperatures, at any HP. These lower temperatures result in longer Time-Between-Overhaul increments, along with lower NOx, CO and GHG production.

The ZSI inlet boost compensates for degraded air seals within the turbine, delaying overhauls.

Technology

The ZSI process has been developed over a period of 20 years, and is currently “Patent Applied For”.

The Technology Demonstration Project was installed on a Saturn compressor set, in West Texas, operational & tested in March 2010.

Hot weather performance & emission testing is currently underway.

Application

The ZSI system can be used on any gas turbine, new or old, at any site.

ZSI technology works with other add-on, exhaust emissions clean-up systems, like SCR’s.- Because the engine is boosted, it can operate with a higher backpressure, reducing the size & cost of the SCR installation.- Lower tons/yr from the unit improves the operating cost of the SCR, thru lower ammonia usage. - ZSI boost recovers the performance losses normally associated with these systems & enhances the overall performance of the station.

System Integration

No modification of the engine controls is required, and the engine operates within OEM parameters.

The ZSI process uses PLC logic and is easily integrated into existing SCADA systems for local operation or remote dispatch, without the need for on-site operators.

The ZSI system components are pre-assembled & tested to minimize station outage time. Typical installation and commissioning time is 2–3 days from arrival on site, for a Saturn application.

R&D Demonstration Site

1980 Saturn Engine/Compressor Set

R&D Demonstration Site

The ZSI Inlet Boost Unit installs between the turbine inlet air duct and the air filter house