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SUPERCRITICAL CO2 REFINES COGENERATION n ENHANCING SCADA FOR COGENERATION nEFFICIENCY BREAKTHROUGH IN SOLAR THERMAL CELLS nREFURBISHMENT
DRIVES GROWTH IN RUSSIA n AWARD-WINNING CHP IN THE UKS nMEXICAN INDUSTRY TAPS COGEN POTENTIAL nTHE MAN DRIVING DOUBLE-DIGIT GROWTH AT MWM
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London 2012 Games
leave CCHP legacy
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March - April 2013
CHPS VITAL ROLE IN EUROPE IS DE THE SOLUTION FOR INDIA? EUROPEAN TRIAL OF FUEL CELL MCHP MIXED PLASTIC WASTE BECOMES A FUEL
UK STATELY HOME TURNS TO CHP NOVEL WASTE HEAT RECOVERY IN FOOD INDUSTRY OHIOS COGENERATION BOOST BIOGAS FROM MEAT WASTE RUNS CHP PLANT
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Commercial CHP
to enjoy growth
worldwide
1303COSPP_C1 C1 3/26/13 9:00 AM
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Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 18
Policy; CHPs vital role in Europe
When Member States with
constrained budgets review
their policy approaches
towards the electricity sector in
particular, CHP does not always
get the appropriate attention.
Cogeneration is the best
available technology in the
paper, chemicals, refnery and
food sectors but is a challenge
for national policy makers, who
often are not fully aware of its
role and operation in industry.
There is also a tendency to turn
the troubles in the electricity
sector into troubles in industry
as a whole. This is a challenge
for the cogeneration sector.
Adapt and respond
Support measures for
renewables have recently
been revised in many EU
Member States. Germany
provides a good example of
how CHP legislation can adapt
and respond appropriately to
negative market conditions
and promote energy effciency
and signifcant emissions
reductions.
CHP is well supported in
Germany, where the original
scheme has seen at least three
revisions in the past six years, all
aimed at refning the support
so as to trigger a budgeted
and desired change.
To overcome an
unfavourable spark spread,
the nations CHP law offers
a subsidy that tops up the
market price for electricity.
In this way investors face an
acceptable time period before
seeing a return on investment.
For some German
businesses that have installed
CHP this has fallen from seven
years to four because of the
new measures. In addition,
given the disadvantage of CHP
installations covered by the EU
ETS over heat-only producing
installations, the German law
offers a bonus to these classes
of cogeneration units on top of
the subsidy.
However, it is not easy
to make good legislation.
Gradually and increasingly EU
Member States are realising
that policies will need fne
tuning once introduced.
European nations are
presenting policies in which
revision and adjustment
processes are transparent and
follow a clear procedure.
Industry and business
also has a role in ensuring
that nations draft good
legislation. They must be
active and present right at the
beginning, when new laws are
proposed. They must work in
the early days, often unseen
and without great acclaim,
to propose, comment and
caution governments as their
policymakers devise new
legislation for a specifc sector.
Policy devised for one sector
can unintentionally impact
another sector. Unfortunately
as CHP straddles the heat and
electricity markets, it tends
to experience such negative
outcomes more often than
desirable ones. Legislation
concerning fuel or aimed at
the electricity utility sector will
also impact cogeneration.
The CHP industry, business
and the wider stakeholder
group must recognise this and
be prepared to contribute to
the evolution of legislation to
lower the risk of unintended
consequences.
Strong support
Despite the long shadow
of the economic crisis, the
EU has re-committed itself
to improvements in energy
effciency. The European
Parliament has passed Energy
Effciency Directive (EED)
2012/27/EC, which is major
energy-related legislation
that aims to close the gap
emerging between its energy
savings target and progress
on energy savings in the 27
Member States.
For more information, enter 9 at COSPP.hotims.com
1303COSPP_18 18 3/26/13 9:08 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 19
Policy; CHPs vital role in Europe
While the EED is written
specifcally with CHP in
mind, the details of how it
is implemented will dictate
whether it is successfully
translated into national
action without unintended
consequences.
The promotion of CHP as
a clear energy effciency
technique with measureable
results has also been
re-emphasised by the
Directive, which all Member
States must now transpose
by 2014. In that process they
must assess cogeneration and
use the results to fnd suitable
support measures for it. Those
short and near-term actions
triggered by the current over-
capacity in the electricity
sector, which tend not to
strengthen CHP, will inevitably
have to come under scrutiny
during the implementation of
the EED.
It would be wise for the 27
national governments of the
EU to consider, how the EED will
impact on their policies that
affect CHP. In this context, the
Commission indicated in its
communication of November
2012 Making the internal
energy market work that in
the future Brussels will take up
more vigorously what it calls
the enforcement challenge
around the internal energy
market. This tendency is widely
expected across energy policy.
Near-term response
The main challenge for the
sector is to ensure that the
effciency benefts already
achieved by CHP and the
decarbonising of industry are
maintained even at a time of
restricted resources. There is
no doubt that cogenerators
will have to make diffcult
changes but these should be
proportionate to the role of
CHP in providing vital heat to its
customers and not just power
to the grid. CHP is at the heart
of best available technology
for several industries. It will
play a vital role in maintaining
these industries through the
economic challenges they
currently face.
A risk exists that despite
the support of the EED, the
current adjustments of policy
will mean that CHP plants
will receive less than equal
treatment and that the
unintended consequences
of such policy will hit cogens
host industries and the citizens
they employ. Should this
materialise the existing CHP
base could begin to erode,
meaning that the energy
savings gap in Europes energy
effciency target to 2020 opens
wider and that hard-won gains
would have to be won again.
Manufacturers of CHP
equipment and industrial CHP
users have a clear role to play
in achieving a high-effciency
low-carbon society in Europe.
Key manufacturers will
present their views on how
the industry is adjusting to
the rapidly changing energy
policy demands at the COGEN
Europe Annual Conference,
on 18-19 April in Brussels.
Industrial users will also explain
their business reasons for
choosing CHP and how this
has helped to reduce energy
bills. For more information, visit
www.cogeneurope.eu.
Dr. Fiona Riddoch is
Managing Director
of COGEN Europe.
cogeneurope.eu
This article is available
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Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 20
Indias on-site power potential
I
t is no secret that Indias
national electricity grid
is in urgent need of a
major overhaul.
Just last year, 10% of the
worlds population faced a
series of power cuts Indias
Northern and Eastern grids
came to halt and 600 million
people were confronted
with the perilous state of the
countrys network system.
Moreover, a grid failure of
this magnitude has focused
attention on the massive
demand for power in India
and its struggle to generate a
much-needed supply.
The bottom line is that
although Indias generation
capacity is the ffth largest
in the world behind the US,
China, Japan, and Russia, its
power development is much
further behind. There are still
almost 289 million people
without access to electricity,
accounting for up to 25%
of the total population. In
rural areas, the fgure is more
like 33%. Some big states,
especially those in the south,
often have a power shortage
of 12% during peak hours, and
even the capital New Delhi
suffers regulalry from supply
shortages.
The root cause of last years
blackout can be traced to the
weak grid structure that has
been allowed to develop for
many years. There is also a lack
of a centralized authority with
overall responsibility for the grid.
As things stand, the Power Grid
Indias dramatic grid failure last year unmistakingly demonstrated the greater need
for decentralized energy in the sub-continent, writes Richard Baillie.
Can distributed energy
provide the answers to Indias grid dilemma?
In July last year, more than half of Indias population was plunged into darkenss following a series of blackouts Credit: Keith Brown
1303COSPP_20 20 3/26/13 9:08 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 21
Indias on-site power potential
Corporation of India Limited is
responsible for the inter-state
transmission of electricity and
controls the national grid
infrastructure, which comprises
more than 10,000 km of power
lines. Local power bureaus or
private suppliers control the
distribution networks. There
is no unifed operation and
management system. In this
sense, different states act on
their own and often draw more
power than they are allowed to
from the national grid, leading
to overloaded grid operation.
To further complicate
matters, its national network
system is categorised into fve
regional grids - the Northern
Grid, Southern Grid, Western
Grid, Eastern Region and
North Eastern Regional Grids.
All are interconnected with
synchronous links - i.e. power
transfer between regional
grids is based on supply and
demand, with the except of
the Southern Grid, which is
connected via asynchronous
links. However, it is proposed
However, it is proposed
that by 2013-14 the latter
is connected to the other
grids synchronously, thereby
creating a single national grid.
This could help to alleviate
matters.
India aims to expand
its generation capacity by
44% over the next fve years.
In June 2012, the countrys
power supply fell short by 5.8%
against a peak-hour demand
for 128 GW, according to
government data.
Another problem, however, is
that most of Indias grid system
transmits electricity by back-
to-back DC interconnections.
In this type of infrastructure,
if there is a breakout in one
states grid system, connected
grids will also be affected,
experiencing substantial
drops in their power carrying
capapcity. Because of this,
it is not possible for different
districts cannot provide strong
support to each other or share
their resources in case of an
emergency.
Thus, serious concerns
have been once again raised
about the countrys growing
infrastructure needs and
inability to meet its energy
demand. Government offcials
concluded, The grid failed
because of the overloading
of power, and contend that
many states tried to draw
more power from the grid than
they were allotted.
The countrys lack of
energy security is a major
constraint to its development.
The slow pace of tariff reforms
is hindering infrastructure
investment at the state level
in most parts of the country.
Furthermore, the government
has allowed wheeling of
power and recommended
a 2% charge. However, some
states do not allow wheeling,
while others have imposed
excessive charges of over
15%. Thus, the centralized
model of power generation,
transmission and distribution is
growing more and more costly
to maintain at current levels to
meet increasing energy needs.
The continuing blackout and
shortage of power are clearly
hampering Indias economic
growth and its capacity for
growth.
For economic, as well as
environmental reasons, India
is now looking to shift towards
a decentralized off-grid model,
including renewable-based
sources like solar, wind, hydro,
biomass, biogas, geothermal
and hydrogen-fuelled fuel cells.
Projects are moving
fastest in the industrial
state of Maharashtra. There,
cogeneration projects with
installed capacity to generate
374 MW of power are now on
line, bringing the total power
generation from cogeneration
plants in the state to 1101 MW.
Of the total power generation,
58%, about 638 MW, will be
pumped in the state grid and
remaining would be utilised by
sugar factories to meet their
daily energy requirements.
The leftovers after crushing
sugarcane are dried and
converted into bagasse.
The bagasse is used for
combustion to generate
power. It meets the power
requirement of the sugar
factories and surplus can be
pumped into the state grid.
Cogeneration has become
additional source of income
for many sugar factories in the
state.
Speaking to the Times
of India, State Sugar
Commissioner Vijay Singhal
said, As many as 22 sugar
factories in the state have
started construction of
cogeneration project in the
vicinity of the factories. The
power is primarily used for
running the sugar factory,
generally during the period
between November and
April. In the last few years,
the crushing capacity of
sugar factories from Western
Maharashtra has increased,
leading to increase in power
generation. Today, 601.4 MW
power is generated by cogen
plants of 37 sugar factories
and another 22 factories are
nearing completion of their
cogen plants. They will add
374.5 MW and once these 22
projects start operating, total
power output will be 1,101 MW
by the end of this fscal.
Tata Power, an independent
power producer and division
of Tata, an industrial giant
with businesses in steel,
software, cars, chemicals,
and telecommunications, is
also exploring whether the
economics of smaller-scale
distributed energy can be
made to add up to a cost-
effective business plan that
can be rolled out across India.
Tata Power is projecting
rapid growth from about 3,000
MW of capacity now to 25,000
MW later this decade. As part
of a long-term sustainability
plan, Tata Power intends to beef
up its use of clean, renewable
power, notably hydropower,
where it already has some
projects under development.
Tata Power is also putting
smaller bets on other clean-
energy technologies for
distributed power generation,
for example, Tata Power is
pursuing a model where a
cooperative of farmers would
sell agricultural residue to Tata
Power, which would operate
an on-site power generation
unit to sell power to that
community. To generate power,
Tata expects to use a small-
scale 100 kW gasifcation
system, while exploring other
technologies, such as wind or
solar, should be explored as
well, he said.
The nation and Tata Power
are on a growth path and it
is [a] diffcult hill [to climb] to
become clean. We hope that
once we are at [the summit],
the next phase of growth
after 2025 will [require] these
[clean] technologies and
[we will] expand on those,
said Tata head of business
development Suresh Malhotra.
If Tata Power does have an
economic interest in pursuing
distributed clean energy, its
near future is mostly centralized
dirty power. Of its 3000 MW of
capacity, about two-thirds of
that comes from coal, gas, or
oil. There are another 450 MW
from hydro and 200 MW from
wind. In the next 10 to 15 years,
sadly much of the new power
to come on line will come from
burning fossil fuels.
Indias Ministry of New and
Renewable Energy (MNRE)
plans and promotes the
development of all sources
of renewable energy. MNRE
is looking to see renewables
1303COSPP_21 21 3/26/13 9:08 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 22
Indias on-site power potential
share of the energy mix rise
from around 8% currently to
more than 15% by 2020.
First of all, its the right thing
to do, but we think well have
a competitive advantage
when CO
2
regulation comes
down the [line] two or fve
years from now, Malhotra said.
From a clean-tech point of
view, we are taking a proactive
approach...We think in the
longer term, grid parity will be
achieved cost-wise.
Furthermore, with the
announcement of the
National Action Plan on
Climate Change (NAPCC),
there is a marked shift in policy
to diversifying the generation
mix to lower-carbon intensity
options. The NAPCC calls
for boosting renewable
energys share of the national
generation from 2% to 5%,
with specifc emphasis on
signifcantly increasing
solars share. It envisions the
increased use of distributed
solar photovoltaic (PV) cells,
but also, as technology
permits, commercial-scale
concentrating solar power.
The Electricity Act 2003 and
the NAPCC together provide
a roadmap for increasing the
share of renewables in the total
generation mix. However, the
utilities policy on renewable
and distributed generation
units seems to overlook the
benefts of the latter in remote
areas.
The potential for using
microturbines and heat
recovery boilers from small
generators is signifcantly
increasing. For example,
NEERU, a biogas company
in Andhra Pradesh, and
Capstone Turbines of the US
are working with Mukund
Dairy Farms in Andhra Pradesh
to set up a microturbine-
based cogeneration system
to generate electricity
and use the residual heat
in a pasteurization plant.
Unfortunately, renewable
energy resources are not
evenly spread across the
country and the high cost of
reneable-based distributed
generation can discourage
local distribution companies
from purchasing more than
their obligatory amount of
renewable generation.
To combat this, the Energy
and Resources Institute
(TERI) is looking to build
distributed generation-based
power system or mini-grids,
which can be installed and
subsequently integrated into
the conventional utility grid or
used to provide electricity for
localised loads.
TERI has designed,
developed, and demonstrated
Indias frst-of-its-kind Smart
Mini-Grid system based on
renewable energy. The aim
was to optimally use smarter
control of distributed energy
sources, combined with
intelligent management of
loads to improve the effciency
and reliability of the overall
mini-grid system.
TERI maintains that its
Smart Mini-Grid has greater
resistance to loading as
compared to the conventional
grid system because it
optimises the use of multiple
energy resources to meet
different loads
The Smart Mini-Grid also
has the capability to respond
automatically to network
problems and minimise
network disruptions. It can
anticipate and respond
to problems and avoid or
mitigate power outages,
power quality problems and
service disruptions by using
real-time information from
embedded sensors and
automated controls. The grid
is also equipped with a self-
healing system that enables
it to rapidly detect, analyze,
respond to disturbances and
restore supply.
The TERI Smart Mini-Grid
facility combines the following
resources -- a 3.3 kWp wind
generator, a 1 kWp thin-flm
solar PV, a 12.5 kW solar PV, a
100 kWe biomass gasifer and a
600 Ah, 48 V storage battery.
A diesel generator has also
been added to the system to
negate the intermittency of
the renewable resources and
hence ensure a reliable power
supply.
Such smart min-grid systems
have great potential, not only
in commercial and industrial
complexes, but also in hospitals,
shopping malls, apartments,
residential complexes,
educational institutions and
remote unelectrifed, as well as
electrifed locations to ensure
maximum fexibility, reliability,
and safety, with an enhanced
effciency of the overall system.
TERIs Smart Mini-Grid
model can provide solutions
to problems of energy security
and sustainability, and ensure
reliable quality power. And TERI
frmly believe that such a model
can be used to strengthen the
Indias electricity sector and
enhance the performance
of rural electricity supply
systems. This system enhances
effciency and offers maximum
reliability fexibility and safety
in the overall electricity
distribution network.
Large-scale implementation
of such systems will go a long
way in helping to meet the
energy needs of the country.
It can also be integrated with
the existing programmes of
MNRE, such as the Jawaharlal
Nehru National Solar Mission,
which aims to achieve 20 GW
of grid-connected solar power
by 2022, as well as the national
rural electrifcation programme.
This article is available
on-line. Please visit
www.cospp.com
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1303COSPP_22 22 3/26/13 9:08 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 23
Ohio leads on CHP
T
he state of Ohio is
being very pro-active
in promoting CHP
across its territory,
and in recent years has
been attempting to put a
structure in place to build
on this effort. The Public
Utilities Commission of Ohio
is actively engaged in a
pilot project with the US
Department of Energy (DOE)
to remove educational
and regulatory barriers to
combined heat and power
(CHP) development in Ohio
and across the nation.
The reasons for this are
fundamentally manifold: to
create distributed generation
in pockets of electricity
constraint; to provide Islands
of Power during outages for
sensitive/critical organizations
including hospitals and data
centers; and to provide black
start capabilities for everyone
else. Ohio is also looking to
assist industries in developing
emission compliance
strategies and to expand
customer choices to remain
economically competitive.
Ohio clearly has
tremendous opportunity for
CHP. Approximately 766 MW
of capacity is installed in
the state, and the US DOE
estimates Ohios market
could be 15-times that current
amount by 2025. Indeed, in
2011, the DOE released a report
The US state of Ohio is pushing ahead with plans that beneft cogeneration,
including new legislation that redefnes CHP and provides fnancial incentives,
says Richard Baillie.
Ohio sets its
sights on a bigger role for cogen
Although Ohios exisitng installed CHP base is low relative to other US states, it has ambitions to change that
1303COSPP_23 23 3/26/13 9:09 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 24
Ohio leads on CHP
outlining various scenarios for
CHP potential in the state. The
fndings suggested a potential
of approximately 8000 MW
if systems were unable to
sell power and 11,000 MW if
systems could export power.
As a suite of technologies,
CHP and waste heat recovery
(WHR) have the potential to
signifcantly raise industrial
energy effciency, increase the
use of distributed generation of
electricity and reduce demand
on traditional generation
facilities, such as fossil fuel-fred
assets. That said, currently, with
few actual CHP installations,
Ohio is near the bottom in the
US for implementation, with its
766MW of installed capacity.
The reason for the gap
in terms of potential versus
implementation can be
attributed to several factors
in Ohios law, regulatory
environment and investor-
owned utility culture. All three
of those barriers legal,
regulatory and cultural must
be overcome in order to make
industrial effciency and lower
fossil fuel emissions a reality.
To help achieve these
goals, American Electric Power
Ohio (AEP Ohio) signed a
stipulation in a major rate
and restructuring case in
September 2011. This case
lasted several months, and
involved the participation
of all the major entities that
traditionally participate at the
Public Utilities Commission of
Ohio. The signed settlement
includes a provision that
requires AEP Ohio to procure
350 MW of CHP or WHR
resources. This settlement is
seen as a major win for CHP/
WHR development interests
in Ohio, and for clean
energy advocates and their
supporters. And as a direct
result of just this one case,
Ohio is currently poised to
increase the amount of CHP/
WHR in the state by 46%.
What happened in the
case was that the Ohio
Environmental Council
(OEC) reviewed AEP Ohios
proposed resource and rate
plan, identifed gaps and then
prepared an aggressive case
arguing for the inclusion of
CHP/WHR resources.
The OEC then began direct
negotiation with the company,
working to incorporate
CHP and WHR into a global
settlement for the case. The
OEC also worked directly
with other stakeholders to
incorporate CHP/WHR goals
and objectives into the
negotiation efforts by the Ohio
Manufacturing Association
who was a critical partner
in pushing for a CHP/WHR
solution to the case.
This achievement was made
possible through legal action
and staff, as well as stakeholder
engagement with fellow
environmental organizations
and the manufacturing
community. Soon, the OEC will
begin work with AEP Ohio and
manufacturing stakeholders to
build an effective mechanism
to secure this new power
resource from the marketplace,
and achieve essential cost
recovery.
Similarly, in Duke Energy
Ohios three-year rate case, the
companys recent stipulation
also contained a provision
that moves Ohio closer to
CHP reality. In that case, Duke
agreed to work with OEC to fnd
and evaluate CHP potential
in the companys Cincinnati
service territory. The results will
be an integral part of Dukes
2012 Long Term Forecast fling.
Sources of fnancing
There are various sources of
fnancing for cogeneration in
Ohio. The Energy Loan Fund
is a programme that provides
low-cost fnancing to small
businesses and manufacturers
for energy improvements that
reduce usage and associated
costs, cut fossil fuel emissions,
and/or create or retain jobs.
Funding is provided through
the Advanced Energy Fund
and the federal State Energy
Program, as well as the
American Recovery and
Reinvestment Act.
The Energy Loan Fund is
expected to result in energy,
economic, and environmental
impacts that include a
minimum reduction of 15%
in energy use relative to
existing conditions, a return
on investment that allows the
loan to be paid back within
a reasonable time period
and job creation or retention
plus an improvement in
environmental quality
Eligible activities include
energy effciency retrofts,
distributed generation, such as
CHP systems, as well as high-
effciency traffc signals and
street lighting. The maximum
loan amounts for the Energy
Loan Fund are 80% of eligible
project costs up to US$250,000
for small businesses, 80% of
eligible project costs up to
$1 million for manufacturers
and 90% of eligible project
costs up to $1 million for public
entities and non-profts.
In addition, federal funding
is available through the US
DOEs State Energy Program.
Authorisation for the State
Energy Program is under
10 CFR Part 420, while state
funding is also available
through the Advanced Energy
Fund, which is authorized by
sections 4928.61 to 4928.63 of
the Ohio Revised Code.
The Ohio Air Quality
Development Authority also
helps to fnance air quality
facilities for small and
large businesses, utilities,
government, and universities.
Such facilities constitute an
key tool that organizations
can use to become more
competitive and successful
in their respective felds, while
preserving the environment.
A legislative approach
As well as fnancial incentives,
there have been some
recent legislative changes
that make CHP in the state of
Ohio a much more attractive
proposition. Two bills that
passed through the Ohio
General Assembly in June
2012 support cogeneration
projects by qualifying them
for use by the states investor-
owned utilities to meet certain
requirements under Senate Bill
221 (SB 221), Ohios landmark
energy law enacted in 2008.
One bill, known as SB 289,
passed by both the Ohio
House and Senate classifes
cogeneration technology as
a renewable energy under
Energy Loan Fund will cover $250,000 of project costs for small businesses
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the states renewable portfolio
standard (RPS), which requires
utilities to procure 12.5% of
their energy from renewable
sources by 2025.
The other bill, known as
SB 315, introduced in the
Senate at the request of
Governor John Kasich
classifes CHP technology
as both renewable energy
and energy effciency. Thus,
it qualifes it for inclusion
in the RPS or as an eligible
technology under SB.221s
energy effciency and peak-
demand reduction provisions,
which require utilities to achieve
certain annual benchmarks for
energy savings and demand
reduction.
SB 315 allows project owners
to choose which classifcation
renewable energy or energy
effciency, but not both to
apply to a particular project.
This bill promotes waste
energy recovery (WER) and
combined heat and power
projects by qualifying them
for use by Ohios investor-
owned utilities in order to meet
certain portfolio standard
requirements under SB 221.
Specifcally, SB 315 allows
WER systems to be used to
satisfy requirements under:
(a) Ohios RPS; or (b) SB 221s
energy effciency standards,
which require utilities to
achieve cumulative energy
savings of 22% by 2025.
SB 315 also makes a clear
distinction between WER
and CHP. The bill defnes a
waste energy recovery
system as a facility that
generates electricity through
the conversion of energy from
either: (i) exhaust heat from
engines or manufacturing,
industrial commercial, or
institutional sites, except for
exhaust heat from a facility
whose primary purpose is
the generation of electricity;
or, (ii) reduction of pressure
in gas pipelines before gas
is distributed through the
pipeline, provided that the
conversion of energy to
electricity is achieved without
using additional fossil fuels.
Generally, WER systems
capture waste energy from
an industrial or commercial
process, but do not introduce
additional fossil fuel sources.
On the other hand, a
combined heat and power
system is defned as the
co-production of electricity
and useful thermal energy
from the same fuel source
designed to achieve thermal-
effciency levels of at least
60%, with at least 20% of the
systems total useful energy
in the form of thermal energy.
CHP systems often introduce
additional fossil fuel energy
sources, such as natural gas.
The defnitions of WER and
CHP are important because SB
315 allows WER project owners
to choose whether to qualify a
system as a renewable energy
or energy effciency resource.
Notable success stories
The following case study
is illustrative of a growing
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 26
Market sector Generation potential (MW)
Paper 2329
Chemicals 2838
Primary metals 430
Food 310
Other industrial 767
Commercial/Institutional 3082
Total 9800
Table 1.Ohios potential CHP market
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www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 27
Ohio leads on CHP
number of facilities that are
cutting costs and increasing
their generation effciency
through the use of CHP.
With the enrollment of
34,000 students across eight
campuses, Kent State University
(KSU) is Ohios second-largest
university. The 880-acre
main KSU campus contains
115 buildings, and has an
electricity load of close to
80 million kWh annually,
and is expected to rise with
the continued expansion
of campus buildings and
residence halls.
Seeing this demand
increase on the horizon,
KSU engineers began to
consider CHP as a strategy
to meet growing energy
loads and control costs.
KSU, in conjunction with the
US DOE and Dominion East
Ohio, a leading producer
and transporter of energyin
the US, undertook a study to
investigate the benefts of
deploying CHP technology
at its new power plant facility.
The primary objectives were
to reduce fuel consumption,
decrease emissions, and lower
the cost of electricity.
The study concluded that
all of these objectives could
be met through cogeneration
units. What made KSU such a
good candidate for CHP was
not just its need for power
but also the fact that it has a
substantial year-round steam
demand in both the winter
and summer.
The system consists of a
Taurus 60 turbine, which can
run on natural gas or fuel oil
and a Taurus 70 generator
capable of generating 7.2
MW of electricity - supplied by
Solar Turbines.
Both feature heat recovery
steam generator (HRSG) units,
which enable plant operators
to use waste steam to chill
water. The 60,000 pounds of
steam captured by the HRSG
units provide more than half of
the campus steam needs.
In winter, the generators are
able to provide almost 90% of
KSUs electricity needs, while
in summer they meet 60%
of the load. In the event of a
power outage, KSUs power
system can also island itself
from the grid and produce
enough power for most of the
universitys functions.
The power plant was built in
two phases at a total cost of
$23 million. The savings on fuel
costs are substantial enough
to eclipse the CHP systems
annual maintenance costs
of more than $400,000. Total
annual savings are expected
to be more than $700,000.
Other commericial CHP and
WER projects in Ohio, funded
by the Offce of Energy include
Toledo Museum of Art and the
Toledo Convention Center,
Ohios manufacturing
sector also appears to offer
strong opportunities for CHP to
make inroads ( Table 1).
The biggest source of
Ohios waste comes from
ineffciencies in the power
sector. Almost one-third of
all energy consumed in the
state is lost during generation
and transmission, largely as
a result of an outdated grid.
According to offcial fgures,
more than 1 quadrillion BTUs
of energy, worth an estimated
$17.6 billion, was lost in this
way in 2009.
Ohio ranks in the top
fve states in the US for CHP
potential but is way down
in 44th place as regards
its adoption. By distributing
generation closer to end users
and encouraging the use of
CHP and WER, the state has
the potential to signifcantly
cut emissions while saving
substantial fossil fuel. costs
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Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 28
Fuel cell micro-CHP in Europe
A
lthough Elcore
GmbH, a German
maker of fuel cell
micro-CHP units,
only has a few of its products
in homes in its domestic
market, it already has high
hopes of selling plenty on
a fully commercial basis
from later this year before
spreading its wings into
other European markets.
The Munich-based frms
optimism rests largely on being
among nine suppliers picked
in the 53 million (US$71
million) European-wide Field
Trials for Residential Fuel Cell
micro-CHP project (Ene.feld).
Under the initiative,
European Union (EU) utilities,
manufacturers, research
institutes and universities will
collaborate on feld trials
across 12 EU Member States
with fuel cell micro-CHP units
ranging from 0.35 kWe, and
powered with natural gas and,
subsequently, hydrogen.
By September 2014, 960
units are due to be installed,
with each running as a
demonstrator project for
three years, during which
lifecycle costs and barriers
to commercialisation will
beassessed.
For fuel cell micro-CHP,
the project has come at a
good time. Currently, no units
are being sold on a fully
commercial basis in Europe.
Full launch targets have been
pushed back and investor
confdence is low.
Many people that we
speak to in the industry feel
that its now or never for the
technology, says Scott Dwyer,
micro-CHP research manager
at Delta-ee, analysts based in
Edinburgh, UK.
But with things like Ene.
feld and other national feld
trial projects such as CALLUX
and NIP, both in Germany, and
one in Denmark we think its
justifable to expect a wave of
product launches in the next
two to four years.
A range of technologies
is to be scrutinised under
Ene.feld: high-temperature
(HT) solid oxide fuel cells
(SOFC); low-temperature (LT)
SOFC; HT proton exchange
membrane fuel cells (PEMFC);
and LT PEMFC. The units will
be integrated into various
European heating systems
both foor standing and wall
hung either in the home or in
separate installation cabinets.
The goals are to
demonstrate market potential
and segmentation; gauge the
manufacturing and operating
costs, and the environmental
benefts of fuel cell micro-CHP;
develop product specifcations
and harmonised codes and
standards; ready a supply chain
for commercial deployment of
fuel cell micro-CHP in the 12
participating Member States;
and provide evidence to
speed up policy support from
governments and broader
adoption by new and existing
sales channels such as
through utilities.
The European Commissions
Fuel Cells and Hydrogen
Joint Undertaking (FCH JU) is
committing nearly 26 million
to Ene.feld over 60 months
from 1 September 2012, as
one of the Joint Technology
Initiatives (JTIs) under the
EUs outgoing 7th Framework
Programme for funding
research and development.
The European Commissions
Directorate General for Energy
(DG Energy) expects this
spend to leverage at least
the same commitment from
participating industries, half of
whom are small and medium-
sized enterprises (SMEs), such
as Elcore.
Insight into new markets
For Elcore, contributing to
Ene.feld is a no-brainer, given
the benefts it believes it will
reap from installing about
135 trial units in households
in Germany and three other
countries yet to be decided.
Ene.feld will give us
exposure to foreign markets
so that we can learn what
customers there like and
do not like, says Martin
Eichelbrnner, Elcores Sales
An ambitious initiative across 12 European nations, involving utilities, manufacturers
and research institutions, aims to test the potential for fuel cell micro-CHP in the EU
residential market, reports Robert Stokes
Mega trial
opens Europe to micro-CHP
1303COSPP_28 28 3/26/13 9:10 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 29
Fuel cell micro-CHP in Europe
and MarketingManager.
It will also introduce us to
different certifcation regimes.
This will be valuable to us,
though one of the ultimate
challenges that needs to be
addressed is standardisation
of these throughout Europe.
This neatly reinforces key
points about Ene.feld. It
will share the knowledge
gained from testing a range
of technologies in highly
varied residential markets,
climates and types of houses
throughout the EU. Take
Germany, for instance. Elcore
already has a few units
operating in homes there
and plans to offer many more
systems from late 2013, quite
separately from its involvement
in Ene.feld.
According to Eichelbrnner,
these commercial units will be
offered at about 9000 each,
inclusive of value added tax.
Subsidies for micro-CHP units
in Germany currently only
cover up to 500 per unit, but
Eichelbrnner says experience
suggests that German
customers would fnd the
9000 price tag acceptable,
especially set against a
claimed payback time of only
seven or eight years, as well as
savings of up to 50 per cent on
their electricity bills.
Its approach is to offer units
that sweat for customers
by working 24/7 to deliver
baseload electricity of 300
We and baseload heating of
600 Wth. This value proposition
has already been validated
in Germany but Ene.feld
means that households in
several other countries will get
to assess this approach for
themselves, said Eichelbrnner.
In the UK, 9000 (7780)
could look a bit steep to
consumers who tend to
grumble about having to
spend even 1500 ($2300) on a
replacement hot water boiler. So
Ene.feld aims to reveal the
nuances of such socio-
economic barriers to the
deployment of fuel cell
micro-CHP.
In Japan for instance,
says Dwyer, one of the main
routes to market for fuel cell
micro-CHP is through housing
developers who build a huge
number of houses each year
and differentiate themselves,
for example, by telling buyers
they can generate their own
power by having a fuel cell
micro-CHP installed,
But a larger proportion
of people in Japan build or
buy new homes rather than
buying second-hand, which
is more prevalent in Europe.
In Germany, a lot of heating
systems tend to be sold by
installers, who are generally
quite loyal to manufacturers,
says Dwyer. In the UK, France
and the Netherlands theres
a low market for boilers as
people just tend to buy them
as a distress purchase and
begrudge the price.
And the end customer is
more interested in their up-front
cost and installation; the space
that they take up; noise; ease
of operation; energy savings;
reliability; ongoing inspection,
repair and maintenance costs;
the service levels provided by
installers and utilities; and, if
they are sophisticated enough
to take a long view, the
payback time.
Innovative business models
will be crucial in Europe, says
Dwyer. No-one knows which
one will be successful, but
we reckon that as soon as
one takes off therell be quite
a few companies trying to
followthat.
Targeting lower demand
Yet Ene.feld is a large and
expensive EU research project:
53 million is a huge sum for
the trials, as is the 26 million
from the EU, particularly when
the private sector is already
conducting extensive fuel
cell micro-CHP feld trials in
Germany and Denmark.
Why invest so much? For one
thing, DG Energy hopes the
substantial public investment
will catalyse the development
of ways to overcome obstacles
to the EUs ambitious goal of
cutting energy consumption
by 20 per cent.
Based on the most recent
fgures available, EU
households consumed 307.3
million tonnes of oil equivalent
(Mtoe) of energy in 2010.
Viewed another way, residential
users consume 27 per cent of
EU energy. Reducing this by a
quarter would cut 6.75 per
cent from EU energy
consumption, more than a
third of the targeted reduction.
Number of fuel cell micro-CHP units planned for Ene.Field trials
6
233
90
179
130
5
15
70
20
167
30
15
1303COSPP_29 29 3/26/13 9:10 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 30
Fuel cell micro-CHP in Europe
Previous studies suggest this
is achievable, according to DG
Energy. It believes that policies
adopted by the end of 2009
will help cut consumption
by about 8 per cent by 2020.
Some of the outstanding
reduction can be reached
through further measures
on fnancing, more stringent
implementation of the Energy
Performance of Buildings
Directive and the new Energy
Effciency Directive, says a
spokesperson for DG Energy.
Across the EU, average
energy consumption per
household was 1.5 toe in
2009 and annual residential
consumption for buildings was
around 200 kWh per square
metre. But, unsurprisingly given
Europes varied climate and
wealth, Member States showed
considerable differences.
The share of micro-CHP in
general in household heating
and cooling currently ranges
from zero to a fraction of a
percentage depending on
country, according to the
Commissions FCH JU. But
DG Energy sees potential
for all types of micro-CHP to
yield collective signifcant
primary energy savings in
the residential and services
sector through replacing less
effcient heating and cooling
options.
The Commissions estimate
of micro-CHP heaters market
shares for space heating,
based on devices with energy
class labelling up to A+ are:
2010, 0.1 per cent; 2020, 1 per
cent; 2030, 4 per cent. There
is no differentiation between
fuel cells and other types of
micro-CHP in these estimates,
but the anticipated trend is
clear and fuel cell micro-CHP is
of particular interest because
of the alignment between its
characteristics and residential
energy use trends.
The electrical effciency of
fuel cell micro-CHP is higher
than for a normal CHP, says
Mirela Atanasiu, project
manager at the FCH JU.
And we are moving towards
everything being electrical, as
it is in my own house. I do not
need a boiler, and a fuel cell
micro-CHP can provide more
electricity and less heat.
The current state of the
art for fuel cell micro-CHP is
30 per cent electrical
effciency, overall effciency of
7085 per cent, a lifetime of
three years, a capital cost per
unit of 50,000 per kWe, and
hand-made manufacturing.
This is according to COGEN
Europe, which co-ordinates
and disseminates Ene.feld on
behalf of the FCH JU.
The expected performance
with Ene.feld will be 35-50
per cent electrical effciency,
up to 90 per cent overall
effciency, lifetimes up to eight
years, capital costs ranging
from 13,000 to 27,000 per
kWe (excluding a 300 W unit
involved) and with potential
to get below 10,000 per kWe.
The aim is to reach pre-serial to
serial productiontoo.
The manufacturers do
not see fuel cell micro-CHP
as the only solution to cutting
residential energy use, but
as complementary to other
solutions, says Atanasiu.
Other features to Ene.feld
make delving beneath the
headline spend instructive,
according to Dr. Fiona
Riddoch, COGEN Europes
managing director. Its a big
project by any standards,
but a lot of the apparent
complexity is in making the
products themselves and
that is something that the
manufacturers are taking care
of, shesays.
Although the [fnancial]
sums seem huge, much of that
is because of the hardware
involved. The advantage of Ene.
feld is that the manufacturers
are taking responsibility for
identifying implementation
sites and carrying out feld
trials for their own units. So it is
a fairly decentralised project
with no central agenda and
with everyone creating their
own timescales within the
overall remit.
Ene.feld gets underway
Manufacturers Hexis AG,
Switzerland, and Baxi Innotech,
Germany, will be frst into feld
trials under Ene.feld, says
Atanasiu. They were just
waiting for the frst payment
from us, and they will deploy
in the frst quarter of 2013. We
expect most of the projects
units to be in the feld within
two years to run for three
years. Hexis has been talking
to municipalities in Slovenia,
which could be the frst
locations involved, she adds.
The Trento province of northern
Italy is another location that
has engaged strongly with
the project, says COGEN
EuropesDr. Riddoch.
On current plans, 233
units will be installed in the
UK, 179 in Germany, 167 in
Italy, 130 in The Netherlands,
90 in Denmark, 70 in France,
30 in Austria, 20 in Spain, 15
in both Luxembourg and
Slovenia, six in Ireland and fve
in Belgium.
HyER [Hydrogen Fuel
Cells and Electro-mobility
in European Regions
Association], which promotes
the use of hydrogen as an
energy source, is an important
partner in Ene.feld in this
regard, says Antanasiu. They
have very good contact with
regions and municipalities and
have helped manufacturers
fnd places to install units and
put them in touch with utilities.
So we now have all the actors
Ene.eld participants
Fuel cell mCHP suppliers to Ene.
eld are Germanys Elcore, Bosch
Thermotechnik, Baxi Innotech, Riesaer
Brennstoffzellentechnik (RBZ), and
Vaillant; Switzerlands Hexis; the UKs
Ceres Power; Denmarks Dantherm
Power; and Italys SOFCpower.
The research partners are: The
UKs Imperial College, London, and
Element Energy Ltd; Germanys
EIfER Europisches Institut fr
Energieforschung, Gaswarme-Institut
Essen EV, Gastechnologisches Institut
gGmbH; Denmarks Danmarks Tekniske
Universitet; Italys Politecnico di Torino
and ENVIPARK environment park.
Utilities that are full partners in Ene.
eld are: the UKs British Gas; Italys
Dolomiti Energia; Denmarks Dong
Energy; and Frances GDF Suez.
Utilities that have signed letters of
intent to participate include: Italys
Edison, PVB, and ACEA; Slovenias
GIZ DZP; Kiwa and Eneco, both of
the Netherlands; Spains Gas Natural
Fenosa; Germanys Stadtwerke
Rsselheim; and Irelands Bord Gis.
Co-ordination and dissemination
roles are covered by COGEN Europe,
HyER, Slovenias Development Centre
for Hydrogen Technologies, and the
UKs Energy Saving Trust.
1303COSPP_30 30 3/26/13 9:10 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 31
Fuel cell micro-CHP in Europe
in the project and some of the
commercial interests will reach
the point where they can really
take the step forward to full
commercialisation.
COGEN Europes role is key,
adds Antanasiu. Because
there are a lot of competing
commercial interests involved,
COGEN Europe is really the only
one that can co-ordinate it.
Its job is to work with the EU
institutions funding Ene.feld
and to gather and disseminate
information to interest groups
for use by the industry.
Dr. Riddoch also points
out the strong interest and
commitment being shown by
municipalities that are keen
to be testbeds and which
could eventually help to drag
through a fuel cell micro-CHP
market by choosing these
systems for municipal housing
and other public buildings.
A market is no more than
friends talking to each other
about a product or hearing
about it from some source. In
that sense, regions are ideal
multipliers of awareness and
communication, she says.
To win EU funding, the
Ene.feld partners had to
confrm upfront that they had
identifed installation sites. So
the core sites have already
been identifed and the
process is understood, says
Dr. Riddoch. COGEN Europe
will be representing Ene.feld
at Hannover Messe industrial
fair in April. Come and see
us, she urges. The Ene.feld
plan foresees opportunities
for increasing co-operation
at Member State and
regional level with a range of
participants in the supply chain
to the customer, she adds.
Big in Japan
As Ene.feld springs
into action, it has the
Ene.farm feld trials example
from Japan to inspire it. Japan
was installing 5000 fuel cell
micro-CHP units in 2009 but
is expected to bring 50,000
on line this year, according to
Delta-ees Dwyer.
In Japan, we saw huge
corporations such as
Panasonic sharing information
with the big gas utilities and
co-branding products, which
has worked really well for
them. Ene.feld is the frst time
weve seen something similarly
co-ordinated in Europe and its
a step in the right direction.
With this kind of lead in
know-how, and with volume
production bringing down their
unit costs, could the Japanese
enjoy a headstart in Europe
if a real market develops? Is
Europe just kidding itself that
it can build an indigenous
fuel cell micro-CHP industry of
signifcant value?
Japanese companies
looking at Europe have a
number of hurdles to jump
says Dwyer. The gas qualitys
different in Europe, the energy
markets are different, the way
people buy their heating
systems, mean the Japanese
cant just sell a fuel cell
micro-CHP product in Europe
as they would a television.
So they will ask what part
of the fuel cell unit could
they have a cost advantage
for? They could end up using
the same pumps, pipes
and casings as a European
company. So they have to
make the modifcations
and establish partnerships.
Nobody knows whos going to
have the ultimate advantage.
Robert Stokes is a freelance
journalist, who writes on
energy matters.
This article is available
on-line. Please visit
www.cospp.com
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Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 32
Project profle: Waste to energy in Australia
A
chieving the
upmost resource
recovery is
part of the way
A.J. Bush & Sons, from
Beaudesert in Australias
southern Queensland, says
it stays competitive. As a
part of a long-standing
meat rendering industry the
company maximises the
value of the by-products
of processing. Optimising
bioenergy is part of its
overall business approach
to sustainability, and an
added impetus to its drive
for effciency is an annual
carbon tax bill each year of
A$2 million (US$2.1 million),
caused mostly by having
coal-fred boilers that heat
process water.
One way of cutting
this liability is through the
production of electric power
from biogas derived from the
meat waste.
It was money from the
federal government in 2005
that set the company on its
journey into biogas production.
Some A$715,000 came from
the Food Innovation Grant
programme, which added
to an earlier, smaller grant
from the Queensland State
Government to allow the
company to evaluate the
feasibility of biogas capture.
A.J. Bush developed a
project at its Beaudesert site
An Australian project that derives gas from meat waste to generate power
shows the scale of its economic benefts and how such schemes can aid
a national electricity network, writes Tracey Colley
Cutting
the carbon tax bill
Quantum sells all the electricity generated on site to A.J.Bush & Sons Credit: T. Colley
1303COSPP_32 32 3/26/13 9:30 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 33
Project profle: Waste to energy in Australia
in co-operation with Quantum
Power that sees the meat
renderer take responsibility
for the gas treatment system
and everything downstream,
including a covered anaerobic
lagoon (CAL) and gas capture
pipework, While, Quantum
owns the projects gensets,
and is responsible for their
operation and maintenance.
Quantum also sells all the
electricity generated to
A.J.Bush at a discounted
price as part of a long-term
power purchase agreement.
Historically the meat renderer
imported its total electricity
requirements from the grid.
Today coal-fred boilers
at the plant still generate
steam for the company,
which it uses to process
the fairly constant supply
of non-meat by-products it
receives from poultry, pork
and beef processors in
southern Queensland and
northern New South Wales.
The company renders about
4000 tonnes of heads, feet,
offal and guts, feathers and
blood over a fve day working
week, and the plant operates
24 hours a day, 52 weeks per
year, with three shifts, from
Monday morning until midday
Saturday.
Fat, bone and slaughter
foor materials yield tallow
and meat & bone meal, while
poultry by-products produce
poultry oil and poultry meal.
A.J.Bush hydrolyses poultry
feathers and dries them to
produce hydrolysed feather
meal. Some 65% of the weight
of raw material received is
water and the remainder
yields tallow and protein meal.
Australia retains its status
as a country free of bovine
disease BSE, so feedstocks
from within the country
require no extra sterilisation
or pasteurisation other than
for control of normal bacterial
pathogens, and no limitations
exist on which material can be
used for biogas production.
The plant produces around
65,000 tonnes of rendered
tallow, oil and protein meals
each year.
All of this activity means
the plant consumes about
1000 MWh of electricity per
month and has a peak
demand of about 2.2 MW.
The biogas project started
in April 2005 with a trial version
of a CAL, which held 2 million
litres of wastewater. It had a
1.5 mm thick high-density
polythene cover, which was
operated with a ten-day
residence time. Its success
led to the commissioning of a
CAL with a capacity 26 millon
litres in 2007 that is 6 metres
deep and can hold 28 days
production of wastewater. The
new CALs covers are secured
around the edge of the pond
with concrete trenches and
rise and fall depending on gas
generation and usage rates.
Gas continues to
accumulate over Saturday
afternoon and Sunday, when
the main processing plant is
idle, and it falls gradually over
the week as the gas volume
and pond cover lowers. The
pond cover includes safety
vents, which allow biogas to
escape if the pond cover rises
to a certain height above the
water level. This involves the use
of 0.5-metre risers attached to
the underside of the vents.
The pH control of the infuent
is critical to biogas production
rates, so maintaining the pH at
between 6.6 and 7.6 through
the addition of lime has been
required on occasion.
The wastewater leaves the
CAL by gravity fow (an infow-
outfow balancing system)
and is then further treated in
other on-site ponds before
being recycled for irrigation of
crops and pastures.
A manual pumping system
removes rainwater that
accumulates on the CAL cover
during the wet season, and
the area has an anti-personnel
fence to prevent unauthorised
access.
Power generation
Generation of gas occurs at
a rate of about 220 m
3/
hour.
Fans draw gas from both
ponds through ports attached
to the top of the cover into
into pipework uphill to the
gas treatment skid. The uphill
location of the skid and the
elevation of the pipework from
the pond to the skid allows
condensate to drain back to
the pond. The skid includes a
heat exchanger that lowers
the temperature of the gas to
39C, which removes most
of the condensable materials
from it. A fare unit forms part of
the skid and burns excess gas
whenever a generator is taken
off line for maintenance.
Biogas travels from the skid
to two 0.5 MW Shengdong
engines, the frst of which was
commissioned in July 2010
and the second in March 2011.
Power generation from the
gensets has amounted to
about 200,000 kWh per month,
or about 20% of the total
site electricity consumption,
with an electrical effciency
of about 33%. However,
availability has been much
lower than hoped because of
operational and quality issues
associated with the engines.
As the cost of the engines
was less than a biogas
treatment unit to remove
hydrogen sulphide (H
2
S), the
decision was made not to
include a stage for the removal
of the acid gas, but instead
to sacrifce the engines. The
residual H
2
S level in the gas
after treatment is generally less
than 1200 ppm.
Major modifcations had
to be made to the engines
to ensure they complied
with Australian standards
for electrical and gas safety,
and could run without being
continuously attended to, but
there are still operations that
must be performed manually,
such as inspections, and
checks on the coolant.
Economics
Grid connection and export
is not viable because of
unfavourable conditions for
connection to the grid. The
extra capital works which
would need to be installed
due to the network safety
requirements of network owner
Energex would cost about
A$300,000. Also Australia does
A.J. Bush is recognised as one of the most sustainable rendering facilities in Australia Credit: T. Colley
1303COSPP_33 33 3/26/13 9:30 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 34
Project profle: Waste to energy in Australia
not have a feed-in tariff (FiT) or
equivalent for cogeneration,
so each individual CHP plant
operator has to negotiate with
the owner of the network into
which they want to export.
This creates a huge power
imbalance between the
plant owner and the network
owner, as generally there
is no competition and no
opportunity for direct export to
another electricity user nearby.
This is the case with A.J. Bush
and is an inequity that has
been identifed by Australian
government reviews of cogen-
eration and the electricity
network, along with the inef-
fciencies which result from it.
However, little has been done
to remedy the situation.
More signifcantly the A.J.
Bush plants location is in a
region that has serious issues
over peak demand constraints.
In fact the network company
owns diesel gensets near the
plant that operate only at times
of peak network demand for
power. So the biogas gensets
would be able to synchronise
with the grid but they do not
yet export electricity to it.
Carbon tax liability
However, the plants use of
biogas could signifcantly
reduce the companys liability
under the countrys carbon
tax, which came into force on
1 July 2012.
A.J. Bush has to make its
CO
2
emissions known under
the National Greenhouse and
Energy Reporting Scheme,
according to which its site
produces 82,197 tonnes of
CO
2
equivalent (tCO
2
e), two
thirds of which is from the
coal-fred steam boilers. At a
carbon price of A$23/tCO
2
e,
this equates to a carbon tax of
A$2 million per year. In effect
the sites annual use of coal
is about 23,140 tonnes, which
equates to 622,775 GJ/year of
boiler fuel.
Assuming that a biogas
boiler would have about the
same effciency, this means
that the current system could
provide about 50% of the boiler
fuel requirement and 1000 kW
of biogas-generated electricity.
This would not be enough of a
greenhouse reduction to bring
the total site emissions below
the 25,000 tCO2-e threshold
for inclusion in the carbon
tax scheme, but it would
signifcantly reduce the liability
associated with the tax.
Next phase
The next phase in the project
involves four developments. The
frst will be to install additional
pond capacity so that the
percentage of organic matter
degraded anaerobically will
rise. Second is the reduction
in the use of boiler fuel by
allowing cogeneration. Here
heat recovered from the
genset units would raise the
temperature of feedwater for
the boiler system to about
85C. Third comes installation
of a dedicated biogas boiler
and fourth is the replacement
of the Shengdong units
with two 500 kW Cummins
biogas engines and a biogas
scrubber system to reduce the
residual H
2
S levels to less than
100 ppm.
The Cummins engines
are 600 kW natural gas units
that are derated to 500 kW
for biogas operation. Their
internals are sulphur-resistant
and their operation is tailored
to a gas with variable calorifc
value, such as biogas.
Their capital cost is about
AUS$1500 per kW installed,
which includes most of the
cogeneration equipment.
On 12 December 2012,
the company won a grant
of A$6.2 million from the
Clean Technology Food
and Foundries Investment
programme for the new
CAL and dedicated biogas
boiler projects, as part of the
national Carbon Tax Scheme.
They will reduce the intensity
of the carbon emissions of the
steam production by 64% and
cut energy costs by 46%.
A feature of rendering plants
is the very high strength of their
effuent. Almost 1 million litres
of wastewater is generated per
day with a biological oxygen
demand (BOD) of 40,000 mg/
litre or a chemical oxygen
demand (COD) of around
100,000 mg/litre. The effuent
has always been treated by
the use of on-site ponds.
Anaerobic digestion
removes 8590% of the organic
load but such ponds can be
problematic because of the
intense odours they produce.
Such odours released at
ground level do not dissipate
well. The A.J. Bush plant is in
a rural area but there is some
residential housing nearby.
A major beneft for the site
was that the CAL reduces
odours from the pond system,
which is consistent with the
plant being one of Australias
most environmental friendly
rendering facilities.
If the site were to increase
the percentage of BOD that
was degraded anaerobically,
there would be additional
biogas available. The BOD
of the infuent is 40,000 mg/
litre whereas for the effuent
the fgure is 4000 mg/litre, a
fall of 90%. A reduction to only
400 mg/litre, which would be a
cut of 99%, would make even
more biogas available.
In terms of an energy
balance, the gensets use
about 12 GJ of biogas per
hour. The wastewater produces
about 1150 GJ per day, or
about four times the amount
of biogas that the biogas
gensets use or twice the sites
total electrical demand. This
would mean approximately
2 MW of green electricity was
available for export if all the
biogas generated were used
for electricity generation.
However, this is unlikely to be
economical given current
By capturing and utilising biogas A.J. Bush could reduce its carbon tex liability Credit: T. Colley
1303COSPP_34 34 3/26/13 9:30 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 35
Project profle: Waste to energy in Australia
regulatory and economic
conditions. The far preferable
option for the site is to use the
surplus biogas in its boilers,
displacing coal and its carbon
liability.
Realising the potential
In 2011, there were 81
rendering plants in Australia.
These processed 2.5 million
tonnes of raw material to
produce 1.1 million tonnes
of rendered product. The
Beaudesert plant renders
0.2 million tonnes per year
of raw material based on a
52-week operating year. This
has the potential to create
2 MW of power for export.
If replicated across the
industry in Australia, this would
equate to 25 MW of export
capacity, reducing the load on
the national electricity supply
system and providing power
from sources distributed across
the grid rather than being at
one central location. Given
that most plants operate 24
hours a day on weekdays,
which coincides with the elec-
tricity supply system summer
afternoon peaks, they could
assist with reducing the system
peak load.
However, developments at
other plants have taken the
simpler approach of using
CAL biogas in their boilers. The
lack of support for embedded
generation and cogeneration
means that this is the simpler
and more cost effective option
for most sites. As such, this
represents a lost opportunity for
replacing electricity generated
from coal fred power stations
with renewable electricity.
Given the inherent
ineffciencies with coal-fred
generation, transmission
and distribution, with overall
delivered effciency of
about 30% in many cases,
this effectively means that
this sustainable bioenergy
resource is not being used in
a way that would maximise
greenhouse gas reductions
in Australia. By comparison
modern biogas gensets have
an electrical effciency of
over 40% and a total energy
effciency of over 80%, meaning
that biogas embedded
generation can contribute
to cutting emissions. Unless
government policy recognises
this and supports biogas
generation and cogeneration,
this ineffciency is liked to be
locked in for the effective life of
the biogas boilers, which is of
the order of 20 years.
Perhaps the Australian
government needs to take
a leaf out of A.J. Bushs book.
As the companys Beaudesert
plant manager David Kassulke
says, To be effcient we must
utilise every part of the animal,
excluding only the moo, the
cluck and the oink.
Tracey Colley is a freelance
journalist, who write on
energy matters.
This article is available
on-line.
Please visit www.cospp.com
Additional pond capacity is planned at the Beaudesert site Credit: T. Colley
COGEN Europe Annual Conference & Dinner 2013
The main cogeneration event in Europe
20
th
Anniversary
More information at www.cogeneurope.eu
Supporting competitiveness, environment
and securing of energy supplies in Europe
18-19 April 2013, Brussels
For more information, enter 16 at COSPP.hotims.com
1303COSPP_35 35 3/26/13 9:30 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 36
Project profle: Chatsworth targets CHP
W
ork has already
begun on the
new system
at Chatsworth
House - which is being
designed and constructed
by UK-based low-carbon
energy specialist, LowC
Communities Ltd. Utilising
only the low-value timber
felled as part of the estates
normal annual harvesting
operations, the new system,
which is known as Arbor
ElectroGen, will convert the
wood fuel into electricity via
an advanced gasifcation
process. This produces a
clean, combustible gas
that is used to power a
combined heat and power
(CHP) system containing
an engine similar to that
found in large commercial
vehicles - which in turn
drives a generator to
produce around 97%
of Chatsworths annual
electrical requirements.
Known as Arbor ElectroGen,
this advanced gasifcation,
biomass-fuelled CHP system
delivers, low-carbon heat
and power for a variety of
applications. Fuelled by
woody biomass, it can be
used by customers that have
an on-site biomass resource
- such as woodland, or easy
access to a local feedstock.
The feedstock creation
follows a few simple steps by
taking newly cut, small round
wood or similar, chipping to the
required specifcation, (much
larger than traditional heat-
only biomass boilers) drying in
the warm extract air from the
Chatsworth House in Derbyshire, UK has commissioned the construction of a
revolutionary new renewable energy generation system that is set to reduce its
carbon emissions by 90%, writes Dr. Andrew Horsley.
Stately home
adopts advanced CHP system
Advance gasifcation is used to power the CHP system at Chatsworth. Credit: Creative Commons
1303COSPP_36 36 3/26/13 9:30 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 37
Project profle: Chatsworth targets CHP
plant space and that used in
the gas cooling process. There
is no requirement for long-term
storage or chip screening.
The Arbor ElectroGen system
produces an almost equal
amount of heat and electricity
(in the ratio of 1.5:1), the system
offers one of, if not the most
cost-effective ways to meet the
ever-more stringent demands
of both the Code for
Sustainable Homes and
BREEAM. This heat-to-power
ratio should be compared to a
biomass steam boiler and
turbine with a heat to power
ratio of 5:1, a Stirling engine of
3:1 and a high-speed turbine
of 3:1 therefore making it better
suited to matching the power
and thermal demands of a
building, facility or community
network without dumping heat.
Whilst the bulk of the delivery
of the UKs built environment
continues to focus on
producing renewable heat to
meet the demands of planning
requirements, the Arbor
ElectroGen targets renewable
electricity a commodity that,
if supplied from the national
grid, emits around three times
more carbon than the natural
gas required to produce it
and additionally produces
renewable heat
Nearly all of the heat
created by the engines
cooling system and exhaust
will be recovered and used
in a new district heating
network to supply Chatsworth
House, as well as its restaurant
and garden glasshouses
providing around 72% of the
annual requirements for space
heating and hot water.
Nicholas Wood, land agent
at Chatsworth commented:
This project perfectly illustrates
our on-going commitment to
sustainability at Chatsworth.
There is normally a proportion
of timber from our harvesting
operations that is of poor
quality and limited use this
will now be utilised on site as
biomass. All felled areas are
replanted, thus ensuring that
our woodlands continue to
be sustainable. Annually, the
new renewable energy centre
will save around 1350 tonnes
of carbon being emitted
in comparison to grid-
supplied energy produced by
fossil fuels.
We considered many
forms of renewable energy
for the house but the
outstanding environmental
and commercial credentials
of the chosen technology far
outweighed the alternatives.
Indeed, it has been
calculated that, to achieve the
same level of carbon savings
with solar photovoltaic panels,
the estate would have needed
to install around 24,000 square
metres of panels which
would cover the same area
as around 3.5 football pitches
something unthinkable in
such an area famed for its
outstanding beauty.
According to Richard
Griffn, chief executive of LowC
Communities: We are truly
delighted that Chatsworth will
be taking a leading position
in the fght against global
warming and I would hope
that it demonstrates that if
a stately home can achieve
carbon-neutral status, then this
level of reduction is well within
the reach of all other types of
buildings regardless of their
size or age.
Although gasifcation
technology can trace its roots
back to the 1800s when it was
frst used to produce town
gas from coal, the major
technological leap for us has
been to refne the process
suffciently in order to produce
gas that is clean enough to
reliably power the engine.
Many companies have tried
to produce electrical power
from biomass fuels, but theyve
either failed or only managed
to achieve low levels of
effciency and reliability.
Due to the effciency of our
process coupled with use of a
renewable fuel thats absorbed
carbon dioxide during its
lifetime - the technology offers
very low-carbon energy.
This technology could make
a signifcant contribution
towards the UK governments
targets for the year 2020 - cut
ting carbon emissions by
34% and having the country
deriving 15% of its total energy
from renewable sources.
This decentralised approach
to power generation also
ensures that energy is
consumed locally avoiding
the ineffciencies and losses
associated with transporting
electricity long distances.
It also helps to overcome
the increasing problem
of balancing the grid by
producing energy when and
where it is required. Due to
the high temperature of the
gasifcation process, there is
none of the air quality issues
that are inherent in many other
generation technologies and
no visible smoke plume.
Education will also play an
important role in Chatsworths
on-going commitment to
sustainability as its new
Renewable Energy Centre
and its purpose-built building
will become part of the
visitor experience. Members
of the public will be actively
encouraged to see at frst-
hand how the estate is
generating its own renewable
energy and learn more about
the concept and how it fts in
with the drive to reduce the
estates environmental impact.
Innovation in energy
goes back a long way at
Chatsworth. In 1893, the
Eigth Duke of Devonshire
commissioned water-powered
electricity generating turbines
to harness the gravity-fed
water system that was in place
to feed the famous fountains.
This hydropower system is still
producing electricity today.
The Renewable Energy
Centre at Chatsworth is the
frst in a series of advanced
gasifcation projects that LowC
Communities is developing in
the UK. Previously, the company
has pioneered an award-
winning, low-carbon energy
technology based on CHP -
fuelled by UK-grown bioliquids
such as rapeseed oil.
The idea of using CHP
application in Britains stately
homes is also a subject that is
near to the hear of the Prince
of Wales, who recently called
for a major environmentally-
friendly refurbishment of
Britains historic buildings to
avert the climate crisis.
In a new guide aimed at the
owners of run-down estates, he
said it was a tragedy to see
such buildings abandoned,
derelict or destroyed. Not only
because of the loss of heritage
but because of the terrible
waste of resources as the
country struggles to become
more energy effcient. Prince
Charles already uses ground
source heat pumps and other
forms of renewable energy on
his wider estate.
He says historic buildings
should be leading the way
in the fght against climate
change by insulating roofs,
harvesting rainwater and
even generating their own
energy. The guide also
recommends wind turbines
where appropriate despite
the Princes well known hatred
of modern attachments on
older buildings.
Dr. Andrew Horsley is
Managing Director of
LowC Communities Ltd.
www.lowc.co.uk
This article is available
online. Please visit
www.cospp.com
1303COSPP_37 37 3/26/13 9:30 AM
KEEPING EUROPES POWER
FLOWING
Conference & Exhibition
4 6 June 2013
Messe Wien, Vienna, Austria
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Over 3 days the Renewable Energy World Europe
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JOINT OPENING KEYNOTE SESSION
Tuesday 4 June 2013 - 09:30 11:00
Speakers include Reinhold Mitterlehner, Federal
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in the best interests of the industry.
1303COSPP_38 38 3/26/13 9:30 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 39
Waste to fuel conversion
A
plant developed
by Recycling
T e c h n o l o g i e s
treats mixed
plastic waste (MPW) and
provides all the usual
advantages of CHP. It is
also small enough to be
located in or alongside
existing facilities, avoiding
the need for specialist
buildings. Furthermore, it
can sit at a site where the
waste is already located,
overcoming the need for
transport, and adjacent to
processes that require heat,
ensuring high effciencies. Its
low-capital cost also brings
benefts concerning return
on investment (ROI).
Considerable demand
exists for affordable technology
that can use environmentally-
sound methods to extract
value from waste that would
otherwise be sent to landfll.
In the UK, for example,
what drives this need are the
fast-rising costs of landfll and
the ever-increasing political
pressure to reduce the amount
of waste sent there. In the
case of MPW the technology
already exists to liberate its
energy through combustion.
Energy from Waste (EfW)
plants work well, particularly
if preceded by a sorting
plant that can remove most
of the chlorine-producing
PVC. They are better than the
landfll solution but also have
downsides. They tend to be
large facilities that require
material to be transported
to them, which causes the
old problem of creating a
signifcant quantity of waste
heat in a central location,
heat which is diffcult to use
A system is available that generates combustible gas from material that might
otherwise go into landfll. Among other advantages, it can feed a CHP plant,
says Arthur op den Brouw.
Turning
mixed plastic into fuel
Signifcant demand exists for sound methods to extract value from waste that would otherwise be sent to landll Credit: Recycling Technologies
1303COSPP_39 39 3/26/13 9:30 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 40
Waste to fuel conversion
effciently. The plants are also
expensive to build, which
means payback periods are
long, and there are losses in
distributing the power back
from a central location to the
point of use. Consequently
the number of such facilities in
comparison with the quantity
of MPW created is wholly
inadequate to deal with the
volume of waste, at least in the
European Union (EU).
Changing perceptions
But plastic recycling has
come on a long way. Most
consumers are in the habit of
separating some plastics out
of general waste for recycling.
Yet the fact remains that the
majority of plastic used every
year, in Europe at least, ends
up as landfll. Drinks bottles
and milk bottles are made of
PET and HDPE, respectively,
which are widely recycled.
Near-infrared scanners can
detect these materials and
remove them from a conveyor
containing MPW. Once
separated they are washed
and faked mechanically,
ready for re-use.
This mechanical process
does itself consume a
signifcant amount of fossil fuel
but is nonetheless a common
process and the recycled
material is widely used and
traded. However, the material
left on the conveyor is usually
bailed and either used in
refuse derived fuel (RDF) or
disposed of.
The EU creates 47 million
tonnes (Mt) per year of plastic
each year, but only 6.3 Mt
is recycled and 8.6 Mt used
in EfW plants, according to
Plastic Europe.
EfW plants that consume
RDF across the EU do not have
anywhere near the capacity
that would be needed to
process all the MPW, and they
are not uniformly distributed
either. The UK and many other
countries have fallen behind
the likes of Germany and The
Netherlands, which have spent
considerable amounts on
such facilities.
In Britain companies and
local authorities can end up
paying around 45/tonne
(US$69/tonne) to companies
that will accept the RDF. To
sort, dry and bale the material
to RDF standards can cost as
much as 20/tonne, so the
total cost of disposing this
material via the EfW route is
65/tonne.
This shipping of energy
across borders may make
sense in the short term when
compared with the cost of
landflling in a country without
suffcient EfW capacity. But in
the long term the economic
impact of such energy fows
and the environmental impact
of shipping make the practice
unsustainable.
To change this behaviour
a commercially attractive
technology is required that
challenges the categorisation
of such material as waste.
Instead of viewing, it needs
to be seen as a valuable
resource.
British company Warwick
Ventures at the UKs University of
Warwick has commercialised
such a technology. In 2010,
a team at Warwick University,
under the direction of Professor
Jonathan Seville, was looking
at ways of de-polymerising
plastic via pyrolysis.
Recycling Technologies was
subsequently establised.
An increasing number
of engineers and specialist
suppliers have been
developing the solution for,
which aims to provide an
environmentally sound and
economically attractive
system for turning this material
into resource at source.
MPWs true value
Known as WarwickFBR, a
typical installation will use
1 tonne/hour of MPW to
run a 3 MWe generator. The
gap between the material
created and that currently
recycled or used in an EfW
plant is around 32 Mt per year,
according to Plastics Europe. If
we hypothetically consider all
this MPW being used in a feet
of Recycling Technologies
systems, they could generate
up to 98 TWh per year.
To put this in context, the
UKs power demand in 2010
was 310 TWh, according to
DUKES 2012, so the plastic
wasted across the EU last year
could have supplied 32% of
the UK electricity need. Of
course, no one approach will
be used universally to handle
all the material in any waste
stream, but this comparison
does demonstrate how much
energy is contained in the
plastic manufactured and
used each year in the EU alone.
Companies that have
access to MPW could start
viewing it as a valuable
resource. Recognising the
energy content of what is
currently labelled waste is only
one part of the picture; there
have to be ways of turning it
into something that is wanted
at a cost that is attractive.
It is worth contemplating
why countries without the
capacity to use this fuel do not
follow the lead of Germany
and The Netherlands and
build appropriate mass
burning facilities. In our view
the answer is a combination of
cost and the use of the waste
heat. Such facilities are very
expensive and usually require
government assistance to
fnance their construction.
They have often been built to
achieve landfll diversion
targets rather than because of
the ROI they achieve.
Achieving this level of
government commitment to
landfll diversion is diffcult,
particularly in the current
economic climate. Even more
diffcult to emulate is the use
of the waste heat in district
heating schemes. Getting
planning permission to build
a power station at the heart
of thousands of houses and
pipe the heat out to them
is far from straightforward.
In some countries there is a
history of constructing houses
with district heating systems,
but elsewhere, unless such
infrastructure already exists,
retroftting is almost impossible
to justify fnancially.
The WarwickFBR is a
cost effective alternative to
centralised mass burning
facilities without compromising
on the effciencies achieved
via district heating schemes.
A typical installation costs
34 million and can provide
an ROI in less than two years.
This is based on the fnancial
benefts of avoiding landfll
costs, the value of electricity
generated and the value
of the heat that can be
usefully captured. This level of
investment falls well within the
reach of many organizations
and avoids the need for
governments to fnance the
mass burning alternatives.
WarwickFBR plants are
not only more cost effective
per megawatt of installed
capacity but, given the ability
to position them alongside
existing industrial or recycling
processes that require the
heat, the effciency of the
conversion from chemical to
usable energy is as good as
a mass-burning facility replete
with district heating facilities.
The result therefore is that MPW
need no longer be regarded
as waste but as a valuable
resource.
Waste to fuel
WarwickFBR is designed to
be positioned at the end of
a plastics sorting line that
1303COSPP_40 40 3/26/13 9:30 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 41
Waste to fuel conversion
already removes material
such as PET and HDPE. It
accepts the plastic that is
not going to be economically
recycled, using it instead to
provide the electricity and
heat needed to recycle the
plastics that will be. This avoids
the use of virgin fossil fuel in
the recycling process, as well
as the transport of plastic
waste to landfll or as RDF to
mass-burning facilities.
MPW is shredded, the tramp
metal removed and the waste
is then dried and stored in a
bunker. This prepared material
is then fed constantly into a
pyrolysis reactor where, in the
absence of oxygen, the long
hydrocarbon chains that form
the polymers are chemically
cracked into compounds of
shorter chain lengths, which
exit the chamber as a hot gas.
The issue with using waste
material as a fuel is, of course,
that its constituents can vary
dramatically, so the quality of
the fuel produced also tends
to be variable. To combat this
problem the system uses a
reactor management module
to continually adjust the
conditions in the reactor to
even out such variations. By
constantly monitoring the gas
being produced the operating
parameters can be adjusted
to enhance the fuel properties.
Since the machine is
designed to accept general
plastic waste, chlorine will be
present, having come from
PVC, as will fuorine from PTFE
and many other compounds
in varying quantities that have
to be dealt with appropriately.
The bank of fltration and
catalytic devices following
the pyrolysis chamber ensures
that this hot gas is fully fltered
so that the resulting fuel can
be combusted reliably and
without harmful emissions.
This hot, fltered gas is then
condensed into a tank
ready to be pumped into a
combustion device that best
suits the host facility.
The combustion device
could be a steam plant if a lot
of steam is used in the facility, a
combination of a steam plant
and steam turbine to produce
electricity, a medium-speed
diesel engine or a gas turbine
generator. Clearly the latter
needs great capital cost when
compared with a diesel engine
but, as is true for most CHP
plants, the greatly increased
service intervals can justify
this if the generator is required
to run constantly. In most
installations it is envisaged that
a diesel generator will be the
optimal combustion device.
The relative merits of different
power generation approaches
raises an important facet of the
systems design. To maximise
effciency the pyrolysis process
is designed to run 24/7, but
since the fuel generated can
be stored in an appropriate
tank, its use in power
generation can effectively be
decoupled from the pyrolysis
process and the production of
the fuel. So the hours that the
generator runs can be varied
to maximise the value of the
electricity and the quantity of
heat recovered.
In other words, if this CHP
system is installed in a factory
that only runs during the
day, either a large engine or
multiple engines could be run
during the day to consume
the fuel when the electricity
and heat is actually needed
rather than simply to keep up
with the pyrolysis process. For
example a 6 MWe generator
could be run for 12 hours per
day rather than having a 3
MWe unit running constantly.
On-demand power
This ability to generate power
on demand gives rise to the
exciting prospect of using
power generated from waste
to balance other renewables.
Wind turbines produce
electricity when the wind
blows. Solar systems do so
when the sun shines. Neither
always does when the power
is really needed. The ability
to turn waste into a fuel that
can be used to supply power
on demand will enable some
smoothing of this variability.
An interesting point about
the fuel production is its
effective independence
from the use of the fuel to
generate power. This means
the two processes can be
physically remote from each
other. The energy density of
MPW is signifcantly increased
by turning what is often fuffy
material into a semi-solid fuel
that can be transported more
economically to a site where
the heat from the engine can
be used most effciently.
A standard 1 tonne/hour
installation will consume
around 7000 tonnes in
moisture-free weight of MPW
per year. The energy content of
different waste streams will vary
depending on the plastics
it contains, but frequently it
exceeds 33,000 kJ/kg. The
rate of energy conversion
chemical to electrical of the
WarwickFBR is around 34%,
so a CHP plant of this size
will produce around 21 GWh
of electricity per year and a
similar quantity of heat from
the diesel engine.
The heat produced exists
in two forms: hot air recovered
from the exhaust and water at
around 90oC from the cooling
circuit. Clearly the quantity
of heat that can be used will
depend on the host facility
but, in facilities where plastics
are mechanically recycled,
considerable volumes of hot
water are needed for washing
the material. This type of
demand is an ideal way to
use the heat produced by the
engine, ensuring high overall
effciency.
The plant is not too large
either. Space required by the
shredders, separators and
silos will vary from site to site
depending on the nature and
condition of the feedstock, but
the pyrolysis plant itself has the
footprint of a 12-metre shipping
container, as does the typical
engine and generator set. The
fuel tanks are built into 6-metre
shipping containers.
Looking to the future
Recycling Technologies
aim is to continue R&D into
pyrolysis as a mechanism
for turning waste into fuels
in a commercially attractive
way, so the company has
established relationships
with Birmingham Universitys
Dr. Gary Leeke, an expert in
fuidised bed reactors, and
Dr. Athanasios Tsolakis, a
specialist in combustion and
internal combustion engines.
A well-known company
has also entered into an
agreement to purchase the
frst system, and investors have
also recognised the potential
of the approach. Initial
funding has been raised from
the Wroxall Investor Group, a
syndicate of high net worth
investors. This cash injection
allowed the company to start
recruiting the team that is
needed to turn the system into
reality by 2014.
In 2012, investor Peter Jones
OBE joined the board as an
advisor, providing a signifcant
insight into how Recycling
Technologies could contribute
to the political and economic
drive to turn the waste industry
into an resources industry.
Arthur op den Brouw is
Marketing Manager at
Recycle Technologies. http://
recyclingtechnologies.co.uk
This article is available
on-line. Please visit
www.cospp.com
1303COSPP_41 41 3/26/13 9:30 AM
INVITATION TO EXHIBIT
STRENGTHENING ENERGY SECURITY FOR SUSTAINABLE GROWTH
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1303COSPP_42 42 3/26/13 9:30 AM
www.cospp.com Cogeneration & OnSite Power Production | March - April 2013 43
Waste heat recovery
I
t seems odd that one
part of an industrial
process would create
heat as a by-product
and then vent it into the
atmosphere, while another
part of the same process
burns fossil fuel to raise
the temperature of water.
In reality this is what the
food processing industry
commonly does.
A typical food processing
plant refrigerates large
quantities of its products to
keep them fresh, in that way
generating heat, and burns,
say, gas in boilers to create
large amounts of hot water for
cleaning and sanitation.
But an ammonia-based,
high-temperature heat
pump system that employs
a single-screw high-pressure
compressor is helping several
food processing applications
around the world to cut the
waste of this energy, while
reducing the consumption
of carbon-based fuel. Each
of these three projects
required the system to provide
the highest coeffcient of
performance (COP) possible,
a technology solution with
low annual operating and
maintenance costs, and the
use of a non-ozone depleting
refrigerant with zero global
warming impact.
According to Emerson,
which with its project partner
Star Refrigeration, provided
the solution, the systems use
of ammonia refridgerant gives
A novel heat pump system based on a single-screw compressor is cutting
water heating costs in the food processing industry and helping users meet
their sustainability goals.
Turning up
the heat in the food industry
The heat pump technology developed by Vilter over more than 20 years offers a number of benefts to the food processing industry Credit: Emerson
1303COSPP_43 43 3/26/13 9:30 AM
Cogeneration & OnSite Power Production | March - April 2013 www.cospp.com 44
Waste heat recovery
each application a better
performance compared with
competing technologies
when it comes to consumed
resources. Emerson says this is
possible because of the higher
temperatures used.
The system also met each
projects environmental
requirements and kept
operating and maintenance
costs low. Its compressor from
Vilter, which became part of
Emerson in 2009, raises the
temperature of water for boilers
by super-heating exhaust heat
from a refridgeration system.
Savings in each case
arise because the balanced
radial and axial force of the
compressor means stress on
the units bearings is reduced,
and minimising maintainance
and operation costs. The
compressor also delivered a
performance unachievable
with any other type of
compressor, according to Vilter.
Nestls plant in Halifax, UK, is
one of these applications. Here
the food processing company
relies on large refrigeration
systems for chocolate
manufacturing, storage and
distribution. Refrigeration is
essential to cool chocolate
while heat is needed to
separate it from the shaping
moulds.
Nestl had been using
one central coal-fred steam
generation plant for its
requirements but wanted to
capture the waste heat to
replace the need for additional
gas-fred equipment. It also
wanted the new system to help
cut overall energy demand.
One of the few refrigerants
that could meet all of the
effciency and environmental
requirements was ammonia,
an effcient refrigerant
(designated as R-717),
commonly used by the
food and beverage industry
for process cooling and
refrigeration.
However, it has not been
commonly used in industrial
heat pump applications, where
high temperatures are required.
And, according to Sam Gladis,
Vilters Business Director, the
International Energy Agencys
Heat Pump Centre recently
deemed such an application
impossible and said there
were no suitable high-pressure
compressors available to make
using ammonia a reality in
high-temperature industrial
heat pumps. Emerson begged
to differ.
In the Nestl project the
ammonia heat pump has
a dual purpose. The system
delivers chilled glycol at 0C
and hot water at 60C using
waste heat. Heat can be taken
from the 0C process glycol
and lifted to 60C in one stage.
Nestls site has, since the
commissioning of the system
in May 2010, been raising the
temperature of 64,000 litres of
water each day to 60C. And
this hot water is delivered far
more effciently than from the
companys previous coal-fred
steam generator, says Emerson.
Nestls system won the
Industrial and Commercial
Project of the Year title at the
2010 RAC awards in Britain as
it cut process utility costs at
the site by more than $394,000
per year. By reducing gas
combustion it has also cut
CO
2
emissions by more than
500 tonnes per year, and water
consumption has fallen by
around 40%.
Another application
of Emersons heat pump
technology is at the Kraft Foods
plant in Davenport, Iowa, US.
Like many food processing
plants, the company had been
paying for electrical energy
to remove heat from spaces
refrigerated by an ammonia-
based system and venting that
heat to the atmosphere. It was
also paying for natural gas to
heat the hot water it used to
clean the plant hygienically.
Kraft Foods determined that
if the rejected heat could be
captured and used to provide
water heating, substantial
energy would be saved.
The plant installed high-
effciency boilers and invested
in capturing and recovering
boiler stack heat, says Gladis.
The highest pressures
and temperatures in the
refrigeration system were in the
compressor discharge gas.
These provided the best source
for heat to be transferred to the
sanitation clean-up water. The
problem was that ammonia at
typical condensing pressures
condenses at temperatures as
low as 24C to 35C, although
the liquid does at the same
time have a high heat energy.
Conventional heat
exchangers would have
allowed the transfer of this
energy to city water to raise it to
the 63-85C range requirement
of wash-down water, but such
a system would only provide
limited pre-heating of the cold
water supply.
If the refrigeration system
compressor discharge gas,
which was at the high pressure
of 1340 kPa, could be fed
directly into the suction of
a heat pump compressor
and be raised in pressure to
3200 kPa to 5600 kPa, then
condensing this higher-
pressure ammonia with cold
water in a heat exchanger
would capture signifcantly
larger quantities of heat
energy than heat reclaim, and
elevate the cold water supply
The heat pump technology is also heating the hot water for the Norwegian
town of Drammens new districy heating network Credit: Emerson
1303COSPP_44 44 3/26/13 9:30 AM
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