Tom Mos Singer Fuelcells Co Generation
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Transcript of Tom Mos Singer Fuelcells Co Generation
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W at er a n d W ast ew at er
Tom Moss inger , P.E.
Car o l lo Eng ineer s
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October 2007
August 2007
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U.S. Department of Energy - Energy Efficiency and Renewable Energy
Federal Energy Management Program, Director Beth Shearer
Typical headlines that we have been seeing
in the news lately are:
"
Coast; Federal Government ShutDown"
"Massive Blackout Shuts Down New
York City"
"Natural Gas Prices Expected to
Remain High"
"Bills to Rise as Mercury Drops"
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"Electrical Grid Vulnerable to Hackers,Viruses"
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NEARLY a century ago, Henry Forddeclared a customer could have a car inany co or as ong as t was ac . ow,carmakers around the world are trying toconvince consumers that their lineupscome in reen. From BMW to Honda from
Chrysler to Volkswagen, the industry isrushing to make vehicles that use lessgasoline or dont rely on it at all.
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SustainableSustainablePlanetPlanet
reen ayof Livingreen ayof Living
RenewableEnergy
RenewableEnergy
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F r o m Co n s e r va t io n t o P o p u la t io n , a N e w Lo o k a t P la n e t Ea r t h
N e w Op t io n s Ne e d e d
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W h y i s r en e w ab l e en e r g y so
1. Water & wastewater services account for 30-
50% of municipal energy use.2. Equivalent to 3-4% of the nations total energy
use.
3. 19% of electricity usage in California associatedwith movin water
4. 25 to 30% of the cost for water and wastewatersystems operations is for power.
As primary consumers of electricity, water & wastewaterorganizations have the opport unity t o dram atically affect overall
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energy consumpt on.
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Tr ad i t ion a l D igest e r Gas
Techno logy
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Cog ener a t ion Tech n o log ies
.
2. Micro Turbines (30 to 250 kW)
3. as ur nes > ,
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Recip r oca t in g En g in es
1. Proven technology for usingges er gas
2. Strict (and getting stricter) air
3. Regulations moving towards
oxidation catalysts, SCR andEM
4. Installation now requires
remove contaminants no longeroptional
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I n t er n a l Co m b u st i on En g i n e s
1. Electrical OutputEfficiency = 30-35%
2. Advantagesa. Proven technolo for over
40 years
3. Disadvantagesa. Dedicated building for
sound and weather
800-kW Caterpillar Landfill & DigesterGas Fueled Cogeneration System,Sunnyvale, CA WWTP
.
c. Frequent Operator Attention
d. Hi her Emissions
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Micr o Tu r b in es
1. Easy to permit (low emissions)
.
experience (limited)3. Lower efficiency than engines;
approximately 25%
4. Requires >50 psi fuel pressure
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Gas Tu r b in es
1. Strict air permit regulations
.
3. Effective fuel conditioning is required4. Competitive only for
larger installations; greater than 3MW
5. Efficiency typically 25-35%
. fuel pressure
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Fu el Cel lPow er Genera t i on
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Fu el Cel l s
1. Highest efficiency available for powergenera on equ pmen
a. Electrical Efficiency 47%
. -
2. Exempt from air permit requirements*
* Exempt has unfortunately,not been the absolute truth.Permitting agencies have
r u r r ; urequirements are minor.
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Fu el Cel l s
1. van agesa. Low emissions
. y
c. Minimal operator
time for O&M
d. Significant Grantfunding available 1-MW Fuel Cell Energy Fuel Cell
Riverside, CA WWTP
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Env i ron m en t a l Bene f i t s
1. Nearly double the reduction in plant
technologies
. emissions of criteria pollutants
b. Order of magnitude reduction compared toother generation equipment
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Fue l Cel ls Ot he r D r i ve rs
1. Qualifies for simplified interconnection
a. a orn a u e omp an
2. California SGIP grant money currently
a. Up to $7,875,000 total for 3MW plant!
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Sum m ary o f Mot i vat i ons Fo r
Carbon Footprint by up to 50%)2. Power s stem reliabilit and redundanc
steady and constant source of power
3. Hedge against rising electricity rates andfuture energy crises
4. No combustion thus negligible emission
of NOx, CO, SOx, or particulate matter
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Fu e l Ce l l Ai r Em ission Per m i t s
1.Emissions in lb/MWh
NOX = 0.02
Recip Engines
NOX = 3.4
SOX = 0.001
PM10 = 0.01CO = 0.05
VOC = 0.02
CO = 6.8
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Sug gest ed Main t enance I n t er va ls
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Dig est er Gas Fu eled Fu el Cel ls
Operating Installations1. Santa Barbara, CA
Under Construction1. EMWD, CA (Perris Valley) *
. . ,3.
City of Tulare, CA *4. DSRSD, CA5. City of Riverside, CA
2. y o a o,
6. EMWD, CA (Moreno Valley) *7. TID/City of Turlock, CA *
Projects Under Consideration1. TID/Hilmar Cheese Co, CA *
2. MID/City of Modesto, CA *
3. City of Davis, CA *
4. n on an a on s r c ,5. Palm Springs, CA *
6. MRWPCA, CA *
1. EMWD, CA (Temecula) *
2. City of Yuma, AZ *
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. ,
8. City of Livermore, CA *
* CE involved in Design/Implementation
3. y o a em,
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Fu el Cel l Ty p es
Ty p e Elect r o ly t eOpera t i ngTem p. F
Single-Cyc leE lec t r ica l
Ef f i c ien cy %
Ex pec t ed Capac i t yRange
By-Produc tHeat Use
PEMPolymer
Membrane
180 30-35 5 kW to 250 kW Warm Water
AlkalinePotassiumHydroxide
200
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Basic Fu e l Ce l l Sy st em Com po n en t s
1. Fuel source (digester gas & natural gas).
2. Fuel treatment/conditioning to removecontaminants.
3. Fuel cell stack (electrolyte sandwichedbetween an anode and cathode) creates
.
4. DC to AC Inverter converts DC power toAC for use within facility.
5. Heat recovery system to utilize wasteheat (anaerobic digestion).
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W h at is a Fu e l Ce l l?
1. Electrochemical Device Similar to a Batterya. Except Fuel Cells Use an External Supply of Reactants
2. Hydrogen Fuel (Methane) and Oxygen (Air) In3. Electricit and Water Exhaust Out
2
Fu el Cel l
2
H2 Elect r ic i ty
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Tech n o logy Fu e l Ce l l En e rg y
1. General Featuresa.Uses commonly available
Hy droc a rbon Fue l
e .g . D iges te r Gas / Natu ra l Gas
ma er a s
b.No noble metal catalystc. High temperature by-
Internal Reforming
W at e r Vapo r
2. Internal Reforminga.H
2
generated internally
4
2
2
2
Anode
Catalyst
H2+ CO
3H
2O + CO
2+ 2e=
-
.
c. Simple system
d.Negligible NOx and CO
CATALYST
Electrolyte
.
Operationa.Allows unattended
o eration
=
1/2O2 + CO2 + 2e CO3
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b.Highly reliableAi r
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Gr an t s, Fu n d i n g Cal i f o r n i a
1. Business Energy Investment Credit (ITC)a. Federal tax credit now available as a grant
alsob. Fuel cells solar small wind: 30% of eli ible
costs; up to $3000/kW
c. All others: 10% of eligible costs; micro-
2. Self Generation Incentive Programa. 4 500 kW to 1 125 kW based on size for
fuel cell projectsb. Up to $7,875,000 per project for 3.0 MW
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Gr an t s, Fu n d i n g Cal i f o r n i a (cont)
1. California Solar Initiative
a. Performance-based incentive rate:
- -. .
Currently $0.26 - $0.32/kWh produced for 5 years -Municipal
. , ,
2. California Energy Commission
a. Energy Efficiency Financing Program; Up to$3 million; 3.95% fixed APR; up to 15 year term
3. California G$S$ Smart Program
a. Ener Efficienc Financin > 1 million a rox. 4%
APR; negotiable terms up to 12 years
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East e rn Mun icipa l W at e r D ist r i ct
I n st a l la t io n
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East e rn Mun icipa l W at e r D ist r i ct Fu e l
e r o ect u m m ar y
1. Three 250 kW FCE 300MA unitscurrently; ultimately five units 300 kW
2. Digester gas treatment system
a. H2S, siloxanes, water, VOC, etc.3. Electrical interface with utility
4. Hot water heat recovery
5. Hybrid Design-Build/Design-Bid-Build Negotiated Construction
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EMW D Mor en o Val ley , Ca l i f o r n ia
Regio n a l W at er Reclam at ion Faci l i t y Fu e l Ce l l
1. Installation Contract:
a. Three 250 kW Fuel Cells ultimate facility size 1.5 MW
.
c. Balance of plant, including electrical, heat recovery, sitework, pads, etc
2. o a ons ruc on os = . m on
3. State of California SGI P grant = $3.375 m illion
=. ,
5. Carbon Footprint reduced by >50% annually
6. 90% Reduction of RWRFs criteria ollutants
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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EMWD Moreno Valley RWRF AFT Fuel Conditioning System
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y g y
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EMWD Moreno Valley RWRF 750 kW Fuel Cell Project
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y j
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Plan t Oper a t in g Cost s
Pr ior t o Fu el Cel ls :
1. Avera e ower demand: 1,482 kW
2.
Average power cost: $0.115/kWhrAv er ag e 2 0 0 8 Mon t h ly Pow er Cost : $ 1 0 5 ,0 0 0
An t i cipa t ed w i t h Fue l Ce l ls Opera t i ng :
1. n s opera ng: un s a eac
2. Power used by auxiliaries: 20 kW
.
Average Mon t h l y Pow er Sav ings : $5 2 ,500
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Act u a l Oper a t i ng Da t a
. -
2.Total energy produced 3/1 thru 3/27. , -
b. @ average electrical cost of $0.115/kW-hr
= ,
3.Availability: 100 percent since startup
4.First scheduled shut down is Sept 2010
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Tu r l ock I r r i g at i on D ist r i ct
Ce l l I n st a l l at i on
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TI D/ Ci t y o f Tu r lock Fue l Ce l l
r o ect u m m ar y
1. ng e , un
2. Digester gas treatment system
3. Electrical interface with the Citys RWQCF
4. Hot water heat recovery hot water to theCitys RWQCF (1.8 MMBtu/hr)
5. Traditional Design-Bid-Build; pre-purchased
6. Project built to help meet TIDs mandatedRenewable Portfolio Standard requirements of
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20% of power from renewable sources
T l k I i t i Di t i t T l k
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Tur l ock I r r i gat i on Di st r i ct , Tu r l ock ,
Reg ion a l W at er Qu a l i t y Con t r o l Faci l i t y Fu e l Ce l l
1. 1.2 MW Fuel Cell: $3.7 million
2. Fuel treatment system:$1.3 million
3. a ance o p an , nc u ng e ec r ca , earecovery, site work, pads, etc = $2.7 million
4. Total Construction Cost = 7.6 million5. State of California SGI P grant = $4.95 m illion
6. Total Net Construction Cost = $2.7 million
7. Carbon Footprint reduced by 5200 tons annually8. 90% Reduction of RWQCFs criteria pollutants
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9. 47% Electrical Efficiency => TIDs 250 MW plant
TID/City of Turlock RWQCF 1,200 kW Fuel Cell Project
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Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
TID/City of Turlock RWQCF 1,200 kW Fuel Cell Project
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Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
TID/City of Turlock RWQCF ESC Fuel Conditioning System
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A t l O t i D t
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Act u a l Oper a t i ng Da t a
. -
2.Total energy produced 3/1 thru 3/27. ,
b. @ average electrical cost of $0.065/kW-hr
Total Power Savin s = > 34 000
3.Availability: 98+ percent during startup
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Pr o j ect I m p lem en t at io n Met h o d s
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Pr o j ect I m p lem en t at io n Met h o d s
1. Design/build
2. Conventional Design Bid Build
3. Power Purchase Agreement (PPA) bythird party Design Bid Build
Design/build method was selected by Cityof Tulare
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Co m p a r i so n o f Desi g n / Bu i l d
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Co m p a r i so n o f Desi g n / Bu i l d
r op osa s
NetFive-YearEn ine
Five-Year GasCleanin Emission Generated
kW
Rating
Proposed
Equipment
Turnkey
Cost Grant
Construction
Cost
Maintenance
(1)
Maintenance
(1)
Offsets
(4)
Five-Year
Cost
Energy
Value
750
Fuel Cell
Energy DFC
300MA Fuel5,182,545 (3,375,000) 1,807,545 1,092,848 500,500 0 3,400,893 727,299
Cells
750
Deutz 616 V16
Lean Burner IC
Engine
2,567,749 (750,000) 1,817,749 537,650 765,000 71,943 3,192,342 727,299
848
GE Jenbacher
Model JGC316
IC Engine
4,147,000 (848,000) 3,299,000 458,114 500,500 71,943 4,329,557 776,648
750
Ingersol-Rand
250ST 4 493 000 975 000 3 518 000 412 020 500 500 12 000 4 442 520 595 308
Microturbines
750
Ingersol-Rand
250ST
Microturbines
5,043,768 (975,000) 4,068,768 408,924 500,500 12,000 4,990,192 595,308
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750
Fuel Cell
Energy DFC
300MA Fuel
Cells
7,794,757 (3,375,000) 4,419,757 978,000 500,500 0 5,898,257 727,299
Tu la r e Fu e l Ce l l Pr o j ect Su m m ar y
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Tu la r e Fu e l Ce l l Pr o j ect Su m m ar y
1. Three 250/300 kW FCE 300MA units
a. Provision for future installation of 4th unit
2. Digester gas treatment system
a. H2S, siloxanes, water, VOC, etc.
3. Electrical interface with utility
4. Hot water heat recovery
5. Alliance Chico Energy did design/build
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Lesson s Lear n ed
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Lesson s Lear n ed
1. Design/build Get your attorney
involved earlier
2. Include a load bank in the design
3. onven ona es gn uapproach would have been better
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Ot he r Thou gh t s &S u m m a r y
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
Econ om ics and Po l i t i cs
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Econ om ics and Po l i t i cs
1. Primary barrier to implementation of Fuele s s percep on o g cap a cos
2. State and federal incentive/rebateprograms are cr ca
3. Majority of installations occur where the
(California, New Jersey)
.
the price of commercial electricity
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S u m m a r y
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S u m m a r y
1. Fuel cells are the cleanest, most efficientcogeneration technology for digester gas
. well with engines and turbines based on
the grant money available in California
3. You wont have to worry about future
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S u m m a r y (continued)
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S u m m a r y (continued)
1. Permitting is very easy
2. Utility coordination for interconnection is
simple and quick3. ery ow opera or a en on or
maintenance
. ,facility?
GO GREEN!
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Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
Solar Ph ot ov o l t a ic ( PV) Ce l l s
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1. Fixed roof mountedsolar panels that dono rac e sun
2. Single Axis Tracking3. Dual Axis Trackin
4. Concentrated vs.traditional
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So lar Po w er Si t e Co n d i t i on s
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1. Footprinta. n mum acres or
1 MW facility, tracking.
1 MW floating panelfacility
2. Sizinga. Dependent on panel Floating solar array in Oakville, CA
e c ency -
b. Dependent on
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So lar Po w er - Pr o cu r em en t
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1. System Procurement
.
Owner buys panel and pays for all
Full ownership of RECs
b. Power Purchase A reement PPA Third party owns and operates the PV
system and sells power to City at agreedupon ra e
Savings from 30% federal tax creditassed on to owner with lower rates
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RECs negotiable
W in d Pow er - Tu r b in es
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1. Small & Medium Wind
b. Medium: 100 1,000 kW each
c. Architectural Wind Turbine Utilizes buildin aerod namics
d. Typically perform well inlow/moderate wind speeds
2. Large Wind(1 MW - 2.5MW ea)
.
farms3. Future sizes expected
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up o .
W in d Po w er - Si t e Co n d i t io n s
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1. Wind turbine operationis dependent on sitespecific wind
characteristics. be performed todetermine availability
onsitea. Stockton is on the
ed e of a low tomoderate wind zone
3. Wind Resource Map
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. . . .gov/maps/wind.html
W in d Pow er - Econ om ics
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1. Payback Perioda. Dependent on wind resource
, ,costs, energy costs, and
turbine performance.
. Programsa. CEC Renewable Buy Down
$2,500/kW for first 7.5 kWand $1,500/kW for increments>7.5 kW up to 30 kW
b. Self-Generation IncentiveProgram (SGIP)
$1,500/kW for wind turbines
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n arm a m pr ngs,
Lo w Head Hy d r o p ow er
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Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
Lo w Head Hy d r o p ow er
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Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
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Ex ist in g D igest e rs and
Enhancement
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
Ex cess Av a i lab le Dig est er Cap aci t y
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1. Plant currentl has 5 di estersa. 3 older at 1.75 million gallons each
b. 2 newer at 3 million gallons each
c. Newer units are typically utilized
2. Plant was designed for high solids
a. 48 mgd with 630 mg/L BOD
3. Current flows loadin are much lower
a. 32 mgd with 300 mg/L BOD4. Potential for significant digester gas
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
generation enhancement
How t o Ut i l i ze Ex cess D igest e r
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ap ac t y1.FOG Addition
a. Pinellas County, FL
b. Fresno
a. Ventura
b. Riverside
c. Watsonville, CA
d. Waco, TX
.
d. EBMUD
. a. Waco, TX
b. EBMUD
c. IEUAd. Truckee Meadows WRF, NV
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
3. gae
FOG, Watsonville, CA
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Food W ast e
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1. High BOD wastes fed to either dedicated
a. Typical products:
Dairy wastes
Packing plant wastes
ann ng was es
b. Industry benefits and thus participates ifconvenient
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt Food Waste System, TMWRF, NV
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Co-D igest i on o f H igh St r eng t h W ast esL
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1 ton
23 tons GHG
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
Co-D igest i on o f H igh St r eng t h W ast esL
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1 ton
23 tons GHG1 ton
0.8 tons of GHG
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
1 MW of Electricity
Co-D igest i on o f H igh St r eng t h W ast esL
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1 ton
23 tons GHG1 ton
0.8 tons of GHG
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
1 MW of Electricity
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M et h a n e f r o m Al g ae
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1. Single phase digestionas e o ges er
upsets and decline inmethane production
2. Two-phase digestionpromising. Acid phase
Acid Phase Digester, TMWRF, NV
,methane phase digeststhe contents
3. Promising technologyfrom Europe for cell
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
algae digestion
Car b on Cr ed i t s
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1. Potential to generatecarbon capture credits
2. Algae extracts carbon2
into O23. Additional CO
2
can beintroduced into pondsfrom fuel cell exhaust;
credit if fuel was NGand increasing algae
Fuel Cell and Solar Photovoltaic Technology for Water and Wastewater.ppt
r w r