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Ronald F. Amberger PE
John DeFrees PE
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COMBINED HEAT AND POWER/COGENERATION PROJECT EXPERIENCE


PROJECT:    Evaluating the Feasibility of Cogeneration at an Industrial Facility
SPONSOR:    HADCO Corporation


Assessed the feasibility of cogeneration at an electronics manufacturing facility.  The study evaluated several options including electric power generation, gas cooling, and engine-driven air compressors.  The options of fully independent electric generation and parallel operation with the utility were evaluated considering the rate tariffs of the local electric utility.


PROJECT:    Evaluating the Feasibility of Cogeneration at Beech-Nut Corporation
SPONSOR:    Beech-Nut Nutrition Corporation, New York State Energy Research and Development Authority


Investigated the feasibility of cogeneration as an energy conservation measure.  Considered various system configurations based on reciprocating engines, gas turbines, steam turbines and combined cycles driving generators, air compressors and refrigeration compressors.  Recommended a system configured around a single 1.2 MW natural gas engine.  Plans called for ebullient engine cooling so heat could be recovered as low-pressure steam from the engine jacket to displace high pressure steam throttled for use in the deaerator.  Heat from the exhaust gas would be recovered as high pressure steam to offset current boiler loads.


PROJECT:    Cogeneration Study
SPONSOR:    Jasco Tool Corporation


A cogeneration study was performed at a major tool manufacturing facility in downtown Rochester.  The plant consisted of three large shop buildings and an office building.  The study examined the economic return that might be obtained using cogeneration as the primary source of electrical power.


PROJECT:    Cogeneration Study
SPONSOR:    Rochester District Heating Cooperative


A cogeneration study was performed at a steam generating station in downtown Rochester. The steam plant generates and distributes steam throughout the central business district of Rochester. The proposed design utilized existing boilers, a single-stage generator and the existing distribution system as a heat sink.


PROJECT:    Steam turbine boiler feed pump cogeneration
SPONSOR:    Rochester District Heating Cooperative

Rebuilt an unused steam turbine by applying a new speed governor with remote speed setting capability. Changes piping configuration so that the steam turbine exhausted into the tray-type dearator thus recovering steam energy for heating the deareaor/feedwater heater. The turbine speed was remotely controlled by the boiler operator from the operator control booth either manually or by an automatic control loop controller.


PROJECT:    Preliminary Cogeneration Study
SPONSOR:    The Gleason Works


Reviewed existing bids and proposals for implementing a cogeneration project.  Made alternative recommendations based on annualized load profiles developed from utility data and in-house records.  Provided summary results from system modeling to substantiate recommendation that single 1.8 MW high efficiency engine-generator set would out perform proposed alternatives.


PROJECT:    Combined Cogeneration System
SPONSOR:    Rhone-Poulenc and Crosman Corporation


Examined the feasibility of developing a single cogeneration plant to serve two neighboring industrial facilities.  Results demonstrated the combined electric and thermal loads were unsuitable for unified development.  Made recommendations for separate projects to be pursued by each firm based on an electric generating scheme and engine driven air compressors.


PROJECT:    Cogeneration Options for a Metal Finishing Plant
SPONSOR:    NorthEast Coating Services


The feasibility of using cogeneration as the principal source of heat and power was examined.  Site management requested the system be designed to operate independently of the host utility grid.  It was intended that heat from the cogeneration system be used to offset process and HVAC thermal loads.  Subsequent analysis showed that a thermal load following system rated at 750 kW would provide the most economical service operating in parallel with the utility.


PROJECT:    Preliminary Study of Cogeneration Options at LCGH
SPONSOR:    New York State Energy Research and Development Authority


The feasibility of using cogeneration to provide electricity at an area hospital was examined.  A preliminary evaluation was undertaken to determine whether the potential economic return would justify completing a detailed feasibility study.  Technologies including engine-generator sets, micro-turbines and fuel cells were examined.  Simple payback periods were reported as the primary evaluation criteria.



PROJECT:    Micro-Turbine Applications
SPONSOR:    Capstone Turbine


Investigated the performance of micro-turbine technologies in applications including commercial, institutional and industrial service.  Evaluated electrical and mechanical features required for interconnection of facilities and completed a parametric analysis of the potential cost savings based on the tariffs imposed by utilities across the state.  Provided estimates of the economic return and sensitivity to product and project costs.


PROJECT:    Demonstration of a Modular Gas Turbine Cogeneration Plant
SPONSOR:    New York State Energy Research and Development Authority, Northern Development


Monitored and analyzed the performance of 25 micro-turbine generator sets installed as the primary power source at a plastics injection molding facility.  Turbines operated independent of the utility grid.  Recovered heat used for HVAC services.  Completed comparative analysis of grid supplied power and conventional cogeneration technologies as basis for determining economic benefit thus obtained.


PROJECT:    Independent Power Generation
SPONSOR:    New York State Energy Research and Development Authority, Twin Mills


This project evaluated the application of a diesel generator to provide power to a private saw mill as an alternative to utility supplied power.  Determined fuel consumption characteristics, maintenance requirements, utility savings and economic return expected from running the plant in a grid independent mode.  Project was subsequently implemented by a third party developer based on predicted outcomes.


PROJECT:    Independent Power Generation
SPONSOR:    New York State Energy Research and Development Authority, TC Timber


Review developer proposal for a grid independent power system proposed for a small wood products manufacturer.  Confirmed expected cash flow and savings, recommended changes to the primary plant including equipment selection that would improve the economic return.


PROJECT:    On-site Power Production
SPONSOR:    New York State Energy Research and Development Authority, Confidential

Provided a preliminary evaluation of various cogeneration schemes for a large milk processing plant.  Determined the resulting heat balance would not favor power production independent of the utility grid.  Identified viable alternatives including replacement engine-drives for the refrigeration and air compressors with paybacks of less than three years.


PROJECT:    On-site Power Production
SPONSOR:    International Snack Food Producer (Confidential)


Provided a preliminary evaluation of several cogeneration schemes proposed for application a t major snack food producer’s upstate facility.  Options included relocation of two 800 kW turbine generator sets from a sister plant located out-of-state.  Recommendations centered on circumstances that would produce an economically viable project based on a comparative analysis of gas turbines or large reciprocating engines as the potential prime movers.


PROJECT:    On-site Power Production
SPONSOR:    New York State Energy Research and Development Authority, Lydall Thermal/Acoustical, Inc.

Provided an evaluation of cogeneration options designed to support a proposed expansion of a paper manufacturing facility.  Analysis required projection of future electric and thermal loads based on preliminary specifications of a new equipment line and changes to the existing utility profiles.  The resulting thermal and electrical load balance favored use of large reciprocating engines with heat recovered as steam and hot water. 


PROJECT:    Evaluation of Hydroelectric Generating Plant
SPONSOR:    New York State Energy Research and Development Authority, North County Community College


Investigated options to improve the utilization of a small (~100 kW) hydroelectric generating plant being operated by a regional community college.  Recommended abandonment of a sell-all/buy-all contract arrangement in favor of on-site usage of the available electricity.  The proposed scheme including augmenting winter heating capacity with an electric boiler to help reduce the consumption of fuel oil.


PROJECT:    On-site Power Production
SPONSOR:    New York State Energy Research and Development Authority, Central New York Dairy Facility (Confidential)


Examined the application of a small (~600 kW) gas turbine generator as the prime mover in a dairy plant application using the existing boiler as the heat recovery system.  It was intended the turbine exhaust be used as a source of preheated combustion air to the boiler to avoid the need for a separate, dedicated heat recovery system.  Configurations based on a single turbine and arrangements of multiple micro-turbines were considered.  The results favored the use single unit exhausting to a custom designed burner adapted to the expected high operating temperature.