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CHP deals with recovering energy that would ordinarily be a wasted byproduct of generating electricity. A number of Energy Concepts products can make use of the waste heat from reciprocating engine or turbine generators. They can provide hot water, refrigeration, or even additional electrical power. This is often done at facilities that produce their own power or other off-grid locations with generators.
Desert Power Company and Energy Concepts Company jointly announce the startup of a combined chilling and power system at a vegetable processing facility in Blythe, California.
The system generates 830 kW of electricity from two natural gas fired reciprocating engines, and 160 tons of 25°F chilling from the engine waste heat. An additional 120kW peak is supplied from solar photovoltaic panels.
Located on the western bank of the Colorado River, Blythe is an amazingly productive crop growing area. Fisher Ranch Corporation processes the produce grown on over 12,000 acres of the Palos Verde Valley, including melons, corn, broccoli, and lettuce.
A cold storage warehouse covering more than half an acre is chilled to 34°F in order to chill this produce prior to shipment all across the United States. With a typical summer daytime temperature of 115°F, this requires 500 tons of chilling, in order to deliver 6,000 gpm of 32°F water to air handler cooling fans throughout the cold store.
The combined electric load for chillers, air handlers, and processing ranges from 600 to 1,000 kW. Summer electricity has become scarce and very costly in this part of California. Hence, Fisher Ranch decided to implement lower cost electric supply options.
The natural gas fired engines operate at about 35% efficiency, and have both SCR for NOX removal and also VOC catalyst. The waste heat powered ThermoChiller is supplied both jacket heat (at 220°F) and exhaust heat from both engines. The aqueous ammonia working fluid is directly heated by the exhaust in a heat recovery heat exchanger. The 160 tons of refrigeration is supplied directly to a cold room some 250 feet distant, where 1,900 gpm of chill water cascades over the ammonia evaporator coils.
The ThermoChiller is located next to a cooling tower, which supplies it 600 gpm of 80°F cooling water. The footprint of the ThermoChiller is 8 feet by 8 feet.
When adding the electricity displaced by the 160 tons of chilling (~160 kW), the effective efficiency of converting natural gas to electricity increases from 35% up to 42%. Also, the additional refrigeration capacity increases plant reliability, and allows the refrigeration compressors to operate in a more efficient regime. These factors combine to provide substantial savings in cost of electricity to Fisher Ranch.
Most gas-fired reciprocating engine installations with extensive emissions reduction have an installed cost of more that $2,000 per kW, not including waste heat powered chilling. The Fisher Ranch installation was below $1,500 per kW, including the chilling. The cost was further reduced by the California Self-Generation Incentive Program.
Building Cooling Heating and Power
In response to the U. S. Department of Energy, Office of Power Technologies’ Packaged Building Cooling, Heating and Power (BCHP) solicitation, Energy Concepts has teamed with a large industrial manufacturer and a combustion engineering firm to design, fabricate and install a skid-mounted, packaged BCHP system based on a commercially available 70kWe microturbine. This BCHP system integrates on-site power generation, thermal recovery and thermally activated cooling technologies to provide overall resource efficiency levels of 70% or greater. A supermarket refrigeration equipment manufacturer will install the BCHP package as part of their “Supermarket of the Future” initiative, designed to optimize energy efficiency, shopper convenience, and food storage quality.
Energy Concepts’ patented waste heat powered absorption cycle will deliver inlet cooling to the microturbine and refrigeration directly to the supermarket cooling plant to increase microturbine efficiency and lower utility bills for the supermarket.
The microturbine will deliver on-site generated power, for peak shaving, reliable grid back-up, and insulation against volatile energy rates. The system is under demonstration in Portsmouth, NH.