P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R AT I O N

A M E R I C A N

I N D E P E N D E N T

P O W E R

SUMMER 2009

www.gmp.uk.com/power

Fuel cells for America

APG1000

The Global Impact of Advanced Power Generation

Its all about high efciency. The 1 MW APG1000 delivers high-speed performance with low emissions in an engine less expensive to operate. Add to that our patented ESM control system, standard on the APG Series, the Waukesha reputation for product durability and know-how, and a history of delivering strong smart gensets that last and last. In addition to the APG1000, Dresser Waukesha offers APG2000 and APG3000 gensets to provide 2 and 3 MW power generation solutions.

The APG Series. A world-class commitment to the power generation industry. The Waukesha Way.

Dresser Inc. Dresser Waukesha 1101 West St. Paul Avenue Waukesha, WI 53188-4999 T. 262 547 3311 F. 262 549 2795
2009 Dresser, Inc. All rights reserved. Waukesha, ESM, and APG are trademarks/registered trademarks of Dresser, Inc., Dresser Waukesha

www.dresser.com/waukesha

P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R AT I O N

Editor: Aidan Turnbull powereditorial@gmp.uk.com Sales Director: Neb Saric nsaric@gmp.uk.com Publisher: Richard Teasdale rteasdale@gmp.uk.com Journal Assistant: Zo Taylor ztaylor@gmp.uk.com Accounts Division: Sally Gasson accounts@gmp.uk.com Far East Sales: C H Park, Far East Marketing Inc femchp@unitec.co.kr German/Danish/Swedish Sales: Mario Dobresko mdobresko@gmp.uk.com Russian Sales: Sergy Stanovkin stanovkin@dars.ru US Sales & Subscriptions: Alex Carter acarter@gmp.uk.com Asia-Pacific Correspondent: John Goss john.goss@ceejay.com.hk

A M E R I C A N

I N D E P E N D E N T

P O W E R

SUMMER 2009

www.gmp.uk.com/power

Fuel cells for America

GMP Global Media Publishing Ltd

New fuel cells for America.

Summer

2009

C O N T E N T S

Cummins new fuel cell - based on Solid Oxide Fuel Cell technology will be the next big thing believes expert Xin Li.

News
Plus Contract News & Products on pages 21 & 22.

6 9 10 12 13 14
New diesel engines from Caterpillar. See page 9.

Diesel Engines CHP

Onsite CHP at America Honda's HQ in Torrance, CA.

Caterpillar Incs improved C175-16 diesel package generator set is designed for standby, prime and continuous applications.

Microgeneration UPS & Trigeneration

NYs Capstone 65kW C65 UPS systems in action.

A portrait of BioTown, USA - Reynolds, Indiana - which serves as a testbed for the latest technology. UPS system developed for New York. See page 13.

Contributors Caterpillar, Cummins, Honda, Environment One, Rotork, ABB, GE Energy, Mitsubishi Heavy Industries, Emerson Process Management, SolvAir. Published by: Global Media Publishing Ltd Global House, 13 Market Square, Horsham, West Sussex, RH12 1EU, UK. Tel: +44 (0)1403 220750 Fax: +44 (0)1403 220751 Website: ww.gmp.uk.com

Controls & Monitoring

The Los Angeles Department of Water & Power is using ABB know-how to up capacity to 2,400 MWs.

Filtration
SolvAirs Youngen Kong and Michael Wood look at S02 & S03 mitigation in flue gases.

15
Rotorks electronic actuators designed for use in the rugged environment of cogen power stations. See page 18.

HRSG
Emerson is upgrading the HRSG controls of the Fellside Power Station using PlantWeb.

16

American Independent Power (ISSN 1468-7100). Distributed by UK Postings Ltd, Unit 18-19, Wornal Park, Menmarsh Road, Aylesbury, Bucks, UK. Subscription price 180.00 per year. Periodicals Postage Paid at MIddlesex, NJ. Postmaster: Please send address changes to Worldwide Independent Power, 544 Lincoln Blvd., Middlesex, NJ 0886-2439

Valves & Pumps

18

Our power portfolio includes

8-10 June - NEC - Birmingham

Rotork CVA electric actuators are being used in some of Bostons power plants with impressive results.

IP&EE2010
Independent Power & Energy Europe

Fuel Cells

20
W O R L D W I D E I N D E P E N D E N T P O W E R

Cummins expert Xin Li is behind a remarkable new development in fuel cells based on an SOFC system.

Next Issue
* Cogeneration * CHP systems * Diesel/Gas Engines * Gas Turbines, * Gen-sets * Loadbanks & Test Equipment * Controls & Monitoring * Boilers * Steam Turbines * Turnkey Projects * Power Plants - and much more.
M I D D L E

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EDITORS LETTER
WELCOME
A warm welcome to this months issue of Worldwide Independent Power - as always bringing you closer to the stories and issues affecting on-site power and cogeneration around the world. For editorial comments, please do not hesitate to contact the editor.

BIENVENUE

Soyez le bienvenu cette issue de Worldwide Independent Power. Comme d'habitude, nous vous apportons toujours plus prs des sujets qui affectent l'nergie et la co-generation sur place autour du monde. N'hsitez pas contacter le rdacteur pour des commentaires ditoriaux.

Aidan Turnbull Editor

WILLKOMMEN

Herzlich Willkommen zur Ausgabe dieses Monates von Worldwide Independent Power. Wie immer bringen wir Sie nher heran an die Ereignisse und Geschichten der Stromerzeugungsindustrie rund um die Welt. Fr redaktionelle Kommentare und Anregungen wenden Sie sich bitte an den Autor.

China power will affects US catalyst prices

ost people within the industry will recognise that HRSG is essentially a heat exchanger which recovers heat from a hot gas stream. Indeed, in a combined-cycle power station HSRG produces electricity more efficiently than either gas turbines or steam turbines alone. When it comes to reducing pollution, the HRSG's emissions control sector contains a Selective Catalytic Reduction system to either reduce nitrogen oxides or employ a catalyst to remove CO. In fact, the inclusion of an SCR dramatically effects the layout of the HRSG. What determines the market price of these kinds of catalysts? Whether it's consumables such as activated carbon or SCR catalysts, it will soon be Chinese activity which determines the price. This is the conclusion reached by the Illinois-based McIlvaine Company based on its latest forecasts and demand analyses. "The reality is that a power plant in the US should plan its catalyst purchases based on two factors. Firstly, the demand in China will be larger than the present world capacity. This will increase cost in the short-term. Secondly, there will be new Chinese suppliers entering the US market which will decrease price in the longer term," says the latest McIlvaine report. The US has averaged 10,000 megawatts (MW) per year of new SCR NOx control systems since 1991, say the researchers. Outside China, other nations have only managed to has managed to install 300,000 MW of these systems since 1980. Here's the crux of the issue. China apparently plans to install 400,000 MW by 2020 and it has over the last few years - installed more MW of SCR than any country apart from the US. Its estimated that by 2020 the Chinese demands for catalyst will be 25% greater than the present world manufacturing capacity. By 2012 Dongfang and Sino Environment will have combined manufacturing capacity in China of 23,000 m3 but this will be only 15% of the 2020 requirement. Over the past 40 years the world outside China has managed to install 382,000 MW of flue gas desulfurization scrubbers. In less than 10 years China has installed 326,000 MW and by 2020 China will be operating 658,000 MW of FGD Systems. This means that it will require twice the limestone used in plants outside China today on the world market. It will also need to buy more slurry pumps, nozzles and agitators than are currently used in FGD systems in the world today. This high level of activity will result in the shortage of some raw materials, especially in the US, unless US industrial output in these sectors is adjusted accordingly. So - does this mean good news or bad for all catalyst users in the US by 2020? Only time will tell.

BIENVENIDO

Bienvenido a esta edicin de Worldwide Independent Power. Como siempre, acercndolo a los temas que afectan a la energa y a la cogeneracin in-situ. No dude en contactar con nuestro editor para cualquier cuestin editorial.

BENVENUTI

Benvenuti a questa nuova edizione di Worldwide Independent Power. Come sempre cercheremo di offrirvi storie e questioni riguardanti on-site power e cogeneration a livello globale. Per commenti editoriali, si prega di contattare l'editore.

EUROPE

ASIA-PACIFIC AFRICA

MIDDLE EAST AMERICAS

5

AMERICAN INDEPENDENT POWER SUMMER 2009

NEWS

In brief...
ABB working on US$140m orders for Mexico
ABB, the leading power and automation technology group is working to supply power solutions worth US$140 million for the Mexican national power utility for substations and SVC (Static Var Compensator) solutions to help expand power capacity, extend the transmission and distribution network, and improve grid reliability. The projects are scheduled for completion in around 18 months.

Improving SmartGrid security

Wurldtech Security Technologies, a leading provider of industrial cyber security testing and certification solutions for critical infrastructure industries, revealed a detailed strategic initiative designed to help improve the security of the Smart Grid. The effort includes the addition of wireless communication capabilities into the award-winning Achilles Satellite security & robustness testing platform to diagnose and remediate vulnerabilities in Smart Grid technology; the expansion of the Achilles cyber security certification program to include resilience benchmarks for smart grid devices and applications; and the creation of the worlds first cyber security research institute and global center of excellence for energy infrastructure protection with particular shortterm focus on Smart Grid issues. The Smart Grid is critical to our sustainable energy future, Tyler Williams, CEO of Wurldtech told AIP. The Achilles Satellite is a unique stand-alone platform designed to allow equipment manufacturers of all sizes to conduct standardised cyber security and robustness testing to identify vulnerabilities in IP-enabled computers systems before their deployed in critical infrastructure networks. By adding additional capabilities to the Achilles platform, enabling security testing over common smart grid protocols such as IEC 61850/870, and the new wireless protocols based on 802.11 and 802.15.4 (WirelessHART, ISA100.11a and Zigbee), suppliers of smart grid devices and applications can benefit from the same advantages previously reserved for the traditional SCADA and control system vendors. Tyler Williams said: If we don't move quickly to make functional security an integral part of the Smart Grid initiatives, we may find ourselves in the unenviable position of trying to fix the car while driving it at full speed. Wurldtech is responsible for yet another game-changer, says Ted Angevaare, Shell Global Solutions global manager of process control security and architecture. He concluded: A focused privatesector effort with activities directed by end-users and managed by an organisation with clearly demonstrated industry stewardship, subject matter expertise is a recipe for success. Shell is proud to be amongst the many supporters of this effort.

Alstom joins USCAP

Alstom has joined the U.S. Climate Action Partnership (USCAP), a broad based coalition of industry and environmental groups committed to developing legislation to address climate change. Philippe Joubert, Executive Vice President of Alstom, told AIP: As a global leader in developing clean power technologies, Alstom offers a full range of technologies that can help decarbonise the power generation and transportation sectors. We are delighted to join USCAP as it is a group that shares our commitment to putting forth actionable policies that reflect the scale and urgency of the climate change challenge.

Siemens steam turbine for Minnesota community

Siemens Power Generation is scheduled to deliver a steam turbine generator for a biomassfueled combined heat and power plant (CHP) located in Shakopee in Minnesota, USA. The plant will generate heat and electricity for the Shakopee Mdewakanton Sioux Community (SMSC) and provide energy for a local malting company, Rahr. The SMSC is a federally recognised Native American tribe whose members are direct descendants of the Mdewakanton Dakota people, the original inhabitants of the Lower Minnesota River. Siemens will deliver a SST-300 steam turbine generator for the plant, which will be jointly built, owned and operated by SMSC and Rahr. The CHP plant will run on 180,000 tons of biomass to provide 16.5 megawatts (MW) base load electricity and roughly 37.000 megajoules per second (MJ/s) of thermal energy. At least 25% of the fuel will come from factory byproduct, while the remaining fuels will be wood waste products and dedicated energy crops.

GE Energy's gas engines in Canada

Last month saw the grand opening of North Americas first GE-designed greenhouse cogeneration plant installed to generate more reliable onsite power and heat for commercial greenhouses and help the country reduce its emissions from energy production. Great Northern Hydroponics, a division of Detroit-based Soave Enterprises, installed the 12-megawatt commercial greenhouse power plant at Soaves sprawling, 55acre tomato greenhouse complex in Kingsville, Ontario.

SUMMER 2009 AMERICAN INDEPENDENT POWER

DHCP = $AFETY
for your GE Hydrogen-Cooled Generator

WHEn HYDroGEn PuriTY DroPs, windage losses increase, operating costs increase and then your plants lose revenue and profitability. Gas purity is also a critical life safety issue, making monitoring for potentially explosive levels essential. E/Ones Dual Hydrogen Control Panel (DHCP) was designed specifically for monitoring and controlling hydrogen purity in GE generators that utilize scavenging seal oil systems. The DHCP contains two independent analyzers that monitor hydrogen purity from both the turbine-end seal drain enlargement and the collector-end seal drain enlargement. Designed to be used in a hazardous location, the DHCP has the ability to automatically increase the amount of hydrogen gas bled from the generator. Its also an easy drop-in replacement for your old hydrogen control cabinet. Featuring digital displays, warnings and alarms the DHCP works with all GE and non-GE control systems. DHCP = $AFETY, its just a little equation, but it delivers huge benefits. Visit www.eone.com/solutions today to find out more about increasing your plants safety and profitability.

Environment one Corporation www.eone.com/solutions A Precision Castparts Company

GE is a registered trademark of General Electric Company

NEWS

In brief...
Rotorks failsafe actuators for Encana
Rotork Fluid Systems has supplied twenty Skilmatic EH electro-hydraulic failsafe actuators for remote gas pipeline applications in northern Alberta. Requiring only a 24 V d.c. power supply, these actuators are designed for low temperature service down to -40C and equipped with solar powered battery packs to facilitate reliable operation even in harsh, sub-zero temperature conditions.

Trent 60s provide power for Boston, Mass

Currently providing 116MW of electrical power to the ISO New England Grid are two Trent 60s bought by the Braintree Electric light Department for its Thomas A. Watson plant in Braintree, Boston. So far three Rolls-Royce/Centrax Trent 60 gas turbines installed in the US have successfully achieved first fire start-up in 2009. The third is located at a power station in the city of Lowell, Massachusetts, near Boston. All three units are Trent 60powered Wet Low Emissions (WLE) generating sets, capable of running on both gas and liquid fuel, with power outputs up to 58MW each. Owned and operated by Montgomery Energy Partners LP, the Lowell site, designated LEnergia, achieved successful start-up in late 2008. The single Trent 60 gas turbine generating set is part of a combined cycle plant re-powering project, replacing an older less efficient gas turbine, to provide efficient, cost-effective, environmentally friendly power to meet growing energy needs of the region. Charlie Athanasia, VicePresident of Power Generation for the Rolls-Royce energy business told AIP: These projects mark a significant milestone highlighting the increased market interest in the aero-derived Trent product for industrial power generation applications. Trent 60 generating sets have already been operating to meet critical electrical power requirements in the UK, Canada, Belgium, Denmark, Germany, Chile and the Middle East, and we can now add the United States to this growing list.

One of the three Trent 60 powered Wet Low Emissions (WLE) generating sets, capable of running on both gas and liquid fuel, with power outputs up to 58MW each.

The USAs new US$800m energy plant

Emerson Process Management has formed a strategic relationship with Secure Energy, Inc. to help build an US$800m alternative energy plant in Decatur, Illinois, the first coal gasification-tosynthetic natural gas plant to be constructed in the US in 20 years. Emerson will serve as the main automation contractor (MAC), responsible for managing and digitally automating the Secure Energy plant which will convert 1.4 million tons/year of Illinois coal into 21 billion cubic feet of pipeline quality natural gas.

Worlds largest CFB from Foster Wheeler

Foster Wheeler AG the major international company with its operational headquarters in Clinton, New Jersey has created the worlds largest circulating fluidised-bed (CFB) steam generator. Described as the worlds first supercritical CFB, it has successfully begun operating at the Lagisza power plant, owned by Polish utility company Poudniowy Koncern Energetyczny SA (PKE). Foster Wheelers Global Power Group provided the turnkey supply of the boiler island, including engineering and design, erection, civil work, start-up, and commissioning. The new CFB replaces 1960s-era pulverised coal units at the power plant and was built adjacent to the old boilers. Many existing plant systems, including coal handling and water treatment, were renovated for use with the new CFB unit. The Lagisza CFB produces 460 MWe of electricity at an efficiency level well above that of typical coal plants. The unit incorporates a number of advanced design features such as compact solid separators, INTREX super heaters, and lowtemperature flue-gas heat recovery that captures valuable heat that would otherwise be lost. The unit incorporates for the first time ever in any CFB highly efficient BENSON vertical-tube supercritical steam technology. BENSON vertical tube is a new steam technology that is more efficient and reliable than conventional supercritical technology prevalent in the market today. This CFB represents a culmination of 30 years of design evolution for developing a fuelflexible technology for utility scale electricity production, said Jaroslaw Mlonka of Foster Wheeler's Global Power Group. [Below]The L&T Vadel complex also developed by Foster Wheeler.

IFTP contracts for Saft worth US$1m

Saft, a world leader in hightech batteries, has signed two contracts totalling more than US $1 million with DRS Technologies. The deal involves the supply of its lithium-ion (Liion) energy storage technology for the Integrated Fight Through Power (IFTP) system for the US government. The introduction of our Li-ion technology into the DDG 1000 platform marks a huge milestone for Saft, said Thomas Alcide, Saft Specialty Battery Group General Manager told AIP. We are excited to receive these two contracts and the opportunity to further our partnership.

SUMMER 2009 AMERICAN INDEPENDENT POWER

DIESEL ENGINES

More power in a smaller package an evolution in diesel gen-sets

Three years after the launch of the basic model, the C175, Caterpillar Inc. has developed an improved C175-16 diesel package generator set for standby, prime and continuous applications. This offers improved performance and low fuel consumption, while meeting future emissions regulations, says the manufacturer.
irst unveiled in 2006, C175 diesel generator sets have successfully completed rigorous field reliability demonstrations in applications spanning the globe, says the US-based manufacturer, Caterpillar. Its latest development - introduced for standby, prime and continuous applications - is the C175-16 diesel package generator set. It is now available worldwide in 60 Hz packages with ratings up to 3.1 MW and 50Hz packages with ratings up to 3.1MVA. The Cat C175-16 generator set package was designed to offer a larger unit rating, higher power density, lower emissions and reduced installation costs. Meeting US EPA Tier 2 requirements, the new generator set addresses current and future needs of the worldwide electric power industry, says Caterpillar. The C175 diesel generator sets have achieved more than 100,000h of proven reliability across all Cat product lines, with over 60,000h in generator set applications. The C175 has been used for applications ranging from distributed generation to prime power for remote communities, industrial processing plants and rock crushing applications. Darrin Heflin, engineering manager for the C175, told AIP: "Our customers wanted more power in a smaller package. In today's economic climates, customers expect their generator sets to deliver improved performance and low fuel consumption, while meeting future emissions regulations. He said: Caterpillar's answer is the C175, designed to provide a reliable, durable, easily serviceable generator set in a single solid package." Five key engine systems comprise the Cat C175-16: fuel system, electronics and controls, air system, cooling system and

The latest C175-16 diesel package generator set. lubrication system. The C175-16's fuel system uses a high-pressure fuel pump and control valve which deliver multiple precise injections within a single combustion event. This results in lower emissions, improved performance and reduced fuel consumption. Driven by the ADEM A4 controller, the C175-16 engine management system provides superior performance even in the most demanding environments. Both hard-wired control signals and redundant data links offer reliable control and communication between engine systems. The air system delivers cooler combustion air at the cross-flow cylinder heads, allowing for higher power density and emission reduction. A new generation of turbochargers was designed for the C175, providing a 5% efficiency boost and longer life when compared to traditional turbochargers. A newly-designed cooling system cools only the parts of the engine which require cooling, resulting in increased efficiency and lower heat rejection. This method of temperature control allows customers to reduce overall operating costs by using smaller radiators. The lubrication system uses a range of Cat advanced high-efficiency oil filters which provide a higher level of filtration efficiency while maintaining the Cat superior capacity, reports the company. By enhancing the lubrication system, the traditional 500h oil drain interval has been changed to 600h. It may be possible to extend this even further with the use of Cat S-O-S Services. This will result in reduced maintenance expenditures and downtime, says Caterpillar.

AIP

Internet link
www.cat2-4mw.com

SUMMER 2009 AMERICAN INDEPENDENT POWER

CHP

Hondas CHP dream realised

For most energy-generation specialists, it's not the sleek cars or bikes which will turn their heads at America Honda's HQ in Torrance, CA, - but the impressive onsite CHP hardware providing offset power, AIP reports.

merican Honda Motor Company's headquarters covers an area of more than 100 acres, and includes 12 buildings with nearly 1.5 million square feet of mixed-use office space for 3,000 workers. Honda This particular CHP power system (right) fulfills a corporate aim - to generate its own electricity for its campus at a lower cost, both fiscally and environmentally, using natural gas. It now produces 1.25 MW of electricity and 10 MMBtu of heat per hour to operate an absorption chiller and provide offset power. A spokesman for the distributor, Cummins Cal Pacific, commented: "What this does is to save up to 30% annually on total campus energy expenditures and demonstrate corporate leadership and environmental responsibility. The American Honda headquarters gets true mileage with a CHP system from Cummins Power Generation." Garth Sellers, American Honda's manager, national facility management, told AIP:. "Our decision to install cogeneration was an entirely logical one it took our environmental commitment a step further. It was time to begin generating our own power." The CHP system for American Honda consists of a 1250 kW PowerCommand QSV91G gas engine generator from Cummins Power Generation, plus three Mueller heat exchangers which capture over 10 million Btu per hour of waste heat in the form of hot water from the engine exhaust, engine coolant and oil systems. The hot water is used to run an absorption chiller. "Our decision to install cogeneration was an entirely logical one - it took our environmental commitment a step further. It was time to begin generating our own power." The PowerCommand QSV91G generating set installed at American Honda is one of the cleanest gas generator sets available today, says Cummins. Without aftertreatment, the reciprocating gas engine

The PowerCommand QSV91G gas engine generator from Cummins Power Generation.

generator's emissions of NOX are 111 parts per million by volume (0.85 grams/BHPhr). This level of emissions meets airquality standards in most parts of the US. However, to meet California's strict airquality standard, the generator's exhaust needed to be treated. Cummins Cal Pacific designed and installed a selective catalytic reduction (SCR) system on the generator set's exhaust which uses a urea injection to reduce the NOX in the engine's exhaust. Following treatment, NOX in the exhaust stream is reduced to less than 14 parts per million by volume in compliance with the state standard. The CHP system is installed in American Honda's Central Plant building, which houses the other mechanical systems for the campus. Currently, the CHP system supplies 100% of the electrical needs of the Central Plant building for most of the year, but the cold water from the chiller is circulated throughout the entire 12-building campus for air conditioning. Sellers reports that the CHP system

operates only during the daytime for now, but American Honda willultimately run the system 24-hours-a-day, seven days a week, in Phase Two of the project when two more buildings will be fed from the generator. The campus has a total electrical load of 5.2 MW and, with the addition of the CHP system which runs only during business hours, utility power consumption decreased 14% during the first year of operation. "When we first looked at this project, the key was to do away with kW demand costs from the utility,"says Sellers. "However, we found we could add the absorption chiller and supply 95-100% of the power needed for the Central Plant. This significantly increased the return on investment. The CHP system has thus far met, and in some cases exceeded, our expectations," he concludes.

AIP

Internet link
www.cumminspower.com/ energysolutions

10

AMERICAN INDEPENDENT POWER SUMMER 2009

W O R L D W I D E LO A D B A N K S P E C I A L I S T S

Crestchic loadbanks maximum power when you really need it

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For more information, contact us on (+44) 01283 531645 Or find us on the Internet at www.crestchic.co.uk You can also email us: sales@crestchic.co.uk or hires@crestchic.co.uk

MICROGENERATION

BioTown, USA - Reynolds, Indiana

It's easy enough for one person to try energy self-sufficiency through microgeneration: put a solar panel on your roof, run your car on biodiesel and you're halfway there. But how easy is it for an entire American town to become self-sufficient? AIP has the answers.

ow easy is it for an entire town to become self-sufficient? That's the question that Reynolds, Indiana, has been trying to answer for the past four years. In 2005 Indiana Governor Mitch Daniels famously nicknamed the town BioTown, USA - a model of energy selfsufficiency for the entire state. The town was chosen mainly because of its small size (population 547), excellent rail and road access, and proximity to organic waste (within 15 miles of more than 150,000 hogs). The finished project showcases efficient methods of converting biomass into energy, use bioenergy to fuel homes and businesses throughout the town, promote alternative energies across the US and show that agricultural energy is safe, reliable, and consistent. These are certainly some lofty goals for such a tiny town, and progress on the project has been slow. In fact, external signs of energy independence in Reynolds have been few and far between. So where does the project stand now? As of June 9th, 2009, the White County Area Planning Commission voted to recommend approval of a re-zoning to allow construction of a methane gasproducing digester. This would use animal and human waste to create methane, which would power local homes and businesses. However, there are still many hoops for the town to jump through before achieving energy independence. While the proposed methane digester will be useful, it may not be enough. And even if it is, the White County Commissioners still need to ultimately decide whether to approve the re-zoning request. Reynolds is a prime example of why communities need to prepare for energy crises far in advance. If it takes a prominent project such as BioTown, USA, nearly five years to achieve its goal - with a population of 547 - how long will it take grassroots initiatives in larger towns and cities?

A methane-gas digester like this may be built soon if the plans are approved.

Water tower in Reynolds, Indiana - the place nicknamed BioTown USA.

Free-standing mini-turbines harness energy from the wind. Indiana Agriculture Director Andy Miller commented: "The purpose of BioTown is to create a model community which is energy selfsufficient. BioTown will create a cleaner environment, develop new markets and enhance value for Indiana waste products while producing its own energy. Our goal is to make Indiana a leader in the future

Solar PV (photovoltaic) panels generate power from sunlight for homes. of agriculture and, to do that, we must be progressive in advancing new uses for all our products and finding more environmentally-friendly ways to AIP dispose of our byproducts."

Internet link
www.in.gov.biotown.usa

12

AMERICAN INDEPENDENT POWER SUMMER 2009

UPS

UPS & trigeneration hybrids

Work on a new trigeneration concept combined with Capstone C65 Hybrid UPS systems - each designed to run on natural gas and produce 65 kilowatts each - is nearing completion in Syracuse University, New York, reports AIP.
yracuse Universitys new onsite electrical tri-generation system - due to be completed within the next two months - will allow a new data centre to operate completely off-grid thanks to a collaboration between Rudolph/Libbe Companies and BHP ENERGY LLC and GEM Inc. The data centre is expected to use 50% less energy than a typical data centre today, making it one of the greenest computer centres in operation. The new data centre will make its own heat and air conditioning while waste heat from the microturbines will be linked to absorption chillers, which will use the heat energy to make cold water to cool the computers. During the Winter waste heat from the Capstone microturbines will also be used to produce hot water for an adjacent building. Computers will be cooled with water rather than air. BHP was selected by Syracuse University and IBM to integrate a trigeneration concept into what the company calls the

world's most advanced data center. This system is focused on 12 patented Capstone C65 Hybrid UPS systems which run on natural gas and produce 65 kilowatts each. BHP is an authorised distributor of Capstone Turbine power generation systems which the company describes as compact, affordable energy systems which reduce energy costs while helping to protect the environment with near-zero emissions.

E3 lineup - Capstone Hybrid UPS. "Syracuse University, the state of New York and IBM are true innovators. We are extremely proud to be working with them on a project that will influence the way data centres are designed and operated all over the world," Hussien Shousher, AIP president of GEM Inc, tells AIP.

Internet link
www.capstoneturbine.com

Solar Taurus T60

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205-590-3505 Tel 205-590-3885 Fax Wesley: wtuggle@maegen.com Art: asigler@maegen.com Greg: gposey@maegen.com Keith: kcoleman@maegen.com

SUMMER 2009 AMERICAN INDEPENDENT POWER

13

CONTROLS & MONITORING

Controls & Monitoring - a megaupgrade for LADWP is underway

ABB is working to increase the capacity of the Intermountain Power Project Southern Transmission System by 25% to 2,400 megawatts by 2010. AIP looks at the MACH 2 control & protection systems which are central to the US$87m upgrade by the Los Angeles Department of Water and Power (LADWP).
ower companies have to deliver more electricity from renewable energy sources to customers by the end of the decade. Thats really the bottom line behind a US$87m order ABB won in Los Angeles, California. The companys technicians are now busy increasing the capacity of the 23-year-old Intermountain Power Project Southern Transmission System by 25% to 2,400 megawatts by 2010. This upgrade is a vital part of the developments plans of the Los Angeles Department of Water and Power (LADWP). As if this wasnt hard enough, at least 75% of capacity has to be maintained during the refurbishment. "This project is very much in line with our focus on increasing energy efficiency and leveraging the power of renewables," Peter Leupp, head of ABB's Power Systems, told AIP. Six months ago the Intermountain Power Agency and LADWP, the operating agent, selected ABB to upgrade the high-voltage direct current (HVDC) system with a state-of-the-art control and protection system, MACH2. ABB also has to provide efficient cooling systems for the valves which convert the current from AC to DC and back, and additional AC filters to strengthen power supply quality. The control system is the brain in an HVDC transmission system. One major advantage of a HVDC transmission is its controllability, reports Leupp. The basic power control is achieved through a system where one of the converters controls its DC voltage and the other converter controls the current through the DC circuit. The control system acts through firing angle adjustments of the thyristor valves and through tap changer adjustments on the converter transformers.

The MACH2 control and protection system developed by ABB. built around a host 1.3 GHz Pentium III dual-processor system and six high performance digital signal processors (SHARC). The open systems strategy in MACH2 is reflected both in the use of industrial standard serial and parallel communication buses, as well as in the use of standard formats for all collected data (such as events, alarms and disturbance data). All critical parts of the system are designed with inherent parallel redundancy in accordance with principles used by for HVDC since the early 1980s. The redundant systems are designed as duplicated systems acting as active or hot standby. At any time only one of the two systems is active, controlling the converter and associated equipment. The other system, the standby system, is running, but the outputs from that system are disabled. If a fault is detected in the active system, the standby system will take over the control, with no disturbance to the transmission, says ABB. AIP

Each pole in a bipolar ABB HVDC link has its own control system and each control system is duplicated. In the normal mode, the control systems of the two stations of a two-terminal HVDC system communicate with each other through a telecommunication link between the stations. Most of the ABB HVDC transmissions are remotely controlled from a dispatch centre for the grid. With MACH2 all functions for control, supervision and protection of the stations are implemented in software running in a family of microprocessor circuit boards. Peter Leupp explained: Today the MACH2 is used in conventional SVC, HVDC and SVC Light and a number of other applications. The most important part of the control system, the converter firing control, is

Internet link
www.abb.com/energy

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SUMMER 2009 AMERICAN INDEPENDENT POWER

FILTRATION

Filtration: SO2 and SO3 Mitigation

With Selective Catalytic Reduction for NOx reduction, higher concentrations of SO3 appear in the flue gas which can pose serious problems to vital systems, report experts Yougen Kong and Michael D. Wood.

ith increasing implementation of Selective Catalytic Reduction (SCR) for NOx reduction, there are higher concentrations of SO3 in the flue gas. In addition to forming a blue plume after exiting the stack, SO3 can react with NH3 to form sticky (NH4)2SO4 (ABS) that can plug up the air preheater. Furthermore, SO3 can pose serious corrosion problems to air preheater, electrostatic precipitator (ESP) and downstream equipment. Among various SO3 mitigation technologies, dry injection of sodium sorbents, such as trona, has been proven to be very effective and costcompetitive. While wet scrubbers have been used to control SO2 for large boilers, they are too capital-intensive for small boilers. In addition, many small boilers do not have enough available space for the installation of a wet scrubber. Dry sorbent injection (DSI) systems using trona or sodium bicarbonate are used for SO2 control for years to effectively remove SO2 at rates as high as 95%. The advantages of dry injection of trona or sodium bicarbonate for SO2 and SO3 include (a) low capital cost; (b) small installation footprint; (c) ease of operation; and (d) multi-pollutant control. In a DSI system, a fine powder, such as trona (Na2CO3 lNaHCO3l2H2O) or sodium bicarbonate (NaHCO3), is injected into the flue gas duct. After injection, either sodium sorbent is calcined into porous sodium carbonate (Na2CO3) which reacts

with acid gases, such as Economizer Boiler SO2, SO3, HCl and HF. SCR The resulting products (Na2SO4, NaCl and NaF) are collected by the Air Preheater particulate control Trona/Sodium Bicarbonate device, such as an ESP or bag filter. The sorbent can be ESP/Bag House Air injected at almost any [Above]: Dry Sorbent Injection (DSI). Blower location as long as the flue gas temperature is Air/Sorbent above 275F. In the case of SO3 control, [Right] An example of a if the sorbent is injected upstream of sorbent SCR, most SO3 will be removed before conveying and 4 entering the SCR catalyst and can conseinjection quently lower the Minimum Operation system in a Temperature (MOT). Flue Gas Duct No supplemental water injection is needed when using sodium sorbents, 3 3 unlike the approach using lime or hydrated lime. A simple blower is needed to deliver the sorbent into the duct through injection lances. 2 2 The key of DSI system design is to distribute the sorbent evenly in flue gas 1 or 2 so that the sorbent and acid gases can be Flue Gas well mixed. Trona (SOLVAir Select 200) is a naturally occurring mineral with a chemical formula of NaHCO3-Na2CO3Duct 2H2O. Since it is produced as a fine powder, it is not necessary to mill trona. Although milling can increase the removal efficiency, the added cost of equipment Internet link AIP and maintenance have discouraged most www.solvair.us users from using mills.

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HRSG

HRSG controls upgrade for Fellside Power Station

As part of an HRSG controls retrofit involving the UKs Fellside Power Station, a Pittsburgh-based company, Emerson Process Management, will replace an outdated Alstom Microrec control system and install PlantWeb digital plant architecture with its Ovation expert control system, reveals AIP.

team from Emerson Process Management has flown to the UK to undertake a retrofit of obsolete plant and turbine controls at Sellafield Ltd.'s Fellside Power Station with Ovation technology. Fellside Power Station is a Combined Heat and Power (CHP) power station consisting of three 40-MW GE Frame 6B gas turbines and one 68-MW steam turbine, for a total generating capacity of 188 MW. The plant provides electricity to the United Kingdom's national power grid as well as steam to a nearby Sellafield Ltd. nuclear facility. This contract calls for Emerson to replace the controls on one gas turbine and heat recovery steam generator (HRSG). The retrofit will take place during a scheduled eight-week outage in September and October 2009. The plant is expected to return to commercial operation in November 2009. For the turbine controls upgrade, Emerson

Fellside Power Station is a Combined Heat and Power (CHP) power station consisting of three 40-MW GE Frame 6B gas turbines and one 68-MW steam turbine. will replace existing GE Speedtronic Mark IV turbine controls with Ovation technology. Emerson will also perform various instrument upgrades on the GE gas turbine, such as installing hydraulic servo valves, linear variable displacement transducers (LVDTs) and flame detectors. For the HRSG controls retrofit portion of the project, Emerson will replace an outdated Alstom Microrec control system, installing its proven PlantWeb digital plant architecture with the Ovation expert control system. The complete scope of the project calls for the Ovation system to monitor and control the Alstom HRSG and supplementary firing duct burners, as well as the GE combustion turbine, including overspeed protection. Ovation will also monitor the generator synchroniser functions and interface with the existing Continuous Emissions Monitoring System (CEMS). Emerson's integrated solution gives Fellside Power Station seamless integrated turbine and HRSG control which provides translates tighter overall control of plant operations, and a concise view of key plant and turbine parameters. "Ovation met all of our key functional requirements and, along with Emerson's engineering and support capabilities, gave us confidence that a retrofit project of this size and complexity could be completed in the very tight plant outage window," explains Ian Rae, project manager, Sellafield Ltd. "Emerson is certainly a leader in the design, installation and support of steam, gas and boiler feedpump turbine control solutions," Bob Yeager, president of the Power & Water Solutions division of Emerson, told AIP.

Typical HRSG layout.

AIP

Internet link
www.emerson.com

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SUMMER 2009 AMERICAN INDEPENDENT POWER

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VALVES & PUMPS

Control valve automation systems the key to power generation

What you really need for rugged, extreme environments found in cogen power stations are highly-accurate control valve automation systems which combine advanced, nonintrusive calibration, valve diagnostics with the simplicity, user-friendliness and economy of electric operation. AIP has the story.
sers of control valves in power-generating facilities - as youd expect - have to be particularly picky about their components. Indeed, operators in the USA and the UK have been happy to provide evidence from the field that the Rotork CVA electric actuator is living up to the demanding expectations of end-users, says the manufacturer. "The CVA is working perfectly, it holds the set point, no deviation and responds very quickly to a change," explains a spokesperson from a major power plant in the Boston area of the USA. Controlled by a 4-20mA signal, the CVA is currently installed on a three-way twoinch hot water blending valve in the station's demineralisation plant. The electric actuator has replaced a spring diaphragm actuator and pneumatic positioner that had proved to be unreliable and suffered from exposure to the harsh conditions which are synonymous with power station environments. The operators are now also able to close the valve at the end of a cycle for isolation of the hot water tank, which they couldn't do before due to the unreliability of the positioner. "It does exactly what we want for positioning. We don't even know it is there," concludes the spokesperson, who is now considering the CVA for further applications in the plant. In the UK, Drax Power Station has a CVA installed on a one-inch globe control valve which regulates the direct steam inlet temperature in the boiler fuel oil pump house. The CVA replaced a pneumatic actuator and positioner and operates from the same 4-20mA signal. Operations have been a success, with zero deviation from the desired value to the measured value

Rotorks CVA actuator. and, as a result, the operators are looking at the CVA as an option for future control applications at the station. Another factor in its favour has been the ease with which it was installed on the existing valve. Available for the direct-drive actuation of linear or quarter-turn control valves, the CVA demonstrates highly accurate control valve automation, combined with advanced, non-intrusive calibration, valve diagnostics and the simplicity, user-friendliness and economy of electric operation. Mechanical features include the Rotork 'double-sealed' enclosure, whereby internal electrical components are permanently protected from the effects of the operating environment. The IP68 dust tight, water tight and temporarily submersible (7 metres, 72 hours) enclosure is universal to all models in the CVA range, including those with hazardous area approvals. The CVA is engineered to deliver high precision valve positioning and facilitate the tightest possible tolerances on the process variable, enabling process quality and output to be optimised. When a loss of mains power occurs, built-in supercapacitors allow the CVA to move the valve to the desired position, programmable as open, close, any intermediate position or stay-put. Manual operation is also optionally available. The CVA utilises a new variant of Rotork's well established 'non-intrusive' communication technology for actuator programming and adjustment. Actuator set-up and configuration is performed using a Bluetooth enabled PDA or PC running Rotork Enlight software. AIP

Internet link
www.rotork.com

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SUMMER 2009 AMERICAN INDEPENDENT POWER

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FUEL CELLS

The latest fuel cell - a dream realised

Research into fuel cell technology is gathering momentum and making a significant contribution to the evolution of a revolutionary, ultra environmentally-friendly way of generating electricity, reports Xin Li, Technical Specialist for Cummins Power.

uel cell technology is tipped to be the largest, 'new' industry of the 21st century, with fuel cells anticipated to become a common source of power for backup systems as well as vehicles, homes and public and commercial buildings. Xin Li, Technical Specialist, Cummins Power Generation predicts that on the basis of current progress Solid Oxide fuel cell-based mobile power products will be commercially available within two to three years, with higher powered (> 100kW) stationary power units becoming commercially available within 7-10 years. Functioning like a battery which uses electrochemical conversion, fuel cells produce electricity from fuel (on the anode side) and an oxidant (on the cathode side)which react in the presence of an electrolyte. Fuel cells can be used in a variety of applications including base load power plants, electric and hybrid vehicles, auxiliary power, off-grid power supply and portable charging docks for small electronics. Solid Oxide Fuel Cells (SOFC) which operate on a mixture of hydrogen and carbon monoxide are more compatible with existing fuel infrastructures including natural gas and the only byproducts are water vapour and a small amount of carbon dioxide. In 2007 Cummins Power Generation was one of six industry teams involved in the DOE SECA programme to successfully complete the Phase One tests of the first Solid Oxide Fuel Cell prototypes. "These units offered the potential to be manufactured at costs approaching to conventional stationary power-generation technology", recalls Xin Li, whose significant contribution to the design and implementation of the low cost air supply system for fuel cell, helped achieve overall system costs and performance meeting

aggressive DOE targets. The resulting solid oxide fuel cell (SOFC) power system (developed with Versa Power) has the potential to directly and seamlessly replace its diesel powered generator sets in many applications. It can provide virtually silent power with significantly lower fuel consumption and exhaust emission than existing generator sets. Additional benefits should include higher reliability and lower maintenance than today's systems. The prototype unit tested for SECA produced three kilowatts of electrical power while operating on commercial pipeline natural gas and ran flawlessly for over 2,000 hours at Cummins Power Generation's test facility in Minneapolis, Minnesota. It demonstrated an efficiency of over 37%, which compares favourably with comparably-sized small IC engine-based generator sets, where efficiency is generally well below 30% or even lower. Commenting on the advantages of the SOFC system Xin Li says: "There are many benefits to SOFC-based energy. The technology represents a highly efficient, clean emission (no exhaust treatment required) source of high quality AC power, which is compatible with other energy resources such as Diesel Generator Sets, Solar and Wind. The power output is quiet making it socially more attractive than traditional engine driven generator sets,

with low vibration levels, and the whole system boasts the added appeal of low maintenance. He reports: SOFC technology can provide a reliable power generator solution for a range of applications. In the case of CHP, in addition to the significant green credentials, the possible financial savings to the consumer are considerable. For example, for home CHP applications the natural gas powered SOFC system can deliver over 70% efficiency. In addition to the SECA program, Cummins Power Generation has been working with the US DOE's Energy Efficiency and Renewable Energy (EERE) office to develop and demonstrate a prototype SOFC mobile auxiliary power unit configured to provide electrical power for cab auxiliary loads in AIP highway trucks.

Internet link
www.cumminspower.com

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AMERICAN INDEPENDENT POWER SUMMER 2009

C O N T R A C T S & A P P L I C AT I O N S

US Turbine contract nears completion

The U.S. Department of Energy's National Renewable Energy Laboratory (NREL) has begun the installation of the two largest wind turbines ever erected at the laboratory - a 1.5 MW Department of Energy (DOE) turbine manufactured by General Electric and a 2.3 MW turbine from Siemens Power Generation. Both turbines are expected to be finished this month. The installation of these two turbines will greatly enhance the research capabilities of the NWTC by allowing the researchers to examine some of industry's largest machines and address the challenges of wind energy.

Emerson contract completed in Colombia

Emerson Process Management has completed a dual fuel-conversion initiative which has enabled the Termocandelaria power plant to operate using either natural gas or oil. The project, implemented by Emerson and Mitsubishi Power Systems Americas (MPSA), went into commercial operation in just 11 months, an aggressive timetable required in order for Termocandelaria to fulfill its regulatory obligations. The project marks the latest collaboration between Emerson and MPSA, which in 2008 formed an alliance for turbine retrofit projects. Termocandelaria, owned by Termocandelaria Power Ltd., is a two-unit, 320-MW power plant located in Cartagena, along Colombia's Caribbean Coast. Converting the plant's two Westinghouse 501F turbines from gas fuel only to dual-fuel operation offered Termocandelaria a low-risk, cost-effective strategy for improving unit startup reliability. By being able to start reliably and generate the requested power on demand, Termocandelaria not only maximises its generating revenue but also avoids financial penalties that would be incurred if it were not able to fulfill its regulatory obligations with the Colombian Energy System. The Colombian electricity market is served primarily by hydro-electric plants located in the center of the country. When there is drought, transmission issues or high demand, these plants are not always able to generate sufficient power to meet the region's needs. In these instances, the Colombian government typically calls on power plants utilising other fuel sources, such as Termocandelaria, to provide additional megawatts. "Startup reliability has been greatly enhanced with Cartagena - a developing city.

Bhutan gets new power technology

Alstom, in consortium with ANDRITZ HYDRO GmbH, has been awarded a contract by Dagachhu Hydro Power Corporation Limited (DHPC) to supply key UK electromechanical equipment to a new hydropower station in Bhutan. The project involves a total investment of 151 million. Alstom Hydro's scope of supply amounts to some 30 million and comprises two 70 MVA generators as well as the entire electrical system including automation and protection. Most of the equipment will be manufactured mainly in Switzerland, Austria and India, says the company.

the dual-fuel capability now in place, Termocandelaria is able to produce megawatts on demand," Miguel Angel Perez Ghisays, Plant Manager, Termocandelaria, told AIP. "The significance of this cannot be underestimated, as the plant's ability to be a reliable source of back-up power plays an important role in maintaining grid stability." For this project, Emerson co-developed with MPSA a new control strategy for the dual fuel conversion, which included logic for water injection, fuel gas and fuel oil systems. In addition to the new logic required to accommodate a second fuel source, Emerson also migrated the existing gas turbine controls from the previous-generation WDPF distributed control system to its Ovation expert control system. As part of the migration, Emerson, a leader in power plant automation and turbine control solutions, converted the existing logic to industry standard SAMA logic. This will enable Termocandelaria to more easily modify control schemes in the future.

Solar Millenium and MAN Ferrostaal share power plant contracts in California
MAN Ferrostaal and its partner Solar Millennium AG are said to be repositioning in the solar power market in the USA. All activities on the US market will, in future, be concentrated in a new joint venture, the Solar Trust of America LLC (STA). Through affiliated companies, Solar Millennium will have a majority share in this company, while a minority share will be owned by MAN Ferrostaal Inc., Cleveland (Ohio), a subsidiary of MAN Ferrostaal AG of Essen, Germany. Solar Millennium will also integrate the American project development subsidiary Solar Millennium LLC, Berkeley, as a future subsidiary of STA. Solar Millennium LLC already has long-term power purchase contracts, known as Power Purchase Agreements (PPAs), for three parabolic trough power plants in California, each of which will generate just under 250 MW. It is currently co-operating with Nevada Energy on the development of projects in the Amargosa Desert with further projects are also under development. STA will continue with development projects in the US, and with its business segments will has plans to cover the entire value chain for solar power plants in the USA.

SUMMER 2009

AMERICAN INDEPENDENT POWER

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PRODUCTS AND SERVICES

Saft batteries for power applications

Sunica.plus batteries are based on Saft's mature, proven pocket NiCd technology. According to the company they have been optimised for use in PV and wind energy applications where they are said to perform beyond conventional limits. The robust Sunica.plus design ensures 20 years of reliable operation, even in the harshest conditions, such as the extreme temperatures found in deserts, with only minimal maintenance. Sunica.plus batteries offer a versatile solution for a wide variety of off-grid applications. The maritime navigation industry has adopted Sunica.plus batteries to support over 100 solar-powered lighthouses off the coasts of Norway and Scotland, as well as the lights which mark the entrance to the Port of Gothenberg and buoys in Dutch harbours. In the oil and gas industry, Sunica.plus batteries provide backup power for instrumentation on offshoreplatforms in Indonesia as well as cathodic protection systems on an oil pipeline project in Algeria. In Australia, a hybrid PV and diesel generator energy system relies on Sunica.plus batteries to support two 3 kW solar arrays at night and during times of peak demand. www.saftbatteries.com

Siemens Energy SPPA-T3000 control system for Arizona

Siemens Energy has successfully installed the innovative SPPA-T3000 control system at the New Harquahala Generating Company (NHGC) in Tonopah, Arizona. With an output of nearly 1,100 megawatts, the three 1x1 combined cycle power plant provides muchneeded electricity to the fast-growing Phoenix and Scottsdale area. The scope of supply included the state-of-the-art SPPAT3000 control system upgrade of the entire plant, including three gas turbines, three steam turbines, six generators, three HRSG's and balance of plant, including integration of the 500KV switchyard. Siemens also supplied product modification packages which were easily facilitated by the new control system to improve the plant overall availability and reliability [above]. The SPPA-T3000 was selected for this project because it is compliant with the latest NERC CIP (cyber infrastructure protection) requirements and features secured java-enabled interface, which is easy for plant operators to use and access at anytime from any location. It is a fourth generation distributed control system, specifically designed to implement the power plant and turbine control on a common control platform. The innovative system also integrates functionalities like operation, engineering, diagnostics, archive, alarm and field devices into one single ease-to-use platform. Dean Motl, O&M (Operation & Maintenance) Manager at the New Harquahala Generating Facility commented: "Exceptional teamwork SPPA-T300: a single easy-to-use between Siemens and NHGC with the SPPAplatform from Siemens. T3000 enabled the harmonisation of the plant overall processes and major components, including gas turbine, HRSG and steam turbine. www.siemens.com

Cogeneration fuel cell from Tognum

A new cogeneration fuel cell system from the Tognum brand MTU Onsite Energy is currently creating a stir in the brewery sector. The HotModule HM300 distributed energy system generates electrical power and heat from biogas. The electrical power output is about 240 kW while the thermal output is more than 200 kW. "This innovative fuel cell serves to combine what is sensible in terms of energy policy with what is necessary for climate protection. Global warming and the decline in fossil fuels not only require a consistent expansion in the use of renewable energy sources, but an increased utilisation of efficient and innovative technologies, commented Karl-Theodor zu Guttenberg. "We are continuously looking for possibilities to use energy more efficiently and to become less dependent on fossil fuels", adds Peter Liebert, Managing Director of the Engineering segment of the private brewery involved. Biogas is a byproduct of the brewing process with an 85 percent methane content, making it an excellent energy source for the fuel cell - a regenerative and almost cost-free waste product, facilitating annual CO2 reductions of up to 1,200 tons, says Tognum. A gas cleansing system also developed by Tognum subsidiary MTU Onsite Energy Fuel Cell Systems removes possible sulphur residues from the biogas which would otherwise be detrimental to the fuel cell stack. At a temperature of HotModule HM300. approximately 650C, the biogas is then converted into hydrogen which reacts electrochemically with the airborne oxygen. Almost 50 percent of the biogas energy content is converted into electrical power, while more than 40 percent translates into waste heat, which has a temperature of roughly 400C. Taken together, the result is an exceptionally streamlined overall efficiency of more than 90 percent. www.tognum.com

BETEs new nozzle from the USA

Designed for incineration facilities which treat combustion gases with a gas scrubbing system, BETEs new nozzle is based on its standard SpiralAir lance design connector. Removal problems are know to occur with other kinds of nozzles when wet limestone slurry is injected into a gas stream with an operating temperature in excess of 1,500F (815C). BETEs designers have come up with a solution - it's easy to remove for maintenance and made of Inconel to withstand the exceptionally corrosive vapour streams. www.bete.com

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SUMMER 2009 AMERICAN INDEPENDENT POWER

Clean your SOX with SOLVAir Select products.

The direct approach for the treatment of SO2 and SO3 in stack gases is SOLVAir Products. Whether in Dry Sorbent Injection (DSI) systems, or in wet or dry scrubbers, our products offer straightforward solutions at low capital cost to the problems of air pollution in the stacks. SOLVAir Select 300, a sodium bicarbonate-based product, shows significant results that are truly amazing when used in DSI. Select 300 performs best at power plants that have an ESP and need to reduce SO2. Use SOLVAir Select 200 trona in DSI systems and you have one of the most efficient, cost-effective ways to control or eliminate SO2, SO3 and HCl emissions in the smokestack. The process requires no slurry equipment or reactor vessel because sorbent is stored and injected dry into the flue duct where it reacts with the acid gas. Call the SOLVAir professionals at 800-765-8292 or go to www.solvair.us for comprehensive documentation on the treatment of SOx in stack gas emissions. Clean your SOX with SOLVAir Select products!

The SOLVAir group. The direct approach for the treatment of SO2 and SO3 in stack gases.

PRODUCTS
Solvay Chemicals, Inc. 1.800.SOLVAY C (800.765.8292) www.solvair.us
Copyright 2009, Solvay Chemicals, Inc. All Rights Reserved Chemical Phamaceutical Group