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Case Study: Steam Turbine Generator Project

CHP facility implemented by:

Midwest Cogeneration Association

Presented by: Andrew Downing Turbosteam LLC

Eastern Illinois University Why CHP?


Through a campus wide energy efficiency program instituted by Eastern Illinois University, Honeywell was contracted to overhaul the existing steam system and install a CHP plant which would be paid for by energy savings generated by the project As part of the larger energy savings program, Honeywell brought Turbosteam in to provide equipment for a very specific piece of the project
EIU Renewable Energy Center

The old plant equipment was past its useful life. We added the turbine generator to provide biomass energy to the facility.
Chad Weber - Mechanical Engineer Facilities Planning & Management

Steam Turbine Generator provided by Turbosteam

Before CHP
Eastern Illinois University operated a 150 psig coal fired boiler (supplemented by natural gas) The primary use for steam is campus heating during winter and shoulder months, with some parasitic steam loads through out the year

Example coal fired boiler system

Sizing their CHP


70,000

2008 Yearly Steam Flow Avg.


60,000

Increasing operating from represented a minimal fuel cost compared to a sizable generation potential New high pressure biomass boilers were selected at 600 psig / 550F to maximize potential for let down through a steam turbine Historical steam flow was evaluated to determine the optimal operation range Exhaust pressure was set at 125 psig to account for any pressure losses. The design allows for a +/- 25 psig swing in operation

50,000 Steam Flow (lbs/hr)

40,000

30,000

20,000

10,000

1/1/2008 1/15/2008 1/29/2008 2/12/2008 2/26/2008 3/11/2008 3/25/2008 4/8/2008 4/22/2008 5/6/2008 5/20/2008 6/3/2008 6/17/2008 7/1/2008 7/15/2008 7/29/2008 8/12/2008 8/26/2008 9/9/2008 9/23/2008 10/7/2008 10/21/2008 11/4/2008 11/18/2008 12/2/2008 12/16/2008 12/30/2008

Date

Turbine generator designed for primarily base load operation

Designing their CHP steam turbine generator

Turbosteam Supplied Skid mounted single stage turbine design Direct Coupled 3,600 RPM 480V induction generator Automatic throttle valve and handvalves for part load efficiency Allen Bradley PLC based control system with touch screen OIT

CHP system execution


Installation of new Biomass boiler Installation of a 617 kWe rated single stage steam turbine generator set Overall thermal efficiency of the plant now more than 70% compared to ~33% for a conventional power plant The campus reliability and heating requirements unaffected by new CHP system

(AVI, MOV)

Realizing the benefits


Using historical steam flow data, Honeywell and Turbosteam were able to estimate the power generation potential of a new CHP system based on the expected performance of the steam turbine generator system Based on historic electric rates, the system is capable of more than $250,000 in gross electric savings per year By generation more than 3.4 million kWh on site, the school reduces its carbon foot print by more than 1,900 tons/yr This generation is equivalent to planting close to 80,000 trees or removing 410 cars from the road
Based on EPA data for Illinois One Tree equals 48 lbs/yr of CO2 reduction, one car equals 9,249 lbs/yr of CO emission

2008 Theoretical Generation Month kWh Generation January 339,843 February 323,168 March 321,121 April 249,758 May 218,874 June 229,428 July 244,147 August 300,943 September 260,626 October 273,843 November 331,616 December 341,971 3,435,340

Conclusions
EIU had an aged boiler that was in need of replacement, Honeywell provided the services and showed the benefits of upgrading that boiler to biomass and adding a CHP system The savings generated by replacing the existing equipment with a high pressure biomass boiler and a Turbosteam steam turbine generator system effectively pays for the boiler upgrade and gives the entire steam plant a payback With the ability to generate more than 600 kW of green power, Honeywell and the University has hedged against future electric increases

Questions