Transcript New Business Venture: Ielios Energy

Mechanical CHP
Gas-Engine Driven
Heat Pump Hot Water Heaters
Stephen Lafaille, PE
7/24/2013
1
Why is a boiler like an iceberg?
7/20/2015
2
Water Heating Costs
$
$
$
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First Costs
$
Fuel
Costs
$
$
$
3
Concept
E
A2
Heat Out
Engine
Waste
Heat
A
A1
Compressor
B
Natural
Gas
Condenser
5 kW
Generator
for
Parasitics
D
78 °F Ambient
120 °F Hot Water
Refrigeration
Cycle
C
Heat From
Outdoor Air
FREE
ENERGY!!!
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Air-Cooled
Evaporator
4
Equipment Comparison
Gas Engine Driven Heat Pump Water Heater
COP = 2.0 (Source Efficiency)
= 5.5 (Site Efficiency)
Commercial Electric Heat Pump Water Heater
COP = 1.2 (Source Efficiency)
= 4.0 (Site Efficiency)
Remember a BTU of Electricity is approximately 4X the cost of a BTU of Gas!
Boiler
COP = 0.85 (85%) (Source Efficiency)
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Conditions: Producing 120°F Hot Water @ 78°F Ambient
5
Source Efficiency Comparison
Overall
Efficiency
Natural Gas
Heat Pump
Water
Heater
200
100
Units of
Energy
Units of
Heat
η=33%
Electric
Heat Pump
Water
Heater
Gas Boiler
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166
Units of
Energy
55
6% Loss
200%
50
200
Units of
Heat
120%
Power
Plant
235
Units of
Energy
200
Units of
Heat
Conditions: Producing 120°F Hot Water @ 78°F Ambient
85%
6
Operating Cost Comparison
Example: Hotel/Condo/Hospital
Average thermal load per month = 4000 therms
400 MMbtu or 117,200 kWh monthly
or
4800 MMBtu or 1,406,400 kWh annually
Assumptions: Natural Gas = $0.90/therm
Electricity = $0.12/kWh (Blended Rate)
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Operating Cost Comparison
COP = 2.0
$27,600*
4800 MMBtu
(2400 MMBtu)
COP = 4.0 (Site Efficiency)
$42,192
4800 MMBtu
(351,600 kWh)
COP = 0.85
$50,823
4800 MMBtu
(5647 MMBtu)
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*Includes service cost estimated at $6000
8
Applications
Domestic Hot Water
Pool heating
Laundry/Food Prep
Process Heating
 Food/Beverage
 Manufacturing
Desiccant Regeneration
Summer Reheat (Humidity Control)






Building Types








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Hotels
Condos
Correctional Facilities
Nursing Homes
Hospitals
Spa/Health Clubs
Universities
Manufacturing Facilities
9
Federal Incentives
 Gas Engine Driven Heat Pumps qualify for the
10% Investment Tax Credit as it is considered
mechanical CHP. This is available until December
21, 2016.
 Per section 48(a)(3)(A)(v) of the IRC the CHP Tax
Credit is defined as:
“A property compromising of a system which uses the same
energy source for simultaneous or sequential generation of
electrical power, mechanical shaft power, or both, in
combination with the generation of steam or other forms of
useful thermal energy (including heating and cooling
applications”
 For equipment placed in service in 2013, 50%
Bonus Depreciation (MACRS) is also available.
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10
Utility Incentives
 This type of equipment falls either under existing
incentive programs with several utilities or under
custom programs
 Many utilities will pay $1.00/therm saved in the
first year. This could be anywhere from $15,000$30,000 depending on the installation.
 Incentives currently available through, National
Grid & NSTAR in New England
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Features and Benefits
 Hot Water delivery temperature 100°F-165°F


Can reach much higher temperatures than electric heat
pumps due to engine waste heat
Also due to higher efficiency can run down to < 20°F
and still be much more efficient than boilers/electric
heat pumps
 Twice the efficiency of a boiler means cutting
heating costs and carbon footprint in half
 Engines now have ultra low emissions with near
zero criteria pollutants
 Simple installation to existing hot water system
 Modular & Scalable
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12
What about the service??
 New industrial engines are very advanced




Electronic ignition-no more spark plug wires to change!
Variable valve timing
Extremely durable
Very long service intervals
 Factory service programs available from most
manufacturers
 Usually a fixed rate billed per run hour

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Facility manager’s know their service costs for the year up
front-no surprises.
13
Mechanical CHP
Advanced Inverter Based CHP Systems
Boston Chapter of ASHRAE
Jeffrey Glick - Tecogen Inc.
7/20/2015
14
Combined Heat & Power (aka cogeneration)
Definition: The simultaneous production of two useful outputs
(electricity + heat) from a single fuel source
27.0%
Electricity out
100.0%
100 kW
Gas in
1,263,000 Btu/hr
55.4%
Thermal out
700,000 Btu/hr
2-for-1:
“A generator that makes free hot water”
or
“A boiler that makes free electricity”
>82.4%
total
(HHV
basis)
>92.8%
total
(LHV
basis)
Benefits to Site
 ECONOMICS
 Cut energy costs by 30-50%
 Qualify for incentives (utility/ fed/ state)
 Reduce exposure to utility rate volatility
 ENVIRONMENTAL
 Cut carbon footprint by 50%
 Increase efficiency
 Lower emissions
 SECURITY
 Black-start capability (supplemental standby
capacity = “convenience power”)
 Power quality
 Reduce US dependence on foreign oil
Cogeneration vs Conventional Energy Source
Conventional Source
Power Plant
 = .33
Assumptions:
8,000 run hours per year
Therms based on HHV of natural gas at 1,020 Btu/scf
Facility
69
23
75 kW
121
52
Natural Gas Well
39
Boiler
 = .75
490,000
Btu/hr
With CHP Installed
Facility
20
Natural Gas Well
65
CHP
39
 Conventional Source Yearly Gas Consumption:
 TECOGEN® Yearly Gas Consumption:
75 kW
490,000
Btu/hr
121,240 Therms/yr
65,200 Therms/yr
Sample CHP Economics (200 kW System Installed)
Value of Electricity Generated
Value of Demand Savings (1 Unit – 100 kW)
Value of Displaced Energy for Chiller (80 tons)
Value of Thermal Energy (Boiler Savings)
REVENUES
Cost of CHP Fuel
Cost of Maintenance Program
COSTS
$ 234,976 /year
$ 21,600 /year
$ 24,832 /year
$ 110,125 /year
$ 391,533 /year
$ 169,586 /year
$ 38,264 /year
$ 207,850 /year
NET ANNUAL OPERATING SAVINGS: $ 183,683 /year
INSTALLED COST:
$ 1,080,000
SIMPLE PAYBACK:
With Tax Benefits
5.9 years
3.2 years
Reliance on Utility Rates
 PaybacksTypically 2 to 4 Years
8
Payback (years)
7
6
5
0.10
0.15
0.2
4
3
2
1
0
0.7
0.9
1.1
Gas Prices ($/therm)
1.3
Environmental Benefits (NOx/CO)
Newest CHP
Technologies
offer NOx/CO
emissions
comparable to
Fuel Cells
Current Engine
Technology
Environmental Benefits of CHP: CO2 Emissions Reductions
GREENHOUSE GAS EMISSIONS FROM: 'SAMPLE TECOGEN
INV-100
CHP Installation
INSTALLATION'
1,400
1,200
1,000
tons CO2/ year
489
49%
Reduction
800
by site's
Tecogen
unit(s)
600
by site's
boiler
400
695
608
200
0
without
TECOGEN
CHP
CHP
with TECOGEN
by utility
power
plant
With a 100 kW
system, 576
fewer tons of
CO2 are emitted
each year at a
typical
installation
Inverter Based CHP Products
 Important Features
 Inverter and permanent magnet





generator
Streamlined interconnection
Black-start capability
Able to handle load changes
without requiring battery banks
High part-load efficiency
Peak shaving capability
Inverter Based Features cont.
 Qualifies for Standardized






Interconnection
 UL1741 Compliant
 CE Marked for European Use
 UL 2200
Black-Start/Grid-Independent Operation
 Compatible With CERTS “Wireless
Droop” Control
Power Quality
 No Reactive Power Use
Power Boost for Demand-Side Response
Enhanced Efficiency
Low Emissions
Internationally Adaptable
 50/60 hz
Multiple Small Units Sometimes Offer Advantages over Large Units
 Up To 1 MW Capacity (10 units)
 Redundancy
 Higher Probability of achieving kW
Demand Savings
 Better Modularity
 Can Expand System Later
 Improved Serviceability
 Familiar, Uniform Components
 Easier Siting
 Can Fit into Facility’s Existing
Irregular Spaces
Multiple Small Units Can Offer Advantages over Large Units
 Sound
 Can Be Installed Within Sound
Sensitive Sites
 Hospitals, Hotels, Nursing
Homes, Schools, Apartment
Buildsing
 Part-Load Performance
 Units Can Modulate to Part-Load
Without Loss of Efficiency
 Master / Slave Controls
 Operate Units as One Large Unit
 Allows Units to be Cycled Off
During Low Load Times
Inverter Interface
To Exhaust After Treatment
& Heat Recovery
Inverter
Rectifier
Variable
Frequency
AC
High Quality
3-Phase,
50 or 60 Hz
Power
DC
Optional DC Input
from Auxiliary Device
(solar PV, Battery, Fuel Cell, etc.)
Natural Gas Engine
Amorphous
Generator
PermanentMetal
Magnet
Generator
Delivered kW
Engine/Generator Output
RPM
1000
2200
3000
Volts
98
207
258
Freq (hz)
135
297
405
KW
39
93
130
Power
Conversion
Volts
Freq (hz)
KW
480
480
480
60
60
60
37
88
123
Opportunities - What to Look for (Cogen Applications)
 Consistent Electrical & Thermal Loads
 Sample minimum feasibility criteria:



Gas
Electricity
Run-Hours
(TBD:
> 4,000 therms/mo usage
> 40,000 kWh/mo usage
> 6,000 hrs/year
Absorption chillers, etc.)
 High Electric Rates

Con Edison/ NStar/ PG&E/ SCE/ SDG&E/ PSE&G/
National Grid/ LIPA esp. energy charges
 Centralized Hot Water Heating & Electric Metering
 Energy- and Environmentally-Focused Buyers



Site willing to invest in long-term savings
“Ultra” low-emissions
Operating costs/ environmental/ efficiency/ LEED/ “Green”
System Concept
 Size system conservatively, to lesser of thermal or
electrical baseload
Made By 150 kW
CHP System’s
Free Waste Heat
Sample Applications and Installations
• Athletic Club, Claremont, CA
– Recreational facility
– 1 100 kW unit & 3 75 kW units
– Application: CHP & stand-by
– Start-up: 2008
– CEC Field Test
thermal loads:
Olympic pool & spas
Family pool & spa
Laundry & DHW
Sample Applications and Installations
•
Athletic Club, Claremont, CA
New 100 kW with 3 earlier units
Sample Applications and InstallationsInstallations
• Hotel, Newton, MA
– 8-story high-rise hotel
– 1 100 kW unit
– Appln: CHP stand-by
– Start-up: 2008
Sample Applications and Installations
 Hospital & Nursing Home,
Bronx, NY
 7-story high rise
 3 100 kW units
 Application: CHP & stand-
by
 Start-up: 2008
Sample Applications and Installations
• Pier 7, Phoenix Beverage
Brooklyn, NY
–
–
–
–
–
Beer Distributor in NYC
Application: CHP & Cooling
Grid Independent Operation
Start-up: 2010
6 100 kW Units
Sample Applications and Installations
• Twin Marquis, Brooklyn, NY
– Manufacturer of assorted
Asian food products
– 2 100 kW
– Application: CHP & stand-by
– Start-up: 2010
– Project partially funded by
National Grid and the Energy
Solutions Center (ESC)
Sample Applications and Installations
 Boys Home, Chatsworth, CA
 Residential facility
 1 100 kW unit
 Application: CHP & stand-by
 Start-up: Jan 2009
Sample Applications and Installations
 Nursing Home & Rehab
Center, Brooklyn, NY
 7-story high rise
 3 100 units
 Appln: CHP & stand-by
and cooling
 Start-up: early 2009
Sample Applications and Installations
 Condominiums, Brooklyn, NY
 38-story high rise
 5 100 kW units’s
 Application: CHP & stand-by
and cooling
 Start-up: early 2009
Sample Applications and Installations
 Residence & Club, New York, NY
 Residential & recreational




facility
10-story high rise
3 100 kW units
Application: CHP & stand-by
& cooling
Start-up: Late 2010
Mechanical CHP
Gas Engine-Driven Cooling Systems
Boston Chapter of ASHRAE
Jeffrey Glick - Tecogen Inc.
7/20/2015
39
The Gas Cooling Market Is a Growing
Segment in HVAC Industry
 Rising Cost of Electric Cooling
 Stable and Inexpensive Gas Rates
 Refrigerant Issues
 Available Incentives
$300/Ton in Connecticut
$350/Ton in New Jersey
Custom Program in Massachusetts
 Increasing Acceptance of Gas Cooling
Chiller Decision Is No Longer an Automatic Choice
for Electric
Peak Seasons for Gas and Electricity Sales
% Of Peak
100
90
80
70
60
Cooling Season
50
J
F
M
A
M
J
Electricity Sales
J
A
S
O
Natural Gas Sales
N
D
Electric Chiller
CONDENSER
Hot Refrigerant Vapor
ELECTRIC
MOTOR
Warm Refrigerant Liquid
EXPANSION
VALVE
COMPRESSOR
Cold Refrigerant Vapor
EVAPORATOR
COOLING
COILS IN
BUILDING
Cold Refrigerant Liquid
Natural Gas Engine Driven Chiller
CONDENSER
Heat Recovery
Hot Refrigerant Vapor
GAS
ENGINE
Warm Refrigerant Liquid
EXPANSION
VALVE
COMPRESSOR
Cold Refrigerant Vapor
EVAPORATOR
COOLING
COILS IN
BUILDING
Cold Refrigerant Liquid
Hybrid Chiller Installation
Engine Driven Chillers
 Benefits:
 Lower Operating Cost/Lowest Life Cycle Cost
 Most Efficient Technology Available




High-Efficiency Screw Compressor
Variable Speed Engine Drive
Very High Part Load Efficiency
Continuous Load-Following Capability
Run Green - Run Clean
 LEED Certification Potential
 Heat Recovery Capability
 Environmentally Friendly




Non-CFC Refrigerant
Reduced Global Warming
Reduced Fossil Fuel Use
Reduced CO2 Emissions
Engine Driven Chillers
 Engine Driven vs. Electric
 Significantly Lower Operating Costs
 Peak Electric Demand Reduction
 Heat Recovery Capability
 Superior Part Load Efficiency
 Avoid Electric Service Capacity Upgrades
 Mission Critical Applications


Stand-by Generator Size Reduction
Back-up Cooling During Power Outages
Engine Driven Chillers
 Engine Driven vs. Absorption
 Lower Operating Costs


High COP; Much Higher at Part Load
Low Parasitics
 Easy Retrofits


Smaller Footprint
Can Use Existing Tower, Pumps, Piping
 Familiar Vapor Compression Technology
 Low Temperature Capability
Importance of Part Load Efficiency
3.0
2.5
Engine Driven IPLV = 2.6
COP
2.0
1.5
1.0
DF Absorber IPLV = 1.1
0.5
0.0
0
25
50
% Full Load
75
100
Engine Driven Chillers
 Design “Non-Issues”
 Noise Level
89 dBa @ 3 Feet
 Similar to Electric Chiller at Full Load
(Lower than Electric Chiller at Part Load)
 Vibration
 Low Inertia Engine
 Neoprene Pads Sufficient in Most Installations
 Neither Have Been an Issue at Any Installation

Engine Driven Chillers
 Design Considerations
 Cooling Tower
Minimal Additional Flow Required for Cooling
Engine (~7%)
 Much Less Flow than for Absorbers
 Exhaust
 Piped to Outside
 Exhaust Muffler for Sound Attenuation
 Temperature Less than 500°F

Engine Driven Chillers
 Design Considerations - Continued
 Low Pressure Natural Gas
Less than 1 psi required
 Waste Heat Recovery
 Over 225°F Available
 Simple Design/Installation
 Easy Disassembly for Access
 Electric Service
 Single Phase 208/230v

Factors Affecting Chiller Economics
 Equipment Operating Efficiency (IPLV)
 Gas and Electric Rates (Including Demand)
 Use of Heat Recovery
 Utility Rebates
 Equipment and Installation Costs
 Electric Power Requirements
(Transformer, Switchgear)
 Standby Generator Requirements
Characteristics of Good Gas
Engine Chiller Applications
 High Electric Demand Rates
 Existing Absorption Chiller Installation
 Insufficient Electric Power
 Cooling Necessary During Power Outages
 Hot Water Needed
 Process Applications
 Eligible for Utility Rebates
Typical Gas Engine Driven
Chiller Applications
 Hospitals
 Nursing Homes
 Colleges/Schools
 Hotels
 Industrial/Process
 Multi-Family Residential
 Department Stores
 Ice Rinks