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The Siemens SGT-300 VOC CHP Solution
Steven E. Sexton
The Siemens VOC CHP gas turbine solution defines the future of integrated plant design and sustainable industry via a remarkable economic model.
The high destruction efficiency of regulated volatile organic compounds (VOC) by Siemens 7.90MW(e) SGT-300 significantly enhance the value of a typical economic sensitivity model for a cogeneration plant operating with fixed and variable output. This is good news for industry.
Thousands of existing facilities that use VOC abatement equipment and many more with the potential to use VOC abatement equipment represent a ready replacement market for the SGT-300 VOC CHP Solution. Given the goals of the USEPA and the USDOE to strategically deploy distributed generation (DG) throughout the power grid, the opportunity for energy efficiency and superior economics is at hand.
Preliminary data suggests there may be over 25,000 industrial facilities in the United States that might be able to take advantage of this alternative technology. If 60 percent of these facilities adopt the technology by 2030, the primary energy savings might exceed 1.25 quads of energy. This is equivalent to the petroleum production that might be provided by opening the Alaska National Wildlife Refuge.
Introduction
The Siemens 7.9-MW(e) SGT-300 VOC solution is a stationary industrial gas turbine technology featuring advanced combustor designs that enable the gas turbine engine to ingest volatile organic compounds (VOC) in the form of vapors and gases and thermally oxidize hydrocarbons to the end products carbon dioxide and water. VOCs originate from various solvents and fuels when used in industrial processes. Waste VOC emissions are ingested into the air intake of the gas turbine and are utilized in the gas turbine combustion chamber as a supplemental fuel in addition to the natural gas that is directly injected into the combustor to fuel the operation of the engine.
Now that the United States and the world are determined to conserve valuable energy reserves and reduce climate change gasses via energy efficiency, high-Btu value solvent and fuel (VOC) emissions are a promising opportunity fuel. This is because VOCs have high heat value and can now be utilized by industrial gas turbines incorporating advanced designs. Therefore, VOCs can be sensibly used in the generation of electricity and valuable waste heat onsite. This technology solves a pollution control issue; conserves energy and reduces GHG via energy recycling. It replaces legacy VOC abatement equipment and the associated life cycle costs and promises to be a catalyst for long-term investment in onsite combined heat and power for industry.
Regulatory Drivers
Combined heat and power systems result in energy conservation, efficiency, reductions of greenhouse gases, and reliable and uninterruptable power and steam for heating and cooling for industrial facilities when connected to an interactive grid; and CHP answers the call for Homeland Energy Security. The benefits of energy conservation and reductions of greenhouse gases are social benefits not included in break-even analysis when considering contributions of revenue vs. total fixed cost of a VOCGEN CHP system, yet these social values are drivers of change. In addition, the United States Department of Energy and the United States Environmental Protection Agency has determined that combined heat and power (CHP) fueled by clean-burning natural gas is a best available long-term strategic plan for American industry based on energy efficiency.
The Market
Because combined heat and power systems comprising gas turbines are capital intensive, to date, combined heat and power have found limited applications with the exception of large-scale downtown heating districts, and university, medical and military institutions. In the United States, Con Edison distributes 30 billion pounds of 350°F (180°C) steam each year through its seven (7) cogeneration plants to 100,000 buildings in Manhattan, which is the largest steam district in the world. The peak delivery is 10 million pounds per hour (corresponding to approx. 2.5 GW). This steam distribution system is the reason for the steaming manholes often seen in New York-based movies (Reuters: Research and Markets).
To make economic sense of many of these type of projects, government or “public” funds and tax incentives have been applied as a means to create workable project financing solutions for investors, lending institutions and the end user/owner. Large scale industrial users of energy like wood, pulp and paper mills and mining operations will justify and build onsite combined heat and power systems, but it is not entirely common. Past breakthrough applications, featuring smaller scale systems include publicly funded landfill and municipal digester gas; convention and conference centers, hotels, casinos and biomass, which are currently in hot pursuit. The financial viability of commercial projects typically depends on government subsidies and incentives, stable electricity and natural gas prices and recently “guaranteed savings” by developers, however, these are commercial applications as opposed to industrial applications. Industrial applications are small scale CHP in the range of <50MW such as well field; distribution and storage; transportation and transfer; and manufacturing, which is the focus of the Siemens VOC CHP Solution.
Economics
Economics are the key to the implementation of new energy and environmental technologies and businesses. We have witnessed the recent surge of investment in renewable clean energy alternative fuels and technologies. We also have seen many investors pull back from their optimism and investments in renewables after witnessing the actual cash flows and balance sheet results from these popular clean energy projects and businesses. A good energy idea in today’s marketplace must demonstrate compelling economics to justify investment. From the big picture, investing in new technology without real savings is just trading dollars. It may move the economy along but that is the type of short term thinking that has contributed to the existing economic issues we face with energy today. What is needed is real lower costs and greater returns that result in wealth generation and result in long term projects that create jobs.” Many believe that widely deploying combined heat and power in industry can create jobs, real wealth and can be a very positive change for industry.
We must wisely put into practice long term sustainable planning and projects using energy efficient equipment and systems; projects that we can put into operation now to eliminate energy-intensive and expensive combustion technologies.
The leaders in combined heat and power, including industry associations and state and Federal agencies are accurate in their approach and thinking about combined heat and power and they are on target to deploy combined heat and power. I urge investors and industry leaders to get involved in financing combined heat and power projects because “efficiency” means savings and that translates into long term projects, long term profitability, competitiveness and meaningful change in the American economy.
Market Barriers and Barrier-Breakers
Combined heat and power has not been widely deployed in the past for several primary reasons, but regulations and policies are shaping up. Some barriers and barrier breakers include:
- Electricity and natural gas prices must exceed certain price thresholds to justify the capital investment and the difference between purchased electricity and purchased natural gas. This “spark spread,” condition must be perceived to trend over time to realize a return on investment acceptable to investors and industrial operators and owners.
- Throughout the period of electrical deregulation, electric power monopolies have resisted combined heat and power by offering low rates for electrical power to industry and they charge tariffs and other standby charges needed for demand response to maintain generation assets in case of DG power system failures and unexpected demand for power.
- Electricity and natural gas prices have been “volatile” in that prices trend up and down based supply and demand and money market conditions and this makes it difficult to predict and guarantee that a combined heat and power installation will be able to achieve the “savings” anticipated at startup.
- Standard grid interconnect switchgear has just recently been developed thanks to changing standards, new Federal legislation and policies. This has helped the states to make the changes they needed to standardize the design of switchgear technology and to begin to build the new “smart grid.”
- The Federal Government has led the way for out-put based environmental regulations for energy efficient technology that has lower emissions because it burns less fuel. Some states are modeling from that example by incorporating new provisions in their rules and regulations.
20-Year Plan
My proposed 20-year plan to deploy the VOC solution involves replacing approximately 100,000 boilers, chillers, pollution control thermal oxidizers, flares and other combustion and thermally activated devices that are utilized at manufacturing, petrochemical and synthetic organic manufacturing facilities; including bulk oil, gasoline, ethanol and biogas at loading and unloading facilities in truck, train, and shipping terminals. There are approximately 100 EPA-regulated industrial categories subject to the Clean Air Act that are major sources of VOC emissions. These industries have emission sources from operations such as paint and coatings, plastics, semi-conductor, pharmaceutical manufacturing, etc. Remarkably, many major source facilities enjoy “grandfathered” air quality permit status and are able to emit 50 to 100 tons of VOC annually. The good news is that the Siemens VOC CHP solution can be an attractive economic proposition and energy efficiency opportunity for these industries. The result can be a true net reduction of ozone and carbon emissions in air shed inventories wherever the application is deployed.
Regardless of the fact that we have a VOC destruct gas turbine technology and a well-defined niche market, it does not guarantee that our plan or the government plan for combined heat and power will be implemented as widely and quickly as needed to turn around energy efficiency economics for industry within the United States. As of now, the economy is in a recession, credit is not flowing and investors are apprehensive, but we must consider the future and agree that the economy of the United States and of the world may not change for the better unless we work together to change it.
Combined heat and power is well-understood and practiced. The technology consists of off-the-shelf system designs together with pre-tested, pre-certified and pre-packaged equipment designed for rapid deployment once project development details, including risk and feasibility assessments, permitting and contracts are in place.
Market Projections
Gas turbine combined heat and power technology, the compelling economics are not just highly efficient energy generation and greenhouse gas reductions, but VOC abatement. On the surface, it sounds like a very nice emerging waste-to-energy technology but it significantly represents better economics. That is because it can also eliminate the life cycle costs of legacy boilers, chillers, flares and thermal oxidizers. What we have then is a new economic model for air pollution controls. It is a wealth-generation model created by increasing income and decreasing spending; where payback periods can be less than 1-2 years, it produces excellent internal rates of return and excellent savings for large scale industrial end users. No other air pollution control or CHP technology have claim to this economic model.
Preliminary data suggests there may be over 25,000 industrial facilities in North America that might be able to take advantage of this alternative technology. If 60 percent of these facilities adopt the technology by 2030, the primary energy savings might exceed 1.25 quads of energy. This is equivalent to the petroleum production that might be provided by opening the Alaska National Wildlife Refuge[1].
I have projected that 20 years from initial commercialization, the conversion to industrial combined heat and power technology throughout American industry could contribute an estimated $3.0 trillion USD or more of wealth to the country including jobs, tax base, environmental and health benefits and the value of a decentralized grid and grid security.
Summary
I am certain that most people understand by now that biogas, geothermal and solar (including wind and wave) may never be able to widely power our growing American industry; and nuclear power does not seem to be a sweeping option with uranium supplies low and the overwhelming environmental and health concerns for its use. As fossil fuels reach peak use rates and oil and gas reserves decline around the world, other nations may covet their fuel supplies and we may find the global energy situation to be highly competitive and expensive. If this happens, our concern here in America will be the production of our own energy, conservation of valuable energy reserves and the energy efficient design of sustainable industry to ultimately influence the transformation of our future job market and our economy.
This communication contains statements expressing expectations of future events and/or results, which may include, without limitation, statements concerning anticipated financial performance, business prospects, technological developments, potential markets, new products, research and development activities and similar matters. Such statements constitute forward-looking statements. A projected financial statement based on management expectations. A forward-looking statement involves risks with regard to the accuracy of assumptions underlying the projections made pursuant to the Safe Harbor provision of the Private Securities Litigation Reform Act of 1995. All statements based on future expectations rather than historical facts are forward-looking statements that involve a number of risks and uncertainties, and S.E. Sexton cannot provide assurance that such statements will prove to be correct. S.E. Sexton undertakes no obligation to update or revise any forward-looking statement, whether as a result of new information, future events or otherwise.
[1] This estimate is derived from calculations by Laitner (2004) and compared to ANWR production potential found in Koomey et al. (2003).
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