CHP at a CHP at a Waldbaums Waldbaums Supermarket Supermarket NYSERDA CHP Conference NYSERDA CHP Conference June 25, 2004 June 25, 2004 Hugh I Henderson, Jr., P.E. Hugh I Henderson, Jr., P.E. CDH Energy Corp. CDH Energy Corp. Cazenovia, NY Cazenovia, NY www.cdhenergy.com
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CHP at a CHP at a WaldbaumsWaldbaumsSupermarketSupermarket
NYSERDA CHP ConferenceNYSERDA CHP ConferenceJune 25, 2004June 25, 2004
Hugh I Henderson, Jr., P.E. Hugh I Henderson, Jr., P.E. CDH Energy Corp.CDH Energy Corp.Cazenovia, NYCazenovia, NYwww.cdhenergy.com
Project Team
Host Facility:• Waldbaums/A&PProject Sponsors:• NYSERDA• KeySpan Gas R&D• Oak Ridge National Laboratory• National Renewable Energy LaboratoryOthers:• AGA, Exergy Partners,
GTI, EPA/ETV
CHP in Supermarkets• Peak is 400-600 kW for
typical store• Significant space heating loads due to
refrigerated display cases• Desiccant dehumidification is widely used
in supermarkets– more than 1,000 desiccant units in US stores
• Good balance between thermal and electrical loads
The CHP System
• Capstone 60 kW Microturbine• Nat. Gas Compressor (scroll)• Unifin Heat Exchanger• Hot Water Coils Installed in
Munters Unit MuntersUnit
Capstone C60Gas
Compressor
Unifin HX
Munters HVAC UnitProvides Heating, Cooling & Dehumidification
GasFurnace
Heating HR Coil
Supply Fan
DX Coil
Supply Air Return
Air
Regen HR Coil
Gas Burner
RegenerationInlet
Compressors
Des Wheel
60 tons of cooling 1.2 MMBtuh heating 263 lb/h dehumid
New Coils Added
Installed CHP System
Field Monitoring• Installed data logging equipment to quantify
thermal and electric performance– electrical turbine output (kW, amps, volts)– thermal output of
Unifin HX (flow, ΔT)– turbine exhaust
(T, static P, flow)– desiccant/HVAC unit
performance (T, RH, kW)
CHP Monitoring Points
Capstone 60 Microturbine
WT
Unifin Heat Exchanger
Exhaust Gas
Gas Compressor
Gas Line (½ psi)
To Regen HR Coil
To Heating HR Coil
TEXH1
TEXH2
TGL TGE
FGLYMain 480V
Panel WU
WC
SUD
IUP
PEXH
FGC SV
VEXH
Total Store Power - 09/15/03
22: 0: 2: 4: 6: 8: 10: 12: 14: 16: 18: 20: 22: 0:14 15 16September
0
100
200
300
400
500
Pow
er (k
Wh/
h)
Total (Utility Import + Turbine Output)Utility ImportTurbine Output
Peak Total Demand: 395.5 kW @ 12:15 PMPeak Utility Import Demand: 342.5 kW @ 12:15 PM
Turbine Impact on Store
Overall CHP Performance
input
hrparasiticoutput
GQWW
EFF+−
=
[1] [2] [3] [4] [5] [6] [7] = [1-3] / [2] [8] =
Turbine Parasitic Loads [1-3-4+5+6] / [2]
Power Output Gas Input
Gas Compressor
Heat Recovery
Glycol Pump
Space Heating
Desiccant Regen
"Net" Turbine
Generation Efficiency
"Net"CHP
Efficiency
% of Month in
OperationDate (kWh) (MBTU) (kWh) (kWh) (MBTU) (MBTU) (%) (%)April-03 15,356 209,649 1,097.3 250.0 16,162 0 23.2% 30.5% 39%May-03 30,414 411,031 2,113.0 474.6 29,084 2,045 23.5% 30.7% 73%June-03 39,087 549,741 2,767.1 530.1 18 17,223 22.5% 25.4% 99%July-03 39,185 568,723 2,878.3 635.8 103 72,102 21.8% 34.1% 100%August-03 10,864 161,883 838.9 185.7 0 46,035 21.1% 49.2% 29%September-03 22,210 328,755 1,627.2 359.1 457 40,837 21.4% 33.6% 58%October-03 33,777 465,929 2,312.4 512.2 21,063 12,828 23.0% 29.9% 80%November-03 10,005 138,575 693.8 153.3 5,939 6,192 22.9% 31.3% 25%December-03 5,290 66,833 370.7 81.7 4,688 0 25.1% 31.7% 13%January-04 34,702 417,133 2,394.5 535.4 2,769 0 26.4% 26.7% 83%February-04 27,701 341,383 1,904.6 426.4 92,226 0 25.8% 52.4% 73%March-04 35,160 440,680 2,425.9 544.4 102,987 0 25.4% 48.3% 84%Year 303,749 4,100,315 21,424 4,689 275,496 197,263 23.5% 34.6% 63%
Heat Recovered
Note: Actual natural gas HHV is used.
Daily Capstone Microturbine Performance: Apr 18, 2003 - Jun 09, 2004
0 15 30 45 60 75 90Ambient Temperature (F)
22
24
26
28
30Tu
rbin
e E
ffici
ency
(% H
HV
)
Manufacturer's Rating
EFF_old = 29.8 - 0.0815 * TAOEFF_new = 30.1 - 0.0662 * TAO
Turbine Efficiency Trend
Efficiency Based on Higher Heating Value (HHV)
After Engine Replacement on Dec 29
Summer Days – Desiccant Drying
Turbine Parasitic Loads [1-3-4+5+6] / [2]
Power Output Gas Input
Gas Compressor
Heat Recovery
Glycol Pump
Space Heating
Desiccant Regen
"Net" Turbine
Generation Efficiency
"Net"CHP Efficiency
Date (kWh) (MBTU) (kWh) (kWh) (MBTU) (MBTU) (%) (%)Aug 1, 2003 1,265.9 18,428 92.9 20.6 0 4,868 21.7% 47.8%Aug 2, 2003 1,221.1 18,025 93.1 20.6 0 5,310 21.4% 50.4%Aug 3, 2003 1,223.8 18,025 93.2 20.6 0 5,308 21.4% 50.5%Aug 4, 2003 1,220.1 17,925 93.0 20.5 0 5,358 21.5% 51.0%Aug 5, 2003 1,222.1 17,937 92.7 20.6 0 5,434 21.5% 51.4%Aug 6, 2003 1,210.8 17,836 92.8 20.6 0 4,791 21.4% 47.9%Aug 7, 2003 1,205.5 17,735 92.8 20.6 0 4,649 21.4% 47.2%Aug 8, 2003 1,213.4 17,936 92.8 20.6 0 5,193 21.3% 49.9%Aug 9, 2003 1,222.1 17,936 93.0 20.5 0 5,083 21.5% 49.4%
Aug 10, 2003 22.5 100 1.8 0.4 0 39Totals 10,864 161,883 839 186 0 46,035 21.1% 49.2%
Note: Actual natural gas HHV is used.
Heat Recovered
Winter Days – Space Heating
[1] [2] [3] [4] [5] [6] [7] = [1-3] / [2] [8] =
Turbine Parasitic Loads [1-3-4+5+6] / [2]
Power Output Gas Input
Gas Compressor
Heat Recovery
Glycol Pump
Space Heating
Desiccant Regen
"Net" Turbine
Generation Efficiency
"Net"CHP Efficiency
Date (kWh) (MBTU) (kWh) (kWh) (MBTU) (MBTU) (%) (%)Feb 9, 2004 503.6 6,313 35.7 7.9 1,496 0 25.3% 48.6%
Feb 10, 2004 1,366.0 16,959 93.5 20.8 3,881 0 25.6% 48.1%Feb 11, 2004 1,365.4 16,809 93.8 20.9 4,573 0 25.8% 52.6%Feb 12, 2004 1,365.6 16,533 94.5 21.0 5,067 0 26.2% 56.5%Feb 13, 2004 1,365.6 16,834 93.7 20.9 4,462 0 25.8% 51.9%Feb 14, 2004 1,365.5 16,934 93.5 21.1 4,416 0 25.6% 51.3%Feb 15, 2004 1,365.3 16,433 94.5 21.2 5,474 0 26.4% 59.3%Feb 16, 2004 1,364.9 16,232 95.4 21.2 5,607 0 26.7% 60.8%Feb 17, 2004 1,326.5 16,032 92.6 20.5 5,198 0 26.3% 58.3%Feb 18, 2004 1,296.7 15,932 89.4 20.0 4,420 0 25.9% 53.2%Feb 19, 2004 1,361.7 16,733 93.2 21.0 4,536 0 25.9% 52.6%Feb 20, 2004 1,365.2 16,934 93.5 21.0 4,466 0 25.6% 51.6%Feb 21, 2004 1,365.7 17,134 92.6 21.0 4,227 0 25.4% 49.6%Feb 22, 2004 1,365.3 16,934 93.2 21.0 4,198 0 25.6% 50.0%
Totals 27,701 341,383 1,905 426 92,226 0 25.8% 52.4%Note: Actual natural gas HHV is used.
Heat Recovered
Average Combined Heat and Power Efficiency
0 20 40 60 80 100Avg Daily Outdoor Temperature (F)
0
20
40
60
80
Effi
cien
cy (%
HH
V)
WinterSpring/FallSummer
CHP Efficiency Trends
60% Winter 50%
Summer
Typical Performance of Heat Recovery System
Turbine Exhaust Side Data: 09/15/03
22: 0: 2: 4: 6: 8: 10: 12: 14: 16: 18: 20: 22: 0:14 15 16September
0
200
400
600
800
Turb
ine
Exh
aust
Tem
pera
ture
(F) Entering Unifin HX
Leaving Unifin HX
Glycol Side Data: 09/15/03
22: 0: 2: 4: 6: 8: 10: 12: 14: 16: 18: 20: 22: 0:14 15 16September
0
50
100
150
200
Gly
col T
empe
ratu
re a
nd F
low
rate
(F, G
PM
)
Total Heat Recovered to Glycol (MBTU): 4271
Glycol Leaving Unifin HXGlycol Entering Unifin HXGlycol Flow
Heat Recovery System Statuses: 09/15/03
22: 0: 2: 4: 6: 8: 10: 12: 14: 16: 18: 20: 22: 0:14 15 16September2003
OffOnOffOnOffOnOffOn
Unifin Pump StatusSpace Heating HR Operation (AHU Stage 1 Heat From Glycol)Regen Fan Status (AHU Dehumification)Desiccant Regen HR Operation
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar2003 2004
0
100
200
300
400
500
Hea
t Rec
over
y (M
Btu
/h)
Space Heating
Desiccant Regeneration
Passive HeatLoss
HR Rate in Different Modes
Daily AHU Gas Use: 08/21/02 - 09/10/03
40 60 80 100 120 140Ambient Abs. Humidity (gr/lb)
0
50
100
150D
esic
cant
Gas
Use
(the
rm/d
ay)
Without Microturbine Heat RecoveryWith Microturbine Heat Recovery
Impact of Heat Recovery on Desiccant Gas Use
Gas Savings from Heat Recovery
Daily AHU Gas Use: 09/12/02 - 04/30/04
0 20 40 60 80 100Indoor-Outdoor Temperature Difference (F)
0
50
100
150
200
250
AH
U G
as U
se (t
herm
/day
)
Without Microturbine Heat RecoveryWith Microturbine Heat Recovery
HR Impact on Space Heating
Gas Savings from Heat Recovery
Savings Smaller than Expected!
“What If” Annual Analysis
• Used measured trends with TMY weather data
• Assume more optimum Heat Recovery– Address minor set point/control issues
• What if: turbine ran for entire year– Annual CHP efficiency increases to 48-50%– Heat recovery saves more than 20,000 therms
(mostly space heating)
Economics in Other Locations
$16,135.31 $15,464.63
$8,878.46
$1,203.14
$(14,545.10)
$(24,277.80)$(30,000.00)
$(25,000.00)
$(20,000.00)
$(15,000.00)
$(10,000.00)
$(5,000.00)
$-
$5,000.00
$10,000.00
$15,000.00
$20,000.00
SouthernCalifornia
New York Chicago Long Island Tampa Portland
Net
Sav
ings
ETV Emissions Testing• NYSERDA funded Environmental
Technology Verification (ETV) testing at this site
• High-precision testing in June 03 confirmed CDH’s thermal and power measurements
• Also collected emissions data:
Capstone Rated Performance
Measured Performance
Nitrogen Oxides - NOx (ppmv @ 15% O2) < 9 3.1 Carbon Monoxide - CO (ppmv @ 15% O2) < 40 3.7 Total Hydrocarbons - THC (ppmv @ 15% O2) < 9 0.9
More Information
• CDH Online Monitoring & Project Reports: www.cdhenergy.com
click on: Online data access – Waldbaums(user/pass: waldbaums/microturbine)
• ETV Reportwww.epa.gov/etv/verifications/vcenter3-3.html(sep 03 report)
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