CHP in the Ethanol Industry: The Business Case. April 1st, 2004 Bruce Hedman Energy and Environmental Analysis, Inc
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1 CHP in the Ethanol Industry: The Business Case April 1st, 24 Bruce Hedman Energy and Environmental Analysis, Inc
2 Overview Why CHP for Ethanol What are the viable CHP options What are the critical cost and performance parameters Illustrative economics Critical factors
3 Why CHP Is a Good Fit for Ethanol Energy is the second largest cost of production for dry mill ethanol plants Electric and steam demands are large and coincident Electric and steam profiles are relatively flat Operating hours are continuous 24/7
4 Ethanol Energy Demand Plant Capacities, mmgal/yr Electricity Demand, kwh/gal Steam Demand, lbs/gal Boiler Fuel, Btu/gal DDGS Drier Fuel, Btu/gal Power to Steam Ratio , 27,5 13,.16.32
5 Gas Turbine CHP
6 Gas Turbine/Supplemental Firing CHP
7 Boiler/Steam Turbine CHP
8 CHP System Cost and Performance Gas Turbine Gas Turbine w/duct Firing Boiler/Steam Turbine Capacity, MW Electrical Efficiency, % (HHV) Steam Output, Btu/kWh 4,5 6,7 12, 2, 35, 4, Overall Efficiency, % (HHV) Power to Steam Ratio Installed Costs, $/kw 1,8-9 2, 1, 35 9* Non-fuel O&M Costs, $/kwh <.4 * Incremental costs of steam turbine generator and supporting systems only
9 The Value Equation - Reduced purchased electricity costs + Increased fuel costs + Increased O&M costs + Increased capital expenditure - Displaced capital? - Reliability, other operational savings? - Overall Savings
10 Simple Payback Analysis Payback = Capital Cost/Operating Savings Generic, first cut analysis Parametric calculation of payback as a function of fuel and electricity prices. Useful to identify sites for more complete assessment.
11 Simple Payback Analysis Assume new construction or expansion of existing facility Compare operating costs of CHP system with conventional plant design Natural gas CHP compared to conventional natural gas boilers/purchased electricity Coal CHP compared to coal boiler/purchased electricity
12 Plant Operating Assumptions Plant Capacity, mmgal/yr Operating Hours Electric Use, kwh/gal Annual Electric Use, MWh Baseload Electric Demand, MW Steam Use, lb/gal Steam Use, lbs/hr Annual Steam Use, mmlbs Boiler Fuel Use, Btu/lb Annual Boiler Fuel Use, mmbtu Annual Drier Fuel Use, mmbtu Electric Costs, $/kwh Gas Costs, $/mmbtu , , 963,6 24,125 1,26,3 65,.7 6.
13 Gas Turbine CHP System Assumptions Capacity, MW Run Hours Gas Turbine Fuel, mmbtu/hr Duct Burner Fuel, mmbtu/hr Steam Output, lb/hr Power to Steam Ratio O&M Costs, $/kwh Capital Costs Turbine Genset, $/kw HRSG, $/kw Interconnect, $/kw Misc Equipment, $kw Engineering, installation, etc, $/kw Total Installed Cost, $/kw Gas Turbine , ,45 Gas Turbine w/duct Firing , ,25
14 Gas Turbine CHP Energy Results Purchased Electricity, MWh Generated Electricity, MWh Boiler Steam, mmlbs Boiler Fuel, mmbtu CHP Steam, mmlbs CHP Fuel, mmbtu Total Fuel, mmbtu W/O CHP 48, ,24,5 1,24,5 W/ CHP 3,98 44, , ,46 1,461,353
15 Gas Turbine CHP Financial Results Purchased Electricity, 1 $ Boiler Fuel, 1 $ CHP Fuel, 1 $ Energy Costs*, 1 $ O&M Costs, 1 $ Standby Charges, 1 $ ($3/kW) Total Operating Costs, 1 $ * Does not include DDGS drier fuel W/O CHP 3, ,227. 1, ,599.6 W/ CHP , , , ,587.5 Operating Savings = $1,12,1
16 Gas Turbine CHP Payback Capital Costs = $5,434, Payback = 5.4 yrs Capital Costs = $4,98, Payback = 4.9 yrs CHP System $5,434, - Boiler credit $ 45, $4,984,
17 Sensitivity to Electricity and Natural Gas Prices - Gas Turbine CHP 8 Natural Gas Price, $/mmbtu $4 $5 $6 $7 $8 Simple Payback, yrs Electricty Price, cents/kwh
18 Gas Turbine CHP w/duct Burner Energy Results Purchased Electricity, MWh Generated Electricity, MWh Boiler Steam, mmlbs Boiler Fuel, mmbtu CHP Steam, mmlbs CHP Fuel, mmbtu Total Fuel, mmbtu W/O CHP 48, ,24,5 1,24,5 W/ CHP 3,98 44, , ,275 1,384,141
19 Gas Turbine CHP w/duct Burner Financial Results Purchased Electricity, 1 $ Boiler Fuel, 1 $ CHP Fuel, 1 $ Energy Costs*, 1 $ O&M Costs, 1 $ Standby Charges, 1 $ ($3/kW) Total Operating Costs, 1 $ * Does not include DDGS drier fuel W/O CHP 3, ,227. 1, ,599.6 W/ CHP , , , ,124.2 Operating Savings = $1,475,4
20 Gas Turbine CHP w/duct Burner Payback Capital Costs = $6,266, Payback = 4.2 yrs Capital Costs = $5,366, Payback = 3.6 yrs CHP System $6,266, - Boiler credit $ 9, $5,366,
21 Sensitivity to Electricity and Natural Gas Prices - Gas Turbine CHP w/duct Firing 8 Natural Gas Price, $/mmbtu $4 $5 $6 $7 $8 Simple Payback, yrs Electricty Price, cents/kwh
22 Boiler/Steam Turbine CHP System Assumptions Capacity, MW Run Hours Boiler Fuel, mmbtu/hr Steam Output, lb/hr Overall Efficiency, % (HHV) Power to Steam Ratio O&M Costs, $/kwh Incremental Capital Costs Steam Turbine Genset, $/kw Incremental Boiler Costs, $/kw Total Incremental Cost, $/kw Coal Price, $/mmbtu Gas Turbine ,
23 Coal Boiler/Steam Turbine CHP Energy Results Purchased Electricity, MWh Generated Electricity, MWh Boiler Steam, mmlbs Boiler Fuel, mmbtu W/O CHP 48, ,24,5 W/ CHP 22,68 25, ,325,
24 Coal Boiler/Steam Turbine CHP Financial Results Purchased Electricity, 1 $ Boiler Fuel, 1 $ Energy Costs*, 1 $ O&M Costs, 1 $ Standby Charges, 1 $ ($3/kW) Total Operating Costs, 1 $ W/O CHP 3, ,86.8 5, ,179.4 W/ CHP 1, , , ,787.2 * Does not include DDGS drier fuel Operating Savings = $1,392,2
25 Coal Boiler/Steam Turbine CHP Payback Incremental Capital Costs = $2,175, Steam Turbine $1,2, Incremental Boiler $ 975, Payback = 1.6 yrs
26 Sensitivity to Electricity and Coal Prices - Boiler/Steam Turbine CHP 4 Coal Price, $/mmbtu Simple Payback, yrs Electricty Price, cents/kwh
27 Critical Issues Affecting CHP Economics Reasonable projections of fuel and retail electricity prices are key Understanding and accounting for specific electric rate structures is critical Demand rate Standby tariffs Site requirements will impact capital costs Space and access Permitting Interconnection
28 Critical Issues Affecting CHP Economics (continued) In general, CHP system should be sized to supply within-the-fence energy needs Difficult to sell excess power However, explore opportunities to partner with utility Increased thermal utilization improves economics Increasing thermal output displaces less efficient boiler output Consider the entire range of potential savings Credits for displaced boiler capacity Are there operating savings from increased reliability?
29 Thermal Oxidizer/Steam Turbine CHP
30 Gas Turbine/VOC Destruction CHP
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