-Microturbine Applications -Microturbine Applications - ……4 Years of Experience later…4 Years of Experience later…

Ottawa, Canada 2005Ottawa, Canada 2005

Presented to: DOE/CETC Ottawa 2005Presented to: DOE/CETC Ottawa 2005

Bob Bechtold Harbec Plastics, Inc.Bob Bechtold Harbec Plastics, Inc.

OrganizationOrganizationProject ManagerProject Manager - Bob Bechtold, Harbec Plastics- Bob Bechtold, Harbec Plastics

Funding PartnersFunding Partners - - HSBC plus 3 economic development lendersHSBC plus 3 economic development lenders

EngineerEngineer - - Bruce Keeley, Energy Concepts EngineeringBruce Keeley, Energy Concepts Engineering

Project Plan Vs Actual dates:Project Plan Vs Actual dates: Equipment Delivery-Equipment Delivery- Plan 6-2000 Actual 6-2000Plan 6-2000 Actual 6-2000

This was after 2 other companies failed to be able to deliver as promised and This was after 2 other companies failed to be able to deliver as promised and more than one year was wastedmore than one year was wasted

System Commissioned-System Commissioned- Plan 7-2000 Actual 9-2000Plan 7-2000 Actual 9-2000This was because of other components in the system that were not delivered This was because of other components in the system that were not delivered on timeon time

Monitoring Underway-Monitoring Underway- Plan basic system monitoring 9-2000 Plan basic system monitoring 9-2000 Current real time monitoring and internet Current real time monitoring and internet presentation 11-2004presentation 11-2004

Real time reportingReal time reporting

Historical dataHistorical data

Work in progressWork in progress

Harbec CHP SchematicHarbec CHP Schematic

Harbec CHP WebsiteHarbec CHP Websitewww.northerndevelopment.comwww.northerndevelopment.com

Harbec Site PhotosHarbec Site Photos

CHP Improvements from NYSERDA GrantCHP Improvements from NYSERDA Grant

In Retrospect with 100% HindsightIn Retrospect with 100% Hindsight

We would have built the project with 15 turbines instead We would have built the project with 15 turbines instead of 25 with expansion potential to handle future business of 25 with expansion potential to handle future business growth.growth.

We would have purchased different brand of heat We would have purchased different brand of heat exchangers.exchangers.

We would not have purchased gas compressors.We would not have purchased gas compressors. Initially we thought it was a mistake to put the turbines Initially we thought it was a mistake to put the turbines

inside of the building but since we learned to control inside of the building but since we learned to control ambient heat, we generally agree that being inside has ambient heat, we generally agree that being inside has advantages in the Northern climates.advantages in the Northern climates.

Project Cost Table in US$Project Cost Table in US$ItemItem Actual CostActual Cost Hindsight CostHindsight Cost

25 microturbines 25 microturbines 30 kW each30 kW each

c. $800,000c. $800,000 c. $500,000c. $500,000

200/100 ton 200/100 ton Chiller & Heat Chiller & Heat ExchangersExchangers

c. $200,000c. $200,000 c. $250,000c. $250,000

Electromechanical, Electromechanical, Engineering, Engineering, Proj.Mgr. Proj.Mgr.

c. $100,000c. $100,000 c. $ 80,000c. $ 80,000

TOTALSTOTALS c. $1,100,000c. $1,100,000 c. $880,000c. $880,000

Electrical PerformanceElectrical Performance

Hours of operation to December 31, 2004Hours of operation to December 31, 2004 541,000 total microturbine hours (=21,600/turbine avr.)541,000 total microturbine hours (=21,600/turbine avr.) Maximum hours of operation on one unit is 27,500Maximum hours of operation on one unit is 27,500

Average Electrical PerformanceAverage Electrical Performance 20-24% 20-24% Power Delivered to Load/LHV FuelPower Delivered to Load/LHV Fuel

Estimated Parasitic Losses in kWEstimated Parasitic Losses in kW 50 kW Cooling mode 50 kW Cooling mode 18 kW Heating mode18 kW Heating mode

Power QualityPower Quality Report on any Power Quality Tests Done or Issues foundReport on any Power Quality Tests Done or Issues found

No power quality issues when in stand alone modeNo power quality issues when in stand alone modeOnly power quality issues that exist in grid connect mode are Only power quality issues that exist in grid connect mode are those that come from Utility Power Sourcethose that come from Utility Power Source

Thermal PerformanceThermal PerformanceThermal Output measured in kW(MMBtu/hr)Thermal Output measured in kW(MMBtu/hr)

200,000 Btu/hr per unit per hour recovered200,000 Btu/hr per unit per hour recovered

Average water return temperatures and Delta T across HXAverage water return temperatures and Delta T across HX 100* F to 200* F with 15* Delta T (new heat exchanger)100* F to 200* F with 15* Delta T (new heat exchanger) 100* F to 170*F with 10* Delta T (old heat exchanger)100* F to 170*F with 10* Delta T (old heat exchanger)

CHP Efficiency( we suggest the use of HHV)CHP Efficiency( we suggest the use of HHV) 70% Total not recondensing70% Total not recondensing

Expected Peak Total System EfficiencyExpected Peak Total System Efficiency 70% until we get associated with low grade heat user (Intensive Ag, 70% until we get associated with low grade heat user (Intensive Ag,

etc. then 80 to 90 % is believed to be obtainable)etc. then 80 to 90 % is believed to be obtainable)

(Electrical + Thermal) state which fuel heating value used(Electrical + Thermal) state which fuel heating value used Due to high gas cost we have developed price point relative to cost of Due to high gas cost we have developed price point relative to cost of

gas and cost of electricity currently $7.85 per DThm. So for the last 4 gas and cost of electricity currently $7.85 per DThm. So for the last 4 months we have been thermal load following.months we have been thermal load following.

Cooling system performance COPCooling system performance COP About 0.5 Coefficient Of PerformanceAbout 0.5 Coefficient Of Performance

Emission PerformanceEmission Performance

Report on any emission testing doneReport on any emission testing done.. Unable to test emissions and it’s not requiredUnable to test emissions and it’s not required

NOx,CO, THC in ppm and gm/kWhNOx,CO, THC in ppm and gm/kWh NOx = 9 ppm .223 gm/kWh publishedNOx = 9 ppm .223 gm/kWh published CO = 40 ppm .603 gm/kWh “CO = 40 ppm .603 gm/kWh “ HC = 9 ppm .078 gm/kWh “HC = 9 ppm .078 gm/kWh “

Are emissions in line with equipment Are emissions in line with equipment suppliers estimates?suppliers estimates? Unable to answerUnable to answer

O&M PerformanceO&M Performance

Availability?Availability? Due to redundancy, we never have a time Due to redundancy, we never have a time

when our generating system is down due to when our generating system is down due to equipment failureequipment failure

What would be the current estimate of What would be the current estimate of annual O&M costs excluding (annual O&M costs excluding (includingincluding) ) major hot end replacement in total annual major hot end replacement in total annual US$ and c/kWh?US$ and c/kWh? 2 Year Extended Warranty is c.$65,000 total 2 Year Extended Warranty is c.$65,000 total

and covers and covers all partsall parts for all 25 turbines for all 25 turbines

Institutional ExperienceInstitutional ExperienceDue to low emissions, no EPA/DEC permits were required.Due to low emissions, no EPA/DEC permits were required.We were required to use certified Mechanical Contractors We were required to use certified Mechanical Contractors and a P.E.and a P.E.Our electrical interconnection was simple as Capstone Our electrical interconnection was simple as Capstone turbines were approved by utility, but gas connection was turbines were approved by utility, but gas connection was very difficult. Utility would only allow 20 psi. even though very difficult. Utility would only allow 20 psi. even though 55 to 60 was available. This added significantly to project 55 to 60 was available. This added significantly to project cost due to need for three 10 hp gas compressors.cost due to need for three 10 hp gas compressors.

Supplier SupportSupplier SupportGeneral Information that would be useful to suppliers in General Information that would be useful to suppliers in regard to product support:regard to product support:

All our equipment suppliers have been reasonable and fair except for All our equipment suppliers have been reasonable and fair except for one which was our original heat exchanger manufacturer. That one which was our original heat exchanger manufacturer. That product has now been replaced by a superior one and we no longer product has now been replaced by a superior one and we no longer deal with the original company.deal with the original company.

Adequacy of Technical Support and factory after sales Adequacy of Technical Support and factory after sales support:support:

We sent all (4) of our servicing technicians to be certified by We sent all (4) of our servicing technicians to be certified by Capstone. We have been able to provide 100% of our actual Capstone. We have been able to provide 100% of our actual maintenance as a result with occasional phone assistance.maintenance as a result with occasional phone assistance.

Supply and Costs of Spare parts:Supply and Costs of Spare parts: We currently have an annual parts warranty which covers all We currently have an annual parts warranty which covers all

microturbine parts.microturbine parts.

Warranty IssuesWarranty Issues: : Our original microturbine warranty was extended to over 3 years due Our original microturbine warranty was extended to over 3 years due

to unique and mutually beneficial learning opportunity.to unique and mutually beneficial learning opportunity.

General ExperienceGeneral ExperienceWhat areas need to be improved for future installations?What areas need to be improved for future installations?

Better control of ambient cabinet air on indoor applicationsBetter control of ambient cabinet air on indoor applications Better sealing dampers to prevent blow back of hot exhaustBetter sealing dampers to prevent blow back of hot exhaust Single unit dispatching capabilitySingle unit dispatching capability

What is the opinion of the future market opportunities?What is the opinion of the future market opportunities? We think that the microturbine offers a potential for low maintenance, reliable, We think that the microturbine offers a potential for low maintenance, reliable,

environmentally friendly CHP.environmentally friendly CHP. Experience has shown us that everything works best in Grid Connect with no Experience has shown us that everything works best in Grid Connect with no

load following and no Dispatchingload following and no Dispatching Are there any R&D or development areas that should be looked at?Are there any R&D or development areas that should be looked at?

We think that efforts should be made to increase operating electrical efficiency We think that efforts should be made to increase operating electrical efficiency and that alternatives to use waste heat better should be developed to offer and that alternatives to use waste heat better should be developed to offer customers a more complete solution. Potentials like Rankine Cycle, Hot Oil customers a more complete solution. Potentials like Rankine Cycle, Hot Oil Heat Exchangers, etc. to enhance opportunities to take thermal potential to Heat Exchangers, etc. to enhance opportunities to take thermal potential to process requirements and other beneficial applications. We would also like to process requirements and other beneficial applications. We would also like to see efforts toward using Hythane as a minimum or full hydrogen if possible to see efforts toward using Hythane as a minimum or full hydrogen if possible to encourage renewable energy hybrid systems as hydrogen could be an encourage renewable energy hybrid systems as hydrogen could be an excellent energy storage medium to allow renewable energy to be excellent energy storage medium to allow renewable energy to be dispatchable.dispatchable.

Future Directions and Future Directions and DevelopmentsDevelopments

Thank You.Thank You.bxb@harbec.comwww.harbec.com1-888-521-4416Fax 1-585-265-1306

Bob BechtoldHarbec Plastics, Inc.369 Route 104Ontario, NY 14519

Q & A?