Building Cooling Heating & Power

Onsite Generation, Distributed Generation, IES/CHP/CCHP

Presented By – Nitin Pathakji

Broad USA Inc.
 BCHP – Unbeatable Efficiency
Taking 30% Efficient Generators to 70% Efficient BCHP Systems
Reducing Building Fossil Energy Requirements by 50%

A Distributed Energy Future

e- Grid Ancillary Services

Bulk Power
e-
Power Quality
e-
and BCHP

Remote Power and

BCHP
e- e-
e-

e-

Energy Management,
future BCHP and Peaker, Reliability
Sell to Grid and BCHP
Base-load, and
Industrial Cooling, Heat and Power
Thermally-Activated HVAC Technologies are
Key to Improving Overall Efficiency of DG
Distributed Generation Thermally-Activated HVAC
Technologies Technologies

800ºF

Triple-Effect
600ºF Absorption Chiller
Gas-turbine Solid Oxide Fuel Cell

360ºF Double-Effect Absorption

Water-Cooled Chiller

Micro-turbine
Commercial Phosphoric Acid
Fuel Cell

180ºF

I.C. Engine
Single-Effect Desiccant Technology
Residential
Absorption Chiller
PEM Fuel Cell

Recoverable Energy Quality (Temperature) and HVAC Technology Match

 CO-GEN CONCEPT

USEFUL ENERGY
74.2%
INPUT
100%

ELECTRICAL
OUTPUT 29.7%

LOSSES
25.8%

OTHER
LOSSES 4.8%
EXHAUST THERMAL
LOSSES 21% OUTPUT
44.5%
 Generator Choices & Issues

Design Principle:
“A Generator is a 70% Efficient
Boiler with Free Electricity”
Industrial Turbine Exhaust Fired Absorption System Schematic

Motorized Flue Gas Control Gas Burner

Damper

Flue
Gas
Gravity
Gravity Damper
Damper

Co- Fired
Double Effect
Chiller 1.76
MW (500 RT)
Cooling
Second Exhaust Gas
Fired Double Effect
Chiller
Flue
Gas

First Exhaust Gas 3.514 MW (1,000 RT)

Fired Double Cooling
Effect Chiller 3.52 Natural Gas
MW (1,000 RT) Train
Cooling

Motorized Exhaust Motorized Exhaust

Gas Control Gas Control
Damper Damper Gravity
Gravity Damper
Damper
Two Stage Hi-Temp Exhaust Fired
 2-Stage Exhaust Fired Absorber
 Exhaust from the Gas turbine is taken directly in to the Absorber –
eliminates HRSG and increases capacity.
 Concept combines the criteria for HRSG design and LiBr technology.
 Major portion of the absorber is standard commercial product design.
 Design, development and construction focused on High Stage
Generator and controls.
 Primary control of Chiller is leaving Chilled water temperature.
 Exhaust flow to the machine is controlled by damper or fan.
 Safety Shut down incorporates an inlet damper.
 All other machine safeties and control remain same as standard
machine.
Two Stage Exhaust Fired CT Based CHP P&ID
 Gas Fired Simple Cycle CT BCHP
Generator Model: Taurus 60
Waste heat fired Exhaust:

absorbers are used to Generator Out (C)

Absorber Out (C)
486
200
displace electric Flow (kg/hr) 79,284
Recovered Energy (kcal/hr) 6,054,126
chiller load. HR Chiller:
# Stages 2
Chiller COP 1.3
Chiller Capacity % 100

Typically for multi-MW Output (Tons) 2,603

gas fired simple cycle Elec Chiller kW/ton

Effective kW Generated
0.6
1562
turbines: Generator:
Generator Output (kW) 5500
Cost per kWh $0.07
tonnage per MW of BCHP System:
exhaust varies from Chiller Effective kW
Total Effective kW
1562
7062
550 to 700 tons per Effective Cost per kWh $0.05

MW.
 DOE/ORNL
BCHP Program

• Burns and McDonnell (Kansas City) teamed with:

– Solar Turbines Inc (San Diego – turbine generator).
– Broad USA (New Jersey – absorption chiller).
• Design and construct a 5.2 MW CHP system.
– Electricity from a Taurus 5,200 kW turbine generator.
– Up to 2,500 refrigeration tons (RT) of free waste heat driven
absorption cooling.
– Up to 17,000 RT of additional supplemental gas-fired cooling.
 DOE/ORNL
BCHP Program

• Honeywell Laboratories (Minneapolis)

• Developing and field testing a large CHP packaged
system.
• A 5 MW turbine generator will be combined with a
1,000 RT absorption chiller.
• The prototype will be tested at Fort Bragg, N.C.
 DOE/ORNL BCHP Program

The absorber is fired with exhaust when the CT is operational and with
natural gas or oil if the CT is off. Applications include peaker plants.

TRIPLE FUELED BCHP ABSORBER 44/54 0F / 170/150 0F

1000 tons / 9,500 MBH

Boiler plant
Broad BCHP
(by others)
Gas in Exhaust
DFA HSG
IFA
HSG
Exhaust Exhaust 1060 0F Exhaust 374 0F
50,935 lbs/hr 50,935 lbs/hr

Gas in Turbine 5 kW

Generator
 Chiller Performance

IAT (F) 50 70 90 110

Cooling Capacity
(TR) 992
Exhaust Flow
Available (Lb/hr) 172999 166919 158673 149102
Exhaust Temp (F) 955 966 981 1001
Exhaust flow
Required For 59485 58449 57049 55280
Chiller (lb/hr)
Estimated ∆ P
“WC 7.2

Predicted performance only.

 Turbine Inlet Air Cooling
Industrial Turbine 83.5 MW @ Ambient 95 0F

Evaporative Cooling + 3.7 MW

With Inlet Air @ 50 0F Electric Centrifugal + 8.9 MW
Absorption + 11.4 - 11.6 MW
Integration Schematic of a Microturbine and LiBr Absorption Chiller

127°C (260°F) Flue Gas

Microturbine

Cooling
Tower

Absorption Chiller

288°C (550°F) ExhaustGas

Microturbine
Exhaust Fan
 Single Stage Exhaust Fired Absorber
 Exhaust from the microturbine is taken directly in to the Absorber –
eliminates hot water HEX and increases capacity.
 Concept combines exhaust recovery and single stage LiBr technology.
 Major portion of the absorber is standard commercial product design.
 Design and development focused on Generator and controls.

 Chiller is designed for specific turbine inlet air temp (using TIAC).
 Primary control of Chiller is leaving Chilled water temperature.
 Exhaust flow to the machine is controlled by inverter on damper.
 Safety Shut down incorporates an on/off inlet damper.
 All other machine safeties and control remain same as standard
machine.
Single Stage Lo-Temp Exhaust Fired

Microturbine
SS Exhaust Fired Absorber
Single Stage Exhaust Fired MT Based CHP Layout
Single Stage Exhaust Fired MT Based CHP P&ID
BCHP Test Case Profile
University of Maryland

DOE/ORNL

Microturbine/Absorber/Desiccant
 UMD BCHP System 2
Single Stage Lo-Temp Exhaust
Fired Solid Desiccant
40 kW System
(140,000*)
Exhaust Air 3000 CFM
MICRO TURBINE
@ 225 F of Dry Air
100 kW
Natural (340,000*)
Gas Exhaust Air
@ 500 F

262 kW
(895,000*) 70 kW (20 tons)
Chilled Water Air to
ABSORPTION CHILLER Zone 1
* Btu/hr

67 kW Electric Power

•Turbine efficiency 25.6 %, with chiller 63.5 %, and with

desiccant 79.2%
•Single effect absorption chiller with COP of 0.7
 Desiccant
Equipment on roof

Single Skid
Absorber Microturbine
Cooling Tower

Exhaust Fan

Pumps, Filter, etc.

Absorption Chiller Data
 Comparative Effects

30% Reduction
Not including
input from
Microturbine
Natural Gas/Exhaust Co-Fired w/HEX
 Installed IES with 60 kW Microturbine and 300 RT
Co-fired Double Effect Absorption Chiller
Flue gas exhaust High stage generator of 300 RT co-fired Exhaust Duct to hot water
double-effect absorption chiller heat exchanger

Exhaust gas recirculation for

ultra low emissions

Natural gas train for co-firing

Exhaust gas duct 60 kW microturbine

Co-fired Burner Exhaust, FRG (return exhaust for LoNOx)
and Fresh Air Intake
 IC Engine BCHP
30% Electrical Output, 44% Thermal (jacket & exhaust) HR, 21% Exhaust, 5% Other

Two Stage Steam Absorber: Requires HRSG and high pressure steam
system. High efficiency but expensive.

Single Stage HW Absorber: Simple & Cost Effective

Output Simple HR Boost w/ Exhaust

185 F 205 F
400 kW 20 Tons 120 Tons
IC Engine (.05 Tons /kW) (.30 Tons /kW)

Hot water fired single stage chiller w/ COP = .5 to .7

Dump radiator included
Cooling tower required
Boiler for back-up
Reciprocating Engine with Jacket Water and Exhaust Recovery
and Single-Effect Absorption Chiller

Exhaust Gas Recovery Heat

~ 150 °C (~300 °F)
Exchanger
Exhaust Gas to Atmosphere
81.1 °C (178 °F)

95 °C (203 °F)

Hot Water “Fired”

Jacket Water Heat
Single Effect
Recovery Heat Exchanger
Absorption Water
Chiller

86 °C (187 °F)

82 °C (180 ~ 593 °C (~1,100

°F) °F)
Exhaust Gas Temp
93 °C (200 °F)

Hot Water System

Engine Jacket Water System

Engine Exhaust System

Single Stage HW Fired ICE Based CHP P&ID
 Fuel Cell Characteristics

Fuel Cell Type PAFC SOFC MCFC PEMFC

Commercially Available Yes No No No

Size Range 100-200 kW 1 kW - 10 MW 250 kW - 10 MW 3-250 kW

Efficiency, LHV 36% 45-60% 45-55% 30-40%

CHP Characteristics

(hot water) (hot water/steam) (hot water, steam) 60° C (140° F)

water

Emissions

Nearly zero Nearly zero Nearly zero Nearly zero

Fuel Cell BCHP
New technology
High electrical efficiency
Environmentally friendly
Low heat recovery potential
Large footprint
High cost

Hi-Temp FC
0.16 Tons /kW
 IES
Exhaust Fired or Hot Water Fired
Sites: 20 Ton SS Exhaust Fired w/ Microturbine
25 Ton 2S Exhaust Fired w/ Microturbine
330 Ton 2S Co-Fired w/ Microturbine
2,000 Ton 2S Exhaust Fired w/ Simple Cycle Gas Turbine
130 Ton SS Hot Water Fired w/ 375 kW IC Engine

BCHP Package > Total Components