Bradley International Airport in Windsor Locks, Connecticut has a central energy plant which provides electricity, heating and cooling for the main passenger terminals at the airport. The facility has been in operation since 2002 and features four Waukesha engine-generators. The engines were supplied by Dresser Waukesha’s distributor Kraft Power Corporation of Woburn, Mass. Byproduct waste heat is used for heating and to power a 500-ton Trane single-stage hot water absorption chiller, which supplies chilled water year round for the airport. Two years ago the facility started the process to add the fourth engine, a Waukesha APG2000, rated at 1.9 MWe output natural gas-fired internal combustion engine (IC) and heat recovery hot water boiler. 800°F exhaust from the new engine and 1200°F exhaust heat from the existing IC engines is used to generate 220°F hot water used by the airport. This cogeneration plant was constructed in one year, within an existing building originally used for food preparation by the airlines. (Download Brochure: PDF)
Bristol-Myers Squibb, Wallingford, CT
4.7 MW CHP Application
A reliable power supply is critical to the Bristol-Myers Squibb facility in Wallingford, Connecticut. The pharmaceutical research and development conducted in this facility requires a consistent environment. Temperature, humidity, and ventilation must be closely controlled, so any interruptions in utility service can be harmful and costly. Energy consumption is significant at this one million square foot facility, which operates 24 hours a day.
In 1998, a combined heat and power system with a 4.7 MW natural gas-fired turbine was installed to generate energy on-site. This system is now operated continuously and provides most of the facility’s electricity and thermal energy.
Using the CHP system along with supplemental electricity from the utility and on-site boilers and backup generators has provided the high power quality necessary for this facility. (Download Brochure: PDF)
Central Connecticut State University, New Britain, CT
2.5 MW CHP Application
Several years ago the 294-acre campus of Central Connecticut State University was experiencing problems with its aging infrastructure. The University’s steam heating system, installed in 1950s-60s, was outdated and inefficient, as well as undersized for a campus that has seen significant growth and is continuing to expand. Buried steam pipes often ruptured, requiring costly repairs and disrupting pedestrian traffic. Few buildings on campus had air conditioning, and most that did had trouble with noise from the equipment. (Download Brochure: PDF)
Colby College, Waterville, ME
600 kW CHP Application
Colby, a liberal arts college in Maine, was chartered in 1813, making it the 12th-oldest independent liberal arts college in the nation. In 1998, an ice storm that knocked out power at several other Maine colleges spared Colby, but gave the people at Colby’s steam plant pause.
In the winter of 1996, Colby performed a feasibility study that predicted a 560 kW turbine would carry a simple payback of 2.3 years at a cost of $353,000. Colby could generate its own electricity, reduce its demand and consumption from the local electric utility, and be able to keep running in a power outage. Libby said the college also hoped to reduce its electric rates. (Download Brochure: PDF)
Cooley Dickinson Hospital, Northampton, MA
500 kW Biomass CHP Plant.
Cooley Dickinson Hospital in Northampton, MA is a 600,000 square-foot hospital with 140 in-patient beds that has been in operation for 125 years. The facility has a central energy plant which provides electricity, heat and cooling for the hospital campus. The hospital facility has a 12 month consistent heat load for heating, absorption chilled water, food preparation and centralized sterilization. Cooley Dickinson has operated a Zurn - 550 HP biomass boiler with wet scrubber emissions control since 1984. In 2006, an AFS - 600 HP Water/Fire Tube high pressure boiler was installed. To take advantage of the higher pressure steam supply, two 250KW Carrier Energent Micro Steam Turbines and a 680 Ton Absorption Chiller were added to the energy plant in 2009. One of the turbines reduces the steam pressure from 250 psig to 75 psig for distribution thought the hospital. The second turbine reduces the steam pressure from 75 psig to 15 psig for use in the absorption chiller. (Download Brochure: PDF)
Essex Junction WWTF, Essex Junction, VT
60 kW CHP Application
Until 2003, the Essex Junction wastewater treatment facility used half the waste methane gas produced by its anaerobic digester to fire the boiler that heated the digester. (Anaerobic digestion stabilizes wastewater sludge, reduces sludge volume, and eliminates pathogens.) The remaining waste methane gas was flared, because methane is a greenhouse gas that is 20 times as effective at trapping heat as carbon dioxide, the gas produced when methane is burned.
Although facility officials had been interested in combined heat and power since 1992, high initial costs failed to satisfy the requirement of the facility’s governing board, that all projects have a simple payback of no more than seven years. Furthermore, it was unclear whether sufficient digester temperatures could be maintained when methane was used to fire a CHP system. The system was also required to emit no more pollutants than flaring methane did. (Download Brochure: PDF)
Frito-Lay, Killingly, CT
4.5 MW CHP Plant
The two major components of PepsiCo’s Frito-Lay Killingly, Connecticut manufacturing facility’s CHP system consists of a Solar Centaur® 50 gas turbine and a supplementary-fired heat-recovery steam-generator (HRSG) from Rentech Boiler Systems, Inc., of Abilene, Texas. The Heat Recovery Steam Generator (HRSG) uses the exhaust heat from the gas turbine to produce 325 psig steam used to heat the oil in the chip fryers, through a shell and tube heat exchanger. The two fryers use 24,000 #/hr steam each. The heat exhausted by the fryers is captured and used for space heating. The HRSG produces up to 60,000 lb/hr steam at peak firing capability. The GT's SoLo NOx dry, low-emissions combustion system, together with the SCR incorporated into the HRSG, limit NOx emissions to 2.5 ppm. The HRSG is capable of producing. (Download Brochure: PDF)
Green Mountain Coffee Roasters, Waterbury, VT
280 kW CHP Application
Coffee roasting is an energy intensive process in which reliable power is critical. The coffee beans are brought to a very high temperature approaching flash point, and if power is lost during that process they can go exothermic and cause a fire. To ensure a reliable electricity supply, Green Mountain Coffee Roasters installed a CHP system in 1999 at their corporate headquarters and main processing facility in Waterbury, VT. They were particularly motivated by the possibility of power outages associated with Y2K.
Then in 2003, when the larger roasting equipment was being upgraded, a new, larger CHP system was installed. This 280 kW 480 volt system uses a Waukesha engine to provide approximately 25% of the electricity and most of the heat and hot water required by the facility. (Download Brochure: PDF)
Harbec Plastics, Ontario, NY
750kW CHP Application
Harbec Plastics, founded by Bob Bechtold in 1977, is a custom-injection molder that services customers from a wide range of industries including original equipment manufacturers in the automotive, medical, office products and sporting goods sectors.
Faced with rising energy costs in the 1990s and frequent energy problems like power outages and surges, which had cost the company over fifteen thousand dollars in damaged equipment in one month alone, Bechtold had to make a choice: run more efficiently or pack up and leave New York like many of his industrial neighbors. He chose to stay and in doing so he found a way to thrive. He hired Bruce Keeley of Energy Concepts Engineering and went to work re-vamping his entire facility. (Download Brochure: PDF)
Notre Dame Long Term Care & Assisted Living Centers, Worcester, MA
150 kW CHP Application
Late in 2003, Carol Smith, the Facilities Director at the Notre Dame Long Term Care Center, had just noticed how high the electricity bills were getting when marketing information from Sustainable Energy Solutions Inc. caught her eye. She responded to learn more about how combined heat and power could reduce their energy costs.
By March 2004, a CHP system had been installed in the 123-bed long-term care facility. That was followed in May 2004 by another system in the adjoining assisted living facility, which houses 200 people.
Each building has a 75 kW natural gasfired engine that is run continuously. These provide 75% of the electricity used on site, and the hot water output is enough to satisfy all of the facility’s domestic hot water demand and much of the space heating. (Download Brochure: PDF)
Rochester Airport , Rochester, NY
Greater Rochester International Airport (GRIA) is located four miles southwest of Rochester, NY on the west side of the city and operated by Monroe County. The terminal totals 380,000 sq. ft., with 22 passenger gates. The county strives to maximize the benefits it provides local taxpayers. Reducing energy costs is one of many ways the county seeks to fulfill that goal. At GRIA this was achieved by installing two 750 kW engine-generators that produce about 90% of the site’s electricity. (Download Brochure: PDF)
Seaman Paper, Otter River, MA
283 kW CHP System
The Seaman Paper Company of Massachusetts is a historic mill complex originally constructed in the late 1800s. The numerous connected buildings contain a gross floor space of 80,000 ft2. The facility operates 24 hours a day, 7 days a week, with shutdowns only on major holidays. The facility uses two paper machines with a capacity of up to 100 tons per day to produce a variety of flat tissue papers. Most are used for decorative purposes, but some are waxed and used for food handling. At the time of the project the mill was using an average of 1.7 million gallons of #6 fuel oil and 25.5 MWh of electricity per year. (Download Brochure: PDF)
Simonds International, Fitchburg, MA
1.8-MW CHP System
Simonds International’s facility in Fitchburg, Massachusetts was constructed in 1935 and primarily manufactures metal blades for band saws from steel coils. Simonds is the third-largest metal cutting manufacturer in the world. Simonds installed combined heat and power (CHP) in 2011 for a project cost of $6.5 million and an estimated 4.5-year payback. Construction was completed in 15 months.
"The installation of the CHP co-generation system at our Fitchburg, MA plant has changed our competitive cost position dramatically enabling the company to retain energy intensive manufacturing operations and to consider adding new operations in the future. The project is a win-win as it is good for the company, our employees and the economic health of North Central Massachusetts." Ray Martino President & CEO Simonds International (Download Brochure: PDF)
Smith College, Northampton, MA
3.5 MW CHP Plant
The new Smith College Cogeneration Plant is housed in an existing central power plant. Its power process systems include a Solar Centaur® 40 combustion gas turbine, a Rentech heat recovery steam generator, a 65,000-lb/hr low-emissions packaged boiler, new control room and auxiliary equipment. The Heat Recovery Steam Generator (HRSG) uses the exhaust heat from the gas turbine to produce steam for campus heating in the winter and chilled water production in the summer using steam absorption in addition to existing electrically driven chillers. Two existing 55,000-lb/hr, oil/gasfired, packaged Keystone boilers, provide backup and additional steam capacity to meet campus demand. A 10- inch main steam transmission line connects the plant to the 110 buildings on campus through 5 miles of underground piping. When the gas turbine is generating power at its full 3.5 MW capacity, the HRSG is capable of producing 20,000 lb/hr of 125 psig steam. (Download Brochure: PDF)
Smithfield Gardens, Seymour, CT
75 kW CHP System
Smithfield Gardens, a 56-unit affordable assisted-living facility in Seymour, CT, installed a Combined Heat and Power (CHP) system in the boiler room during the construction phase of the building. The energy-saving cogeneration system consists of a 75 kW Aegen 75LE CHP module, supplied and installed by Aegis Energy Services, of Holyoke, MA. The highly efficient Aegen 75LE module employs an oil cooler, engine jacket, exhaust gas manifolds and heat exchangers, in order to recover otherwise wasted heat. (Download Brochure: PDF)
South Oaks Hospital, Amityville, NY
1.3 MW CHP Application
South Oaks Hospital on Long Island installed a combined heat and power system in 1990 to reduce energy costs. The system had a simple payback of less than five years, and continues to generate almost all of their energy needs. The current operating cost is just 6 to 8 cents per kWh, compared to the cost of approximately 12 cents per kWh for electricity purchased from the utility.
This 350,000 square foot hospital contains a psychiatric hospital, a nursing home, and an assisted living facility. The system generates up to 100% of the hospital’s electricity, with the utility providing backup power and on-site boilers providing supplemental steam. Steam output from the system is used for space heating, space cooling, domestic hot water, laundry, and the kitchen. (Download Brochure: PDF)
Syracuse University , Syracuse, NY
780-kW CHP System
Located in upstate New York, Syracuse University was chartered in 1870 as a private, coeducational institution of higher education.
The University’s $12.4 million, 12,000-square-foot Green Data Center facility consists of 6,000 square feet infrastructure space for mechanical and electrical equipment to run the building, and 6,000 square feet of primary raised-floor data center space for computers system. In 2009 Syracuse University installed twelve 65 kW Capstone micro-turbines and one 300 ton absorption chiller. (Download Brochure: PDF)
University of Massachusetts, Amherst, MA
16 MW CHP Plant
The new UMASS Central Heating Plant is housed in a 45,000 square foot building. Its power systems include a 10 MW Solar combustion gas turbine, 4 MW and 2 MW steam turbines, a heat recovery steam generator, three package boilers and various auxiliary equipment. A 100,000 lb/hr Heat Recovery Steam Generator (HRSG) uses the exhaust heat from the gas turbine to produce steam for campus heating and cooling year-round. Three package boilers, each rated up to 125,000 pounds per hour steam, provide additional steam capacity to meet campus demand in the spring, fall, and winter months. Two 20-inch main steam transmission lines connect the new plant to the campus. When the gas turbine is generating power at its full 10 MW capacity, the HRSG is capable of producing 37,000 lb/hr without any additional firing. Additional duct burners increase the capacity to the full 100,000 lbs/hr rating. (Download Brochure: PDF)
Waldbaum’s Supermarket, Hauppauge, NY
60kW CHP Application
Waldbaum's Supermarket (a subsidiary of A&P Foods) is located in Hauppauge, NY on Long Island. This supermarket was originally a 35,000-sq. ft. retail facility. It was gutted to the block walls, expanded, and totally rebuilt into a 57,000-sq. ft. supermarket which opened in July 2002. The store uses energy-efficient T5 light fixtures, so the load in the sales area is about 1.2 watts per square foot. The facility electric demand is never expected to drop below 200 kW in this store. The 480-volt power generated by the microturbine is wired directly into the store's 480-volt main panel. This Capstone 60 kW microturbine CHP system was integrated in July 2002 with a 20,000-cfm Munters Drycool air-handling unit previously installed at Waldbaum’s in order to use the available heat from the generator. The Munters unit provides cooling and heating to the main sales areas of the store. The unit also includes a desiccant section to provide dehumidification. (Download Brochure: PDF)
Williams College, Williamstown, MA
3 MW CHP Application
Williams College, located in the Berkshires of western Massachusetts, was established in 1793 and now has 2,000 students. The college’s central heating plant operates throughout the school year to provide space heating and domestic hot water for the 450 acre campus and process heat for the dining hall.
In 2000, the college began planning to upgrade the heating plant with the addition of a new boiler. Motivated by predictions of increasing electric rates, they decided to incorporate the boiler into a combined heat and power system that would generate electricity as well as steam. Installation of the new boiler and CHP system was completed in 2004. (Download Brochure: PDF)