relationship with a power plant supplies steam to the factory, and burns the factorv wood waste to nro- duce it. New and Both cogen plants and independent power plants (producing only) are getting bigger. Some of the latest include the Chesapeake plant, a other non-utilitv P-f~865 gas/oil-fueled peaking plant that will pm- U duce up to 375 MW destined for Virginia Electric Power; a cogen plant situated on power plants the Exxon Bayway refinery site in New Jersey, billed as the “largest non-utility cogeneration plant in the United States,” producing 614 MW of power and more Ey Mona Reynolds, Special Projects Editor however. is being used in conven- than 1 million Ib/hr of steam for refinery tional and fluidized bed boilers. Waste operations; and a -fired com- Owners of cogeneration and independent from coal-mining operations in Pennsyl- bined-cycle IPP system initially delivering power plants continue to choose natural vania is being used, and its use is a 295 MW, the first phase in what will gas a their primary fuel. Gas turbines hold double benefit. It serves as fuel to gener- eventually be a 440-MW plant. a substantial lead as the type of prime ate , and with time the acidic Following is a sampling of recently or mover chosen, used either in simple cycle waste will be consumed and gone from soon-to-be completed cogeneration, small or in a combined-cycle setup. the area. power, independent power, and other Other fuels are not out of the picture. A plant in Virginia has a symbiotic non-utility power plants.

Staunton (Roanoke) River. The facility has a 25-year power pur- chase and operating agreement with Virginia Power to sell energy and capacity to the utility. Plant supplies steam to furniture The plant will sell steam for process and space-heating require- plant, uses waste wood as fuel ments to The Lane Co. furniture manufacturing facility in Alta- vista. Lane has an agreement that requires the cogeneration plant to Altavista, Va. is the site of a 70-MW coal-fired cogeneration deliver up to 130,000 Whr of dry saturated steam at a pressure of facility designed, constructed and operated by a joint venture 200 psig. In turn, the plant will purchase up to 100 tons per day of between LG&E Power Systems Inc. and Westmoreland Energy, available waste wood from Lane, to be burned as supplemental Inc. fuel. Altavista’s site covers approximately 36 acres, bordered by a Major equipment at the Altavista plant includes two Babcock & mix of industrial, commercial, and residential properties and the Wilcox 280,000-lbhr steam coal-fired stoker boilers and a single condensing steam turbine-generator manufac- tured by Mitsubishi Heavy Industries. Other key systems include coal unloading, storage and conveying facilities; lime and ash convey- or with storage facilities; water intake, pipe- line, and water discharge facili- ties; scrubber and flyash baghouse equipment; Exxon thermal DeNO. system; switchyard; and steam lines to Lane. A standby gas-fired boiler large enough to meet contractual steam supply obligations to the Lane factory has been installed. All potable water for the plant will be ob- tained from the town of Altavista, and non- potable process water requirements will be taken from the Staunton River. Sanitary sew- age will be discharged to the town’s sewer system. After required treatment, all site run- off and process water will be discharged into the river. Westmoreland Energy, Inc. is a subsidiary of Westmoreland Coal Co. LG&E Power Sys- tems, Inc. is a subsidiary of LG&E Energy Systems Inc., whose parent company, LG&E Energy Corp., is also the parent company of Louisville Gas & Electric Co.

Virginia cogen plant burns wood waste as part of its fuel mix.

POWER ENGlNEERlNGlJULY I992 23 ..

Kegional waste-to-energy plant serves 14 towns

Decemher 5. 1991 marked the first pruces5ing oi WBIW hi the new American Rei-Fuel waste-to-energy facility in Prestoii. Conn. 'lhc plant now accepts waste irom I I member tou'n, 01 the Southeastern Connecticut Regional Resourccb Rc~~cryAu- thorit) tSCKKRA) as well 8%thc communilie\ 01 Guilfd. Madison Ind East Haddam. Negotiations are on-going mith other eastern Connecticut towns to fill the remaining csp;icity at the 622-tpd facility. Waste is received six days a week. Facility tiperations to process the waste and generate electricity continue 24 hours a day, seven days a week. About 10% of the electricity generat- ed from the 17-MW turhine-generator is used for plant operat. ing reqummenm: the balance is sold to Connecticut Light 8: Power. The plant uses a roller grate technology licensed by American Ref-Fuel from Deutsche Babcock Anlagen of Germany. New 62-tpd waste-tosnergy plant serves municipalities in For the southeastern Connecticut project, an American Ref-

Fuel Darent comoanv. Brownine-FerrisI Industries. Inc. (BFI) is . I. .. provibing interim landfill capacity for disposal of ash generated American Ref-Fuel is a partnership formed by subsidiaries of at the facility while the SCRRRA develops and obtains neces- BFl and Air Products and Chemicals, Inc. to design, construct, sary permits for its own regional ash landfill. own and operate waste-to-energy plants.

Construction of the Sumas, Wash. zerodis- charge piant Is in its early stages. It will

beoin1. ooeration in March 1993.

components, and Calpine is managing the con- struction of the project by supervising both the general contractor, a joint venture of lndustrial Power Corp. and Haskell Corp., and the engi- neer, Hipp Engineering of Vancouver, B.C. Sumas Cogen has acquired I5 years' worth of natural gas reserves in northern British Co- lumbia and northwest Alberta to fuel the facili- ty. The gas will be transported to the Canada- U.S. border through the Westcoast natural gas pipeline. The project site is located near the border, and to avoid intrastate gas transporta- tion charges, a 3.5-mile natural gas pipeline is bekg ConStNCted to bring the gas from the border to the project site. The will be steam injected at 55,000 Ib/hr for NO, reduction, and the HRSG RO system, off-site demineralizer will include a selective catalytic reduction (SCR) unit as well as a carbon monoxide converter. Both the SCR and CO converter are make zero-discharge plant feasible being supplied by Englehard. To minimize the impact of the facility's wastewater on City of The Sumas Cogeneration Project, under construction in Sumas, Sumas water treatment facilities, a zero-discharge water treatment Wash., is a conventional combined-cycle cogeneration facility that system will be utilized. After evaluating several systems, the will produce approximately 125 MW of electric power for sale to owners chose a Harris Engineering system because of low capital Puget Sound Power & Light. It will also supply 25,000 Ibhr of and operating costs and minimal operator interface. The Harris low-pressure steam to an adjacent lumber dry kiln, which also is system consists of a cascading series of thermally driven evapora- under construction. tor modules followed by a filter press. The resulting non-hazardous The facility is owned by Sumas Cogeneration Co., a pannership waste will be trucked to a landfill. of Calpine Corp. of San Jose, Calif. and NESCO of Redmond, To eliminate the zero-discharge salt volume associated with the Wash. It will use a General Electric gas turbine, a Vogt unfired waste from chemicals normally used in on-site demineralizer heat recovery steam generator (HRSG), and a 36-MW GE steam regeneration-and to eliminate the cost of these chemicals-two turbine. Construction began in March 1992. and commercial oper- in-series reverse osmosis units were incorporated into the design of ation is scheduled for May 1993. the boiler feedwater treatment system. The final stage of water The plant is being constructed in a non-traditional owner-con- treatment will be accomplished by a portable demineralizer that struct arrangement. The partnership has procured all of the major will be regenerated off-site.

24 POWER ENGINEERINGNULY 1992 Emissions limits for Barbers Point are lower than federal new source performance standards (NSPS). Barbers Point emission IimitsforSO,, NO,anddustare0.3,0.11, andO.OlSib/MMBtu Coal-fired plant will produce respectively. NSPS standards are 0.6,0.6. and 0.3 for the same emissions: 18% of Oahu’s power Currently, there are no emissions limits for carbon dioxide, However, recognizing that CO, may contribute to global warm- Almost all of Hawaii’s electricity is presently supplied by oil- ing, AES-BP is contributing to the purchase of a 143,000-acre fueled power plants. The AES Barbers Point plant on Oahu will nature reserve in Paraguay. The CO, saved by preserving this be the island state’s first large coal-fired power plant. It will forest will he approximately equal to the CO, which will be supply approximately 18% of Oahu’s electric energy. emitted over the life of the plant. Construction started in late March, 1990. The project is Barbers Point will use a salt-water cooling tower for condens- currently about two months ahead of schedule. Steam blows er cooling, selected because it reduces the plant’s fresh water were completed in early April of this year, and commercial requirements by about 90%. The salt water is supplied from on- operation is expected this month. The plant will produce 180 MW of electricity for sale to the Hawai- ian Electric Co. (HECO) under a 30-year contract. The plant will be base loaded with some dispatch, primarily at night. Dispatching will be under HECO control. Minimum dispatch will be 63 MW. Barbers Point will produce about 30,000 lh/hr of 45 psig, 345 F steam for export to the nearby Chevron oil refinery under a 20-year extendable contract. Coal will be burned in two circu- lating fluidized bed (CFB) boilers. Local limestone is added to the coal. The limestone is calcined in- side the boiler, and reacts with the sulfur in the boiler gases to form gypsum. At its 180-MW rate output, the plant will use approximately 90 tph of coal. The coal, being supplied from Indonesian Borneo, will be unloaded at Barbers Point Harbor by a bulk cargo unloader. The AES Barbers Point project provided the quantity of bulk cargo shipments needed to finance the installation of the bulk cargo unloader. The un- loader will provide low-cost un- loading of other bulk cargoes on oahu. The coal will be carried from the harbor to the plant in a pipe con- veyor. This conveyor is unique in that its belt folds over on itself to form a pipe which completely en- closes the coal. The pipe conveyor eliminates windblown coal dust while maintaining a slim profile. The pipe system can make sweeps as small as 800-ft radius. This capability eliminated the need for an intermediate coal The Barbers Point plant is Hawaii’s first large coal-fired power transfer point. When completed, the system will be the longest plant. and largest capacity overland pipe conveyor operating in the world. The circulating fluidized boilers operate at relatively low site shallow wells, temperatures, which significantly reduces the production of The plant is being built under a turnkey contract with Multi- nitrogen oxides when compared to conventional boiler opera- power Associates, a joint venture of National Power Develop- tion. In addition, the boilers are provided with ammonia and ment Corp., Pyropower, and the Pritchard Corp. NPDI is a Steam injection to further reduce the nitrogen oxides. The am- subsidiary of Marubeni. Pyropower is a subsidiary of Ahlstrom. monia reacts with the nitrogen oxides to form nitrogen and water The prime construction contractor is Hawaiian Dredge and vapor. Construction. Construction management is by Black 81 Veatch.

POWER ENGlNEERlNGlJULV 1992 25 Lone Star Energy Co., another Enserch unit, will operate the facility. Construction was complicated by the site itself. It lies within the city limits of Buffalo, and is approximately 100 ft wide and Combined-cycle plant uses 1000 ft long. A rail line lies along one side; the distance between the center of the nearest track and the nearest wall of the new new low-emissions combustor facility is 8 ft. An $87-million cogeneration facility, built by Ebasco Construc- Electric power produced by the new plant will he purchased tors, Inc., went into commercial operation in May within the by Niagara Mohawk Power Corp. Thermal energy will be sold to city limits of Buffalo, N.Y., five months ahead of schedule. Outokumpu American Brass, Inc., a copper and copper alloy The General Electric Frame 6-powered combined-cycle facili- manufacturer adjacent to the power plant. ty produces 62 MW, and is one of the first to use GE's dry low In addition to the GE gas turbine, major components include a nitrogen oxide combustor to reduce emissions. Deltak heat recovery steam boiler, GE steam turbine, and Ha- Ehasco designed, engineered and constructed the plant under mon cooling towers. a contract with Encogen Four Partners, L.P., whose managing general partner is EDC Four Inc. Ebasco and EDC Four are A new6BMW cogen plant occupies a 100-fi-wide space between wholly owned subsidiaries of Enserch Corp., Dallas, Tex. a manufacturing plant and a rail line.

uted control system is from Bailey Controls. Metric Construc- tors, an affiliate of the J.A. Jones Group of Charlotte, N.C., is providing construction services and balance-of-plant equip- ment. Metric also is providing detailed design services through Florida plant constructs 570-acre Black & Veatch. lake for use as cooling pond Power from the plant will be sold to Seminole Electric Coop- erative and Tampa Electric Co. Construction will he completed this fall on a 295-MW indepen- Construction began in January, 1991. One highlight of the dent power plant in Hardee County, Fla., as the first phase of project was the construction of a 570-acre lake to be used as a what eventually will he a 440-MW facility. The plant owner is cooling pond in place of cooling towers. The power block site is Hardee Power Partners, an affiliate of TECO Power Services, adjacent to a reclaimed phosphate mining area; reclaiming the which is the wholesale power producing arm of TECO Energy, mined area as a cooling pond was considered a positive enhance- Tampa. ment to the land. Because it is less energy-intensive, the cooling Long-range- -. plans call for two General Electric combined- pond also is more efficient than cooling towers. cycle systems. each rated at 220 MW. IO he in\talled at the site. 'The first unit. featuring two gas turhincs and an 80-MWsteam turbine. is scheduled to begin commercial operation in January IYY3. In addition. a third gas turbine will hegtn simple-cycle operation at the same time. That unit eventually will become part of the second combined-cycle block. planned for commercial opera- tion in 2003. In the initial configuration-one combined-cycle unit plus the \Imple-cycle gas turhine-plant output will he approximstely 295 MW fcir site suninier conditions. Natural gas u ill be the priinary fuel for the gas turhincr, u,ith distillate oil as n hackup. GE Porer Gencrxtion. the turnkey COIII~~L'IO~for the $IM)-niillionpro~ect,is providingthesteani turbines and gcneratori. along with thr gas turbines. The heat recov- ery steam generator is iroiii Vogt and the plant's dihh-

Florida independent power plant will use 570-acre lake (upper left of photo) as a coollng pond.

6 The CFB technology uses pulverized limestone to removi more than 90% of the waste coal’s sulfur dioxide emissions- better than government-mandated levels. The suspension in ail

Pennsvlvania~ cogen dant fires (fluidization) of the coal, ash and limestone allows recycling o: Y v 1 unhurncd karhon hack 10 [he comburtion chamher and &c~lll&* waste enhances environment the capturcof SO.. uhich eitnunales the nced for ddditlonal SO abatement equipment. Lower combustion temperatures mini. A new 85-MW coal refuse-fired cogeneration facility at Ebens- mize thermal nitrous oxide formation and ash fouling and slag burg, Cambria County, Pa. is providing 85 MW of electric ging caused by coal deformation. power to Pennsylvania Electric Co. and an effective solution to The plant’s continuous emission monitoring system allow! one of the area’s most persistent environmental concerns. The ongoing checking of air quality levels, and ensures compliancc $190-million facility is the first to use waste from bituminous with pollution control standards. coal as fuel. The plant contains unusual features, including dual fuel sup A 35-year supply of fuel to operate the Cambria facility is ply, redundancy of critical components, and technology to con taken from two sources: a 30-million-ton waste coal pile adja- trol fuel moisture levels to minimize interruptions in its cent to the plant site, and another smaller waste coal pile near operations. Carrolltown, Pa. During the first three years of operation, fuel Designed with two fuel sources, the facility has two coal will come from the remote source, During the subsequent 30 + crushers, two reclaiming systems and two refuse Crushers tc years the facility will consume approximately 1,200,000 tpy ensure uninterrupted flow of the waste coal. The ability 01 from the coal refuse pile adjacent to the facility. cogeneration plants to keep fuel flowing has been identified Effectively disposing of waste coal, a by-product of the coal as a key factor in operation success. The plant design alsc mining process, has been an environmental concern throughout features a dual system for removing ash from the combustion Pennsylvania and other coal-mining regions. process. At the plant’s dedication, Mark Singel, Pennsylvania lieuten- The plant requires roughly 2500 tons of waste coal daily ta ant governor, said, “This project has moved our state one step operate. One 25-ton truckload of bituminous Coal refuse is closer to its goal of a cleaner, healthier environment. At the delivered to the plant approximately every 5 minutes on a same time, the project supports economic growth and energy 10-hour-per-day. 6-day-per-week schedule. It is dumped onto independence from foreign oil through the innovative use of a the receiving hopper from which it is moved by enclosed con- veyor to the first screening unit, which rejects any material larger than foul inches in diameter. The material is then transferred by conveyor to the refuse storage dome (which can contain up to 20,500 tons). where it is stacked out by the stacked reclaimer. Next. the material moves by conveyor to the fuel handling build- ing where it is deposited on a vibrating screen which rejects any pieces larger than 2 inches. The remaining material moves to the crusher, which crushes and screens it in size to 114 in. or smaller. The crusher is equipped with circulating heated air to remove moisture as need- ed. Then the material is transferred by a 620-ft conveyor to the refuse boiler fuel bunker and is ready for use by the combustors. The plant also uses run-of-mine coal as a backup supply of fuel as well as Coal-minina waste for Dlant in Cambria Countv. Pa. is moved bv for start-uos and flame s tahilization. It is ourchased on the soot enclosed c&eyor to a storage dome, where ii is stacked out by market as’needed. stackerlreclaimer. The run-of-mine coal also is delivered to the plant in 25-ton trucks and stored in a covered pile. The handling system for this fuel is served by two separate crushers and a separate conveyor coal mining by-product.” from the fuel handling building to the run-of-mine fuel bunker in The Cambria County facility is owned by the Cambria Cogen the boiler building. Co., a Pennsylvania partnership consisting of Air Products and Another unusual feature of the installation is the moisture Chemicals, Inc. as general partner and Energy Investors Fund, control built into the fuel processing system, a factor that can L.P. and Allstate Insurance Co. as limited partners. It was built affect material flow rates significantly. Once the waste coal is and is being operated by Air Products and Chemicals, Inc., and received by truck, it is handled by a series of enclosed conveyors employs two circulating fluidized bed (CFB) boilers to produce and structures and is never exposed to outdoor elements. 820,000 Ib/hr of 1550 psig, 955 F steam. The steam drives a Ash produced during the combustion process is returned to single turbine-generator train to produce approximately 98 MW waste coal piles to help neutralize their acidic nature and aid in of electricity. About 13 MW are consumed by the facility, and their reclamation. approximately 85 MW are exported to Penelec. An average of According to Air Products and Chemicals, the plant has 12,900 lb/hr of low-pressure steam are supplied to a nearby achieved an availability rate of over 95% in its first year of nursing home for space heating, operation.

POWER ENGlNEERlNGNULY 1992 27 Wood-waste-burning power plant pipes wastewater to local town’s lagoon system, reducing town’s groundwater dlscharge.

handling system and the boiler. Initially, 100% of the energy produced will be sold as electric power on a long-term power sales agreement with Consumers Power Co. The design of the plant allows for the future uses of process steam to support a planned lumber drying kiln at the sawmill. The Grayling project is scheduled for commercial operation during the third quarter of 1992. Black & Veatch Power Devel- opment Corp., a subsidiary of Black & Veatch, is the turnkey contractor. Construction is being managed by TBC, a joint venture of Townsend & Bottum Inc. and the Christman Co. In its design of the project, Black & Veatch utilized approach- es developed for much larger utility power designs, including 3-D computer modeling, This project is the first time these types of design tools were applied to a small power producer. They resulted in a well documented design in which the owner could see the modeled layout of the plsnt before it was built. This approach also reduced the potential for interferences in the field, which is a benefit on a fixed price project with a tight schedule. The project also has a unique service watedwastewater sys- Wastewater discharge plan tem. It is interconnected with the water treatment lagoon system benefits local water system for the town of Grayling, which is approximately three miles from the power plant. An overland piping system has been The fuels to be used at the Grayling generating plant at Grayling, designed which carries power plant wastewaters and blowdown Mich. dictated the design. The plant is located adjacent to an to the town’s lagoon system. In return. a portion of the power existing sawmill and utilizes sawmill wastes such as sawdust and plant’s makeup water is taken from the tertiary section of the planer mill fines in addition to wood lot forestry operations lagoon system. This arrangement avoids the need for a separate wastes and some whole tree chips as fuel. discharge to the area groundwater system from the power plant. The most difficult of the fuels are the sawdust and planer mill It also reduces the town’s groundwater discharge since the plant fines. The plant is designed to burn up to 40% heat input from uses and evaporates more water than it discharges to the town’s this type of fuel, which required careful attention to both the fuel lagoons.

for construction of the plant. Site construction began in February 1991; turbine-generators were delivered in July. Interconnection was made to the Virginia Peaking plant has Power 230-kV line’in February 1992, and commercial operation dual-fuel capability was scheduled for this spring. The Limited panners of Commonwealth Atlantic L.P. are Hano- A peaking power plant recently completed in Chesapeake, Va. by ver Energy Co. and Chickahominy River Energy Corp. Hanover is the Commonwealth Atlantic Limited Partnership utilizes simple- a wholly owned subsidiary of Mission Energy Co. and Chickahom- cvcle combustion turbines ourchased from Westinnhouse Electric iny is a wholly owned subsidian, of Long Lake Energy Corp. Corp. on a turnkey basis. The facility consists of three combustion turbines rated at 312 MW on natural gas in the summer and 375 MW on No. 2 distillate oil in the winter. Water injection will be used to reduce the NO, to 25 ppmvd on gas and 42 ppmvd on distillate oil. A leased mobile water treatment system will provide demineralized water for NO, injec- tion. The water will he stored in a 1-million- gallon storage tank, which is sufficient for 30 hours of operation. Westinghouse is responsible for the total turnkey project; it has subcontracted with Black & Veatch for the balance of plant engi- neering, BOP procurement, and construction. B&V has subcontracted to Metric Constructors

The Chesapeake plant will deliver up to 375 MW to the Vlrglnla Power grid.

20 I Deltak recovery boiler and a steam turbine for steam generation. Demineralized water is provided by an Aquatec treatment system. 46-MW cogen plant A distributed control system from Westinghouse monitors and controls plant functions. delivers steam for oil recovery The project utilizes the latest emission control technologies to i Because much of the energy reserves remaining in the western achieve stringent clean air standards. These include a snperheat- f United States are in the form of heavy crude oil, many producers ed steam injection system to reduce nitrous oxide emissions, a have turned to thermally enhanced oil recovery to aid in extract- selective catalytic regenerator in the heat recovery steam genera- ing this oil. By injecting steam into existing wells, oil viscosity tor to further reduce NO, emissions. and a catalytic converter to 1 can be lowered enough to allow economical recovery. reduce carbon monoxide emissions from the boiler. The Live Oak cogeneration plant near Bakersfield, Calif. Prior to development of the cogeneration project, oil and gas supplies steam under pressure for this purpose. It delivers up to producers in the area had utilized steam produced at the site by a t 40,000 Ib/hr of steam to the nearby thermally enhanced oil conventional steam generator. By efficiently producing both recovery project operated by Texaco, Inc. It also supplies 46 electricity and steam, Live Oak cogen provides improved pro- MW of electric power to Pacific Gas and Electric Co. duction and profitability because the steam required for oil Destec Energy, Inc. and its subsidiaries were responsible for recovery is readily available at a substantially lower cost. all aspects of the development of the project, from feasibility Compared to expenses incurred when conventional steam studies to operation and management of the finished plant. The generators were used, Live Oak cogen provides its steam host 1 partnership formed to own Live Oak has long-term contracts overall energy savings equivalent to approximately 200,000 with PG&E for electric power sales and a contract with Texaco barrels of oil a year. " Inc. for steam sales. The facility t purchases natural gas from PG&E. Live Oak cogen began opera- 2 tion in March of this year. It uti- S lizes a steam-injected natural gas- n fired aero-derivative General n Electric turbine, packaged by 'r Stewart & Stevenson Services, to e generate electric power, and a e

It S Process steam from 46-MW Cali- fornia cogen unlt alds in crude 011 - recovery.

3 a process steam. It also powers, simultaneously, a GE automatic- n extraction condensing steam turbine. To comply with environmental concerns, the plant's design ,- Cogen plant design~ factors in stringent sound and NO, control requirements. Steam is is overcomes site obstacles injected into the turbine to limit NO, emissions 1- The Fort Orange cogeneration project, on line since February 1992, provides 60 MW of power to Niagara Mohawk Power Co. It also provides process steam for operations at the adjacent Fort Orange paper mill. The site's conditions presented some challenges to design. Located over soil that contains compressible pockets of peat, the two-acre site was covered with up to 7% ft of a compacted fill material to keep all Structures above the 100-year flood plain elevation. All structures were supported on steel H-piles to counter a soil settlement of seven to nine inches. The piles were coated with visco-elastic asphalt material to reduce the downdrag caused by the friction of the settling soil. The combined-cycle plant was engineered by Parsons Main for C.N.F. Constructors, Inc., the turnkey contractor. It was devel- oped and is owned by Cogeu Engineering Technology, Inc. (CETI). A General Electric Frame 6 combustion turbine is the core of the plant. Fueled by natural gas or distillate oil, the turbine exhausts into a Deltak heat recovery steam generator, which provides the

Remediation of the site was requlred before the Fort Orange cogen unlt was constructed.

DWER ENGlNEERlNQNULY 1892 U.S.’ largest non-utility cogen plant to start up in New Jersey

According to Cogen Technologies, its plant at Linden, N.J. is the largest non-utility cogeneration plant in the United States. Con- struction began in January, 1991, and commercial operation is scheduled for this month. The $500-million combined-cycle plant will he capable of pro- ducing up to 614 MW of electric power and more than 1 million Ibhr of steam. The power will be purchased by Consolidated Edison under a 25-year contract. Low, medium, and high pressure steam has been contracted for by Exxon for refinery operations. The plant lies on an 8%-acre site within the confines of Exxon’s Bayway refinery The plant will operate on natural gas as fuel to power five turbines. During 15 days each winter, natural gas normally con- sumed by the Linden plant will be provided to Public Service Electric & Gas for public distribution. On these occasions, the plant will operate with butane as a backup fuel, without degrada- tion of emission standards. The five gas and three steam turbines in the plant were supplied by General Electric: the gas turbines are the GE 7EA model. The supplementary-fired waste heat boilers are from Nootermriksen. Duct burners were provided by John Zink Co. Ebasco developed the plant under a turnkey contract. The plant includes an air-cooled condenser system supplied by GEA Power Cooling Systems. According to GEA, the system, Ccgeneratlon plant in New Jersey, sald to be the US.’ largest, consisting of three condensers, is considered to be the largest of its will dellvar 614 MW. kind in North America, and one of the largest in the world.

The original steam host, a textile mill. experienced financial difficulties, and the steam contract was set aside. In looking for a replacement steam customer, the company Developer switches site offered to provide low-cost energy in exchange for the cus- tomer’s current emissions. Negotiations were begun with to accommodate new plant DuPont. The DuPont site was located adjacent to the city-county line. This summer, Cogentrix will place its ninth and largest coal-fired The county was seeking industrial development, but a citizen’s plant in operation. The standard 220-MW cogeneration facility, in group campaigned against the plant. The city of Richmond, Richmond, Va., will consist of four of the cogen developer’s however, was receptive, and the plant site was moved across the standard 55-MW modules. line, still adjacent to the DuPont plant. Each module will consist of two 292,000 Ibhr, 1525 psig. 955 F Stoker coal for the plant will be provided by rail. All ash will ABB Combustion Engineering boilers and one General Electric be commercially re-used by Reuse Technology, an affiliate of controlled extraction turbine-generator. The T-G consists of a Cogentrix.