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In,Dust'ry-'Phase 1 JPL PUBLICA TON 78-42 Poteptiarfor' Cogpeneration of- Heat and Electricity in Galifornia In,dust'ry-' Phase 1 'Final Repo(t, 78-25536 (NASA-CR-157168) POTENTIAL FOR COGENERA2TION OF HEAT AND E ECTRICITY IN CALIFORNIA (Jet INDUSTRY, PHASE I Final Report Unclas Propulsiom Lat.) 179 p HC A09/MF A01 CSCL 10B G3/414 21318 N RERODUCED BY NATIONAL TECHNICAL INFORMATION SERVICE U S DEPARTMENT OFCOMMERCE VA. 22161 L , SPRINGFIELD, ,Preoared for Stat6 of.-alhfornia Energy 'Resources Conservation and Development Qoi-nmmason by Jet Propulsi6n Laborafory-_ California Institute of Techndl'oy Pasadena, California ­ NOTICE THIS DOCUMENT HAS BEEN REPRODUCED FROM THE BEST COPY FURNISHED US BY THE SPONSORING AGENCY. ALTHOUGH IT IS RECOGNIZED THAT CERTAIN PORTIONS ARE ILLEGIBLE, IT IS BEING RELEASED IN THE INTEREST OF MAKING AVAILABLE AS MUCH INFORMATION AS POSSIBLE. JPL PUBLICATION 78-42 Potential for Cogeneration of Heat and Electricity in California Industry - Phase I Final Report H. S. Davis R. M. Gurfield V. C. Moretti M. L. Slonski May 1, 1978 Prepared for State of California Energy Resources Conservation and Development Commission by Jet Propulsion Laboratory California Institute of Technology Pasadena, California Prepared by the Jet Propulsion Laboratory, Californta Institute of Technology, for the California-Energy Resources Conservation and Development Commission by agreement with the National Aeronautics and Space Administration. LEGAL NOTICE This report was prepared as an account of work sponsored by the State of California Energ5 Resources Conservation and Development Commission, but does not neces­ sarily represent the views of said Commission or any of its employees except to the extent if any that it has formall% been approved by said Commission at a public meeting For information regarding any such action communicate directly with the said Commission at 1111 Howe Ae, Sacramento, CA 95825 Neither-said Commis­ sion nor the State of California, nor any officer, employee thereof or any of its contractors or subcontractors makes an' warranty, express or implied, or assumes any legal liability whatsoever for the contents of this document Nor does any party repre­ sent that use of the data contained herein would not infringe privately owned rights ABSTRACT This report summarizes the results of a Phase I study conducted by the Jet Propulsion Laboratory for the California Energy Resources Conservation and Development Commission to determine the potential for cogeneration of heat and electricity in California industry. The primary effort of the Phase I study was to conduct an indus­ trial survey of 12 selected plants in the State of California. Infor­ mation collected during the study was organized into four categories: technical, economic, environmental, and institutional. In this Phase I study the technical aspects of industrial cogeneration are examined on a site-specific basis. Following this work, a Phase II study will investigate further and analyze the site­ specific economics, environmental constraints, and institutional bar­ riers that impact industrial cogeneration. The Project Manager was Herbert S. Davis. Participating in the study were Vincent C. Moretti, who performed the technical analysis, and Robert M. Gurfield and Marie L. Slonski who were responsible for the survey organization as well as the economic and institutional factors. The duration of the study was approximately five months and involved 10 man-months of effort. The Project Coordinator was Phil Nesewich of the California Energy Resources Conservation and Development Commission. iii ACKNOWLEDGEMENTS We gratefully acknowledge the participation and assistance of the following orgtnizations: Industrial Companies California Paperboard Corporation California Portland Cement Company Exxon Company, U.S.A. Hunt-Wesson Foods, Inc. Husky Oil Company Kaiser Steel Corporation Kelco Company Owens-Illinois, Inc. Simpson Paper Company Simpson Timber Company Spreckels Sugar Company Union Oil Company Electric Utilities City of Santa Clara Electric Department Los Angeles Department of Water and Power Pacific Gas and Electric Company San Diego Gas and Electric Company Southern California Edison Company We also wish to express our appreciation to R. Manvi and D. S. Pivirotto for valuable discussions and to the Jet Propulsion Laboratory Cogeneration Review Board for its guidance in this effort: J. M. Spiegel, chairman, and members D. S. Hess, F. R. Livingston, R. L. Phen, J. A. Plamondon, and R. P. O'Toole. iv CONTENTS I. EXECUTIVE SUMMARY 1-1 A. , OBJECTIVE AND SCOPE -i--------------------------------1-1 B. FINDINGS --------------------------------------------- 1-4 C. RECOMMENDATIONS FOR FUTURE WORK ---------------------- 1-8 II. SURVEY DATA ------------------------------------------------ 2-1 A. TECHNICAL ANALYSIS ----------------------------------- 2-1 B. ECONOMIC, ENVIRONMENTAL AND INSTITUTIONAL ISSUES .....- 2-13 III. INDUSTRIAL SURVEY ------------------------------------------ 3-1 A. SITE SELECTION --------------------------------------- 3-1 B, SURVEY PROCESS --------------------------------------- 3-2 BIBLIOGRAPHY ----------------------------------------------------- 4-1 APPENDIXES A-I. COGENERATION SITE REPORT, PAPERBOARD PRODUCTS INDUSTRY (RECYCLED PAPER): CALIFORNIA PAPERBOARD CORPORATION, SANTA CLARA ------- A-i A-2. COGENERATION SITE REPORT, CEMENT MANUFACTURING INDUSTRY: CALIFORNIA PORTLAND CEMENT COMPANY, MOJAVE PLANT ------------------------------------------------ A=13 A-3. COGENERATION SITE REPORT, PETROLEUM REFINING INDUSTRY: EXXON COMPANY, U.S.A., BENECIA ----------------------- A-23 A-4. COGENERATION SITE REPORT, FOOD PRODUCTS INDUSTRY: HUNT-WESSON FOODS, INC.------------------------------- A-33 V A-5. COGENERATION SITE REPORT, ENHANCED OIL RECOVERY: HUSKY OIL COMPANY ------------------------------------ A-41 A-6. COGENERATION SITE REPORT, STEEL INDUSTRY: KAISER STEEL CORPORATION, FONTANA PLANT -------------­ A-51 A-7. COGENERATION SITE REPORT, ORGANIC AND INORGANIC CHEMICALS: KELCO COMPANY, SAN DIEGO PLANT ----------------------­ A-61 A-8. COGENERATION SITE REPORT, GLASS CONTAINER INDUSTRY: OWENS-ILLINOIS, INC., OAKLAND PLANT -----------------­ A-69 A-9. COGENERATION SITE REPORT, PULP AND PAPER INDUSTRY: SIMPSON PAPER COMPANY -------------------------------- A-79 A-10. COGENERATION SITE REPORT, TIMBER INDUSTRY: SIMPSON TIMBER COMPANY ------------------------------- A-89 A-lI. COGENERATION SITE REPORT, SUGAR BEET REFINING INDUSTRY: SPRECKELS SUGAR COMPANY, MANTECA PLANT --------------- A-99 A-12. COGENERATION SITE REPORT, PETROLEUM REFINING INDUSTRY: UNION OIL COMPANY, WILMINGTON ------------------------ A-109 B. ENERGY BALANCE EQUATIONS ----------------------------- B-i C. ASSUMPTIONS AND SUPPLEMENTAL COMPUTATIONS ------------ C-i GLOSSARY --------------------------------------------------------- G-l FiguresI 1-I. Selected Cogeneration Site Locations in California ------------------------------------------- 1-3 1-2. Base (Noncogenerating) System ------------------------ 2-2 2-2. Cogeneration System (Topping Cycle-Gas Turbine) with Excess By-Product Energy and Utility Grid Tie-In ----------------------------------------------- 2-3 vi OIGINAL pAGE ) OF pooB. QUALIT 2-3. ogeneration System (Topping Cycle-Steam Turbine) With Purchased Electricity --------------------------- 2-4 2-4.- Cogeneration System (Bottoming Cycle-Steam Turbine) With Purchased Electricity --------------------------- 2-5 2-5. Cogeneration System (Bottoming Cycle-Gas Turbine) With Purchased Electricity --------------------------- 2-6 2-6. Cogeneration System (Topping Cycle-Gas Turbine) With Supplemental Boiler Firing ---------------------- 2-7 Tables 1-1. Selected Cogeneration Sites in California------------ 1-2 1-2. Calculated Goeneration Potentials at 12 Locations in California --------------------------- 1-5 1-3. Economic, Environmental and Institutional Issues ----------------------------------------------- 1-6 2-1. Base System Energy Requirements ---------------------- 2-9 2-2. Cogeneration System Energy Requirements-------------- 2-10 2-3. Economic, Environmental and Institutional Issues ----------------------------------------------- 2-14 vii SECTION I EXECUTIVE SUMMARY More energy is required to produce industrial process heat and electricity separately than would be required to produce them in combin­ ation with each other. Combined generation,-or cogeneration* of heat and electricity is, therefore, one strategy for energy conservation. Prompted by recent increases in electricity and fuel costs, industry is now reconsidering this once popular concept. A. OBJECTIVE AND SCOPE The objective of this Phase I study was to conduct an industrial survey within the State of California to: (1) Determine the feasibility and desirability of industrial cogeneration and the utilization of waste heat from elec­ tricity generating plants at selected sites, and (2) Determine the economic, institutional and environmental barriers to industrial cogeneration of heat and electricity at selected sites. Previous studies have estimated industry-wide and nation-wide potentials for industrial cogeneration. In contrast to these studies, the scope of this investigation was limited to 12 plants, all of which are located in the State of California. Regional, local, and individual differences in attitudes toward the economic, environmental, and insti­ tutional issues of cogeneration can thus be explicitly recognized. The 12 plants selected for the industrial survey are listed in Table 1-1 with the site selection
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