ORNL/TM-2004/144 Guide to Combined Heat and Power Systems for Boiler Owners and Operators C. B. Oland DOCUMENT AVAILABILITY Reports produced after January 1, 1996, are generally available free via the U.S. Department of Energy (DOE) Information Bridge: Web site: http://www.osti.gov/bridge Reports produced before January 1, 1996, may be purchased by members of the public from the following source: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone: 703-605-6000 (1-800-553-6847) TDD: 703-487-4639 Fax: 703-605-6900 E-mail: [email protected] Web site: http://www.ntis.gov/support/ordernowabout.htm Reports are available to DOE employees, DOE contractors, Energy Technology Data Exchange (ETDE) representatives, and International Nuclear Information System (INIS) representatives from the following source: Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831 Telephone: 865-576-8401 Fax: 865-576-5728 E-mail: [email protected] Web site: http://www.osti.gov/contact.html This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. ORNL/TM-2004/144 GUIDE TO COMBINED HEAT AND POWER SYSTEMS FOR BOILER OWNERS AND OPERATORS C. B. Oland July 30, 2004 Prepared for the U.S. Department of Energy Industrial Technologies Program Prepared by OAK RIDGE NATIONAL LABORATORY Oak Ridge, Tennessee 37831 managed by UT-BATTELLE, LLC for the U.S. DEPARTMENT OF ENERGY under contract DE-AC05-00OR22725 ii CONTENTS Page LIST OF FIGURES................................................................................................................................ vii LIST OF TABLES.................................................................................................................................. ix ACRONYMS.......................................................................................................................................... xi ACKNOWLEDGMENTS...................................................................................................................... xiii EXECUTIVE SUMMARY .................................................................................................................... xv 1. INTRODUCTION ........................................................................................................................... 1 1.1 SCOPE AND OBJECTIVES................................................................................................... 2 1.2 APPROACH ............................................................................................................................ 3 1.3 COGENERATION OPPORTUNITIES .................................................................................. 4 1.4 REFERENCES ........................................................................................................................ 5 2. COGENERATION TECHNOLOGY ISSUES................................................................................ 7 2.1 TECHNOLOGY DESCRIPTION ........................................................................................... 7 2.2 NATIONAL ENERGY ACTS................................................................................................. 9 2.3 ENVIRONMENTAL REGULATIONS.................................................................................. 11 2.3.1 Clean Air Act................................................................................................................ 11 2.3.1.1 National Ambient Air Quality Standards ..................................................... 14 2.3.1.2 New Source Performance Standards............................................................ 14 2.3.1.3 National Emission Standards for HAPs ....................................................... 16 2.3.1.4 Permitting requirements ............................................................................... 19 2.3.1.5 State permitting programs ............................................................................ 23 2.3.2 Clean Water Act ........................................................................................................... 24 2.4 BENEFITS AND BARRIERS................................................................................................. 25 2.4.1 Benefits and Potential Applications ............................................................................. 25 2.4.2 Barriers to Implementation........................................................................................... 27 2.5 REFERENCES ........................................................................................................................ 29 3. PRIME MOVERS............................................................................................................................ 33 3.1 STEAM TURBINES ............................................................................................................... 33 3.1.1 Description ................................................................................................................... 33 3.1.2 Design and Performance Characteristics...................................................................... 36 3.1.2.1 Efficiency ..................................................................................................... 39 3.1.2.2 Capital cost................................................................................................... 40 3.1.2.3 Availability................................................................................................... 40 3.1.2.4 Maintenance ................................................................................................. 41 3.1.2.5 Heat recovery ............................................................................................... 41 3.1.2.6 Fuels and emissions...................................................................................... 41 3.1.3 Potential Applications................................................................................................... 41 3.2 GAS TURBINES..................................................................................................................... 42 3.2.1 Description ................................................................................................................... 43 3.2.2 Design and Performance Characteristics...................................................................... 44 3.2.2.1 Efficiency ..................................................................................................... 46 3.2.2.2 Capital cost................................................................................................... 49 3.2.2.3 Availability................................................................................................... 49 3.2.2.4 Maintenance ................................................................................................. 49 3.2.2.5 Heat recovery ............................................................................................... 50 3.2.2.6 Fuels and emissions...................................................................................... 50 iii 3.2.3 Potential Applications................................................................................................... 51 3.3 MICROTURBINES................................................................................................................. 52 3.3.1 Description ................................................................................................................... 52 3.3.2 Design and Performance Characteristics...................................................................... 52 3.3.2.1 Efficiency ..................................................................................................... 54 3.3.2.2 Capital cost................................................................................................... 54 3.3.2.3 Availability................................................................................................... 54 3.3.2.4 Maintenance ................................................................................................. 55 3.3.2.5 Heat recovery ............................................................................................... 55 3.3.2.6 Fuels and emissions...................................................................................... 55 3.3.3 Potential Applications................................................................................................... 55 3.4 RECIPROCATING INTERNAL COMBUSTION ENGINES ............................................... 56 3.4.1 Description ..................................................................................................................