National Animal Disease Center - 4.7 MW CHP System - Case Study
Quick Facts
LOCATION: Ames, Iowa
FACILITY SIZE: Over One Million Square Feet
CHP GENERATING CAPACITY: 4.7 Megawatts
PRIME MOVERS: 1.2 MW Solar Saturn 20™ Combustion Turbine (CT-1), 3.5 MW Solar Centaur 40™ Combustion Turbine (CT-2)
HEAT RECOVERY RATE:
CT-1: 8,300 lb/hr Steam Unfired; 29,000 lb/hr Steam with Duct Firing
CT-2: 23,500 lbs/hr
USE OF THERMAL ENERGY: Steam for Laboratories, Space Heating, Absorption Chillers
FUEL: Natural Gas
BEGAN OPERATION:
2002 – 1.2 MW CHP System (CT-1)
2007 – 3.5 MW CHP System (CT-2)
Project Overview
Located in Ames, Iowa, the National Animal Disease Center (NADC) is the largest federal animal disease center in the U.S. The NADC conducts research to solve animal health and food safety problems faced by livestock producers and the public. Opened in 1961, the NADC today includes over one million square feet of laboratory, animal housing, administrative and other support facilities.
NADC’s first experience with combined heat and power (CHP) began in 2002 when they installed a 1.2 MW CHP plant. That system utilized a Solar Saturn 20TM natural gas fueled combustion turbine with heat recovery from the turbine exhaust gases. The exhaust gases are recycled through a heat recovery steam generator (HRSG) to produce 8,300 lbs/hr of process steam for use in the facility laboratories. The HRSG is also equipped with additional natural gas fired duct burners that can boost the thermal output to 29,000 lbs/hr of steam to satisfy both the process and space heating requirements of the Center. When installed, the thermal capability of the CHP system allowed the NADC to completely avoid operating an existing 40-year-old 70% energy efficient boiler (now used strictly as a backup boiler for added reliability).
Due to the success of the first system (CT-1), NADC installed a second 3.5 MW CHP gas turbine in 2007 (CT-2). The exhaust gases from the second turbine are also recycled and sent through a HRSG producing 23,500 lbs/hr of process steam. Unlike with CT-1, the HRSG on CT-2 does not have duct firing and only operates when the turbine is in operation. Currently, this unit provides base load power to the facility while CT-1 operates only during peak periods.
Reasons for CHP
An opportune time for an organization to consider investing in a CHP system is during new facility construction or during a major facility/boiler room upgrade. In 2001 the NADC was in such a situation. Its existing boiler plant was 40 years old and the maintenance and fuel costs on the 70% efficient boiler were becoming an issue. An analysis of the total facility’s energy requirements revealed several conditions favorable for consideration of a CHP system:
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