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Ducting enhances fresh air delivery to the four Capstone C30s. Exhaust is ported to an exchanger that heats all process water used at the facility. Henry Mak, Technical Development Advisor for SoCalGas, directed Faith Plating to the Washington DC based Energy Solutions Center, a market development organization that introduces and promotes new natural gas technologies. The Energy Solutions Center consortia of utilities, energy industry manufacturers and energy users also secures funding from the US Department of Energy Distributed Energy Resources program, which supports deployment and replication of CHP applications at industrial sites. Rich Biljetina, who is Director of Industrial Technology at the Energy Solutions Center (www.energysolutionscenter.org), reviewed Faith Plating’s proposed microturbine installation and found that it would meet the Department of Energy’s standards for the CHP study program that would collect and monitor operational data for a report to be issued by the DOE. “It was important to select a site where the results could be repeated,” said Biljetina. “There are many businesses that could use the Capstone MicroTurbine for CHP applications the way Faith Plating has.” Four low-pressure Capstone C30s and a Unifin heat exchanger were installed. These “black-start” units auto switch between grid-parallel and stand-alone operation in the event of an outage. Inclusive of some facility modifications, total project cost was less than $200,000 after the SoCalGas incentives (Capstone’s new 60-kWe/115-kWth outdoor solution would be a more compact, fuel-efficient and much more cost- effective choice today). All of Faith’s plating tanks were converted from conventional boiler operation to the new heating loop from the heat exchanger. The loop runs at 170oF to 190oF. Each 14,000-gallon master tank holds plating solution: liquid metal in a sulfuric solution. Faith’s production encompasses work with nickel, copper and chrome. Plating tanks must be maintained at 110oF to 190oF, depending on metal content. Thermostat controls on the tanks monitor proper temperature levels. Like other continuous process manufacturers, Faith Plating is reliant on dependable electrical power. Grid interruptions mean ruined work-in- process along with costly downtime to clean and restart processes. Steady onsite power from the Capstone array eased Faith’s 100% grid dependency. The four C30s supply approximately 60% of the facility’s power during peak periods, slashing electric utility bills by an average of about $5,500 per month, less a net average of $1,500 per month for the gas bill. Faith’s Larry Meyer developed a sludge dryer that uses the leftover exhaust heat, saving the facility up to an additional $1,000/month.PDF Image | Capstone MicroTurbines Address Cost, Emission and Power Reliability Issues at a Classic Hollywood Metal Plating Facility
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