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The system must be the facility’s primary source of power. Since even a momentary outage was as damaging as a lengthy one, standby generation alone was not an adequate solution. A battery UPS may have improved power reliability but would have increased the already high electric costs. The solution also needed to instantaneously load-follow the facility’s needs, which often swing 30 percent several times a minute during full production phases. The onsite system must be a continuous source of quality power to the facility, with some level of redundancy. The odds of multiple primary and redundant units failing simultaneously are extremely low, but, if such a case were to arise, the utility grid would serve as the final backup source. Hot exhaust from the Capstone MicroTurbines fires this Carrier absorption chiller to air condition the Harbec facility using near-zero electrical load. The system must have extremely low emissions. Since Harbec is an ISO 14001-certified facility, Bechtold was committed to designing an environmentally benign onsite system. This commitment led away from reciprocating engine technologies, even those fired by natural gas, as NOx emissions from natural gas engines are many times higher than the best-in-class generating technologies. Thus, he began investigating wind power, fuel cells and microturbines. The system must be efficient. Bechtold wanted a solution that recovered as much of the input energy as possible. He envisioned a system that would capture exhaust heat and put it to valuable use for space heating, process drying and even “power-free” air conditioning via absorption chilling. As an ISO-certified company, Harbec demanded—and received— the utmost quality from Capstone, an ISO-9001 company. A New Way of Looking at Electric Power and Climate Control The electrical loads of Harbec’s building were evaluated, and the microturbine configuration identified. Twenty of the 25 Capstone MicroTurbines were mated to five heat recovery boilers. Each boiler uses exhaust heat from four microturbines to heat water to 210°F. Total system efficiency exceeds 70%. The system must be economically feasible. While attracted to the renewable energy supply represented by wind, and the potential high efficiency and low emissions of fuel cell prototypes, economic analysis clearly revealed that microturbines offered the best up-front and ongoing value for clean, continuous onsite power. Further evaluation of microturbine options led Bechtold to a simple conclusion, “For fully functional, proven technology that met all our criteria, there’s only one company... Capstone Turbine.” In the winter, this hot water is routed to the ventilation system as well as radiant floor heating built into the concrete slab of Harbec’s warehouse area. In warm and humid weather, the heated water fires a 200-ton absorption chiller to air-condition and dehumidify Harbec’s warehouse and production areas without adding any appreciable electrical load (the facility had no air conditioning prior to this installation). The desiccant effect also eliminates the cost of drying raw materials in humid weather.PDF Image | Declaring Independence from Grid Power Uncertainties
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