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projects. Focus on Energy funds projects based on first- year energy savings. The study looked at having the Sheboygan treatment plant create a cogeneration system with an Alliant Energy-Wisconsin Power & Light power plant directly south of the treatment plant. “Ultimately that project fell through, but it got us thinking about cogen,” Doerr said. Cogeneration, or combined heat and power (CHP), creates two forms of energy: electricity and heat. A facility can use the electricity produced onsite or sell it back to the local utility, while the heat generated by the engine or turbine is captured and used to heat water, rooms, or to dry products in a manufacturing process. CHP is far more fuel-efficient and environmentally beneficial than utility power and boiler heating. Through research, plant personnel learned that clean-burning, low-emission microturbines are ideally suited to use methane gas as fuel. Microturbines are quiet, don’t vibrate, and don’t have the constant maintenance issues associated with reciprocating engines. According to Doerr, the treatment plant’s old Caterpillar reciprocating engine needed four gallons of oil each day just to keep running. Eventually, Doerr convinced Sheboygan officials to allocate US$500,000 in 2005 to purchase four microturbines. connections from the wastewater plant to the electrical grid, purchase a gas-cleaning system that removes moisture and siloxanes from the raw methane gas, and purchase a gas-compression system that compresses the clean methane gas fed to the microturbines. In exchange, the city agreed to purchase from Alliant all electricity the microturbines produce, install a heat-recovery module to capture the waste heat, and provide the methane fuel for the microturbines. In addition, the City will purchase the entire microturbine system in coming years at a reduced price. A key benefit of the agreement: the City reaps the financial and societal benefits of producing green/ renewable energy. For every megawatt of renewable energy the microturbines create, the Sheboygan Regional Wastewater Treatment Plant receives one Renewable Energy Credit, which the plant can then sell and earn money. The project got the go-ahead in December 2005 and the 10 Capstone C30 microturbines were installed and running in February 2006. Microturbines Produce Electricity & Heat Today, the 10 clean-burning microturbines have a dual purpose: they generate up to 300kW of electrical power (2,300MW per year) and produce waste heat that maintains the proper 95°F temperature in the digesters. The waste heat also is used to heat the plant buildings in the winter. The microturbines can recover 1 million BTUs of heat per hour, or about 73,000 therms per year – enough heat to keep 60 Sheboygan homes warm each year. “In 2007, the system produced 1,681 megawatts of electricity valued at US$121,000, and 61,000 therms of biogas valued at nearly US$57,000,” Doerr said. The result is a significant energy savings for the City of Sheboygan and the use of a clean, renewable-energy source to provide electricity that otherwise would be generated at the coal-fueled power plant nearby. In 2007, the wastewater treatment plant also sold 2,076 Renewable Energy Credits for US$6,540 because of the green energy the microturbines produced. In total in 2007, the plant received more than US$33,600 in revenues thanks to energy the Capstone microturbines produced. “I think outside the box,” Doerr said “My electricity bill isn’t any higher today than it was five years ago. But utility rates are up 105 percent on average. This CHP system with microturbines is the answer to helping the environment and keeping costs down.” Innovative Agreement with Alliant Principals Dave Broihahn and Jan Scott from Unison Solutions, Capstone’s distributor in the Midwest, are former Alliant executives who have developed systems for wastewater treatment plants and other facilities throughout the Midwest. Working together, Unison and Alliant came up with an out-of-the-box proposal for the City – Alliant would purchase 10 C30 (30kW) microturbines from Capstone Turbine, pay for electrical 21211 Nordhoff Street • Chatsworth • CA • 91311 • 866.422.7786 • 818.734.5300 • www.capstoneturbine.com ©2009 Capstone Turbine Corporation. P1112 Case Study CAP381PDF Image | Government/Municipal Sheboygan Wastewater Plant
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