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system would be at least as “clean” as existed before installation of the system. The basic plan for the system was to combust collected methane in a microturbine to generate electricity. The waste heat from the combustion would then be used to provide process heat to the anaerobic digesters. The 18-year old dual-fuel boiler currently used for process heat would be kept as a backup heating source. Figure 2 shows the system process. Figure 2: Essex Junction Methane-Fueled Cogeneration Preliminary Design Process Diagram Wastewater Plant Anaerobic Digester (Methane Produced) Heat Exchanger (liquid-to-liquid) existing Methane Cool Water Methane Methane Compressor, then Dryer Cool Warm Sludge Sludge Hot Water Existing Heat Exchanger (Air-to-liquid) Microturbine (Combustion of Methane) Exhaust Hot Gas Water (~522oF) Exhaust Gas (~135oF) Electricity Existing Boiler (for backup heat via direct flare of methane) Storage Tank (1,000 gal) During initial investigations, it became clear that methane-fueled cogeneration at a facility the size of Essex Junction was not typical. In fact, no such system existed in New England. The closest, similar facility was in Lewiston, NY. During conversations with Lewiston plant personnel, and a site visit to the Lewiston facility, a variety of “lessons learned” were discussed and incorporated into initial design work. In particular, the issue of siloxanes was raised. Siloxanes are silica-based compounds, typically found in shampoo, which can glassify when subjected to high temperatures. Glassified materials can reduce the effectiveness of heat exchangers, and can create imbalance in microturbines, potentially causing failure. It was determined that a siloxane removal strategy would need to be part of any cogeneration system. As knowledge grew regarding all the required elements for a successful cogeneration project, the estimated initial capital cost grew. In order to meet the 7-year payback requirement from the water board, it became critical to identify additional funding sources and leverage outside resources. The local electric utility was supportive of the project since reduced demand from the WWTF would assist in a transmission and distribution (T&D) constrained area. Unfortunately, there was no funding available from them. Efficiency Vermont was able to commit funding to the project, and help with economic and savings analyses. Efficiency Vermont also helped to “spread the word” about the project, soliciting additional support for it. Ultimately, a project team was put together with 5 different funding sources; a creative solution that made this project a reality.PDF Image | Turning Methane into Money: Cost-Effective Methane Co-Generation Using Microturbines at a Small, Rural Wastewater Plant
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