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product. In addition, the WWTF has also now installed two utility-grade sub-meters to more definitively document the net power generation and net purchased power. Results To date, all aspects of the cogeneration system have operated as well or better than anticipated, with the exception of the methane compressors (These are the compressors that raise the 0.5 pounds per square inch (psi) methane to 100 psi prior to drying and combustion in the microturbines.). Over the first year of operation, the system achieved 90% reliability. While actual maintenance costs for the siloxane removal system (filter media, etc.) are lower than anticipated, the compressor maintenance cost is presently anticipated to be higher. The presence of moisture in the compressors has been the single largest reason for equipment downtime and failure to date. An effective strategy for moisture removal from methane and keeping moisture out of the methane compressors is key to successful system operation and maximizing system run time. When a compressor is not working, the down time has a direct impact on the daily electrical generation and subsequent facility cost savings. Table 1 provides information on the power demand from the electric utility after startup of the 60kW of microturbines. One item of interest is that the facility power factor decreased since installation of the microturbines. Facility personnel are working to pinpoint the cause and ensure that plant-wide power factors remain above 90% to avoid power factor penalty fees from the electric utility. Table 2 compares pre- installation cost estimates and post-installation actual costs. Table 1: Facility Power Information Before and After System Installation Before (Oct 2002 – Sept 2003) After (Oct 2003 – Sept 2004) On Peak Demand Off Peak Demand Monthly Avg. Usage Power Factor 134-235 kW 130-226 kW 166,000 kWh 90 118-215 kW3 94-226 kW4 64,000 kWh 89 3 Oct 2003 value is 215 kW. With out start up month 203 kW is maximum 4 Oct 2003 value is 226 kW. With out start up month 190 kW is maximumPDF Image | Turning Methane into Money: Cost-Effective Methane Co-Generation Using Microturbines at a Small, Rural Wastewater Plant
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