Pepsi, College Point - CHP Fact Sheet - CDH Energy Corp.

Combined heat and power forFood ProcessingDG/CHP ProgramPepsi Bottling CompanyEngines Produce Low Pressure SteamProject ProfileOverviewThe Pepsi-Cola Bottling Company of New Yorkoperates a production facility in College Point. Thefacility operates five to six days per week for up to 22hours per day. The electric demand can approach 2MW in summer when production peaks. Steamconsumption follows a similar trend.Quick FactsLocation:College Point, NY (Con Ed)Installation Date:Spring 2005Operating Experience:6.5 years (as of 2011)CHP Equipment:Four 365 kW IC EnginesGenerating Capacity:1,460 kWFour 365 kW engine-generator sets were installed at thefacility and supply as much as 90% of the site’selectricity. Heat from the engine coolant jackets andexhaust is recovered as low-pressure steam that directlydisplaces load from an existing boiler plant.The ApplicationBeverage plants consume considerable energyprocessing raw materials and handling finishedproducts; Electricity is consumed by various pumps,compressors, lights, conveyors and other devices. Hotwater and steam is consumed cleaning and sterilizingproduction equipment and product containers. Bottlesand cans are typically heated after being filled toprevent condensation from forming on the containersurface; this is a necessity prior to labeling.Heat Recovery Application:Low Pressure Steam (15 psig)Design CHP Efficiency:>82% HHVType of Fuel:Natural GasAnnual Utility Savings:$300,000 per year (estimated)This simultaneous demand for heat and electricity makecarbonated drink plants ideal candidates for CHPtechnology. Reciprocating engine-generators are agood match to these facilities for several reasons.Electrical loads are generally not excessive (< ~2 MW)and can be carried by a moderately sized generator(s).Thermal demands usually dominate site requirementsthough at a ratio favoring an engine’s performancecharacteristics and the output of heat as hot water orlow-pressure steam.Simple Payback:7.3 years (estimated)Containerized Engine and Auxiliaries

CHP System and EquipmentThe CHP system at the Pepsi plant was configured on four natural gas fired enginegeneratorsets. Pre-assembling the generators and electrical components in containers thatwere shipped to site where the remaining equipment was added, minimized installationcosts. Automatic controls sequence the operation of each generator and modulate theelectrical output to follow the site load. No power is exported to the grid. Waste heat fromthe engine exhaust is used to produce low-pressure steam in a pair of heat recovery steamgenerators (HRSG). A limited amount of heat is also recovered from the engine coolant ashot water. Any excess heat is rejected to atmosphere through external radiators mounted ontop of each container.Natural Gas SupplyEngine 1(365 kW)Engine 2(365 kW)Engine 3(365 kW)Engine 4(365 kW)Heat RecoveryBoilerHeat RecoveryBoilerEconomics and Environmental BenefitsProcessSteamLoadsLow PressureSteam LoopCondensateReturnHourly data have been collected from the site by ConEdison Solutions and are available onNYSERDA’s DG/CHP web site starting from October 2007. Preliminary results from thesite indicate the consumption of electricity from the grid has been reduced by approximately400,000 kWh per month. The peak output from the generators has averaged 1,360 kW.Annual savings are expected to exceed $300,000 and should yield payback on the systemwithin eight years. The CHP system’s greater efficiency compared to the use of the plant’sconventional utilities should help to substantially reduce emissions of carbon dioxide aswell as other pollutants and greenhouse gases.“Producing steamfrom the enginesseemed radical, buthasn’t had animpact on thesystem’sreliabily.”~ AnonymousWeb Linksand FurtherInformation:ConEdisonSolutions –Developer/Engineerwww.conedsolutions.comEquipmentSupplierwww.kraftpower.comOtherDG/CHPResourceschp.nyserda.orgInstalled Generator ModulesSummary of BenefitsDetail of a Typical Radiator and SilencerPre-assembled modules reduced cost of installation and minimized site workExhaust heat recovered as low pressure steamCost savings should exceed $25,000 per monthPrepared for NYSERDA by:CDH Energy Corp.Cazenovia, NY 13035315-655-1063www.cdhenergy.comdgchp_data@cdhenergy.com