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Hybrid Technologies for On-site Power Generation
Texas AFRED R&D ConferenceAustin, TX September 12, 2007
Larry OsgoodConsulting SolutionsPERC Consultant &DG Program Manager
TX AFRED Hybrid Generating Systems Presentation Overview
•Basis of work PERC R&D and DG programs
•Why Rural & Remote Power Generation is important
•Hybrid system rationale
•Market entry challenges and approach
•Hybrid optimization
•CHP power units
•Plans to move forward
PERC Research & Development
To invest in new technologies and to foster industry practices that will:
•Bring innovative products and services to propane customers, •Improve the productivity and economic vitality of the propane industry, and •Provide greater value to propane consumers.
www.propanecouncil.org/rd
PERC Distributed Generation Program
•Fuel cells•Micro-turbines •Engine generator sets• Standard• Hybrid (solar, wind, . . .)• CHP• Micro-CHP
www.propanecouncil.org/rd/distr_power_gen.html
Propane 5 kW heavy-duty charging system
Why Rural & Remote Power Generation is Important
• Costs for electric lines average $55,000 per mile in US + power plants & transmission lines
• Electric power is essential for communications, radar, security, education and more
• Recent disasters proved value of DG andpropane fuel supplies
• A propane genset can be effective for standby power anywhere in the world
• But the key issue is, does propane make sense as an on-site power fuel
DG Market Challenges & Strategies
Direct power generation has high costs. If it was easy, it would already be done.
Our strategies to succeed in DG markets:
• Increase performance of engines, lower costs
• Utilize CHP to recover heat and lower costs
• Utilize on-grid systems where incentives available
• Backup power w/ peak-shaving capability
• Gas Heat Pump w/ backup power
• Advanced propane gensets/CHP in solar/wind hybrid systems for affordable off-grid electricity
Why Use Propane/LPG for Local Heating, Cooking and DG Fuel?
•Easily transportable•High energy density, liquid form•Easily stored on site•Can be stored underground•Not a ground contaminant•Self pressurizing gas, no pumps•Clean burning•Efficient•Substantial supplies•Readily available
Fuel-Generated Power is Expensive
•Continuous fuel-generated power?
•Fine for limited uses, such as an RV & back-up power
•Not cost effective for most prime power
•Operating costs are high
•CHP & Hybrid systems lower capital and operating costs
Diagram of a Hybrid Power System
Sunwize Hybrid Solar/Propane Power System
Polar Power Small Hybrid Solar/Propane Power System
Polar Power Mid-size Hybrid Solar/Propane Power System
Hybrid Renewable Systems Have Significant Advantages
• Hybrid = distributed electrical generation combining 2 or more power sources
• Produce electricity on site, where power lines are not available or practical
• Provide power on-site in a cost-effective and environmentally friendly manner
• Hybrid systems are optimal for rural, remote, and developing country applications
Propane Makes Small Renewable Hybrid Power Systems Perform
•Solar photovoltaic (PV) panels•Small wind turbines•Micro-hydro (water) turbines
All the above are “renewable” but are not reliable due to intermittency
Propane gensets provide instant, reliable power
Propane provides renewables with solid on-site performance
Large Renewables Have Significant Drawbacks for State RPS Programs
•High initial costs•Reliability and site issues can be difficult•Require significant power transmission systems
Global GHG Emissions by Sector
8%
14%
24%
14%
5%
3%14%
18%
Important to have higher efficiency and lower CO2 power generating systems
Summary of PERC DG 2007-8 Program Objectives to Move Hybrids Forward
Focus: Bring Propane Hybrid Systems to Market
• Work with engine and generator mfgs. to develop superior propane engines & gensets
• Work with power-electronics suppliers to improve performance & system controllers
• Build relationships w/ other stakeholders including system manufacturers, installers, renewable industry, users & ww agencies
• Present PERC accomplishments and new systems in papers at DG conferences
Early Hybrid System
Fuel Cells in DG / Hybrids ?? No.
Fuel Cell System Performance?- Lower efficiency- Higher cost- Higher maintenance- Shorter life
Biggest issue:Can’t start and stopon demand
Advanced Heavy-duty 2.5 – 5 kW Propane Engine & Genset
Lombardini HD LPG Engine
HD Diesel Based2 cylinder
Factory LPG
Liquid Cooled
3 main bearings
Overhead Valves
Continuous duty
Small Propane & Diesel Gensets Compared (1 – 10 kW)
GensetItem
Standard Propane
Diesel H.D.Advanced Propane
Light Load OK Wet stack? Fine
½ - Load Efficiency
13 – 16 % 17 – 18 % 20 – 26%
Full - Load Efficiency
18 – 20 % 20 – 22 % 24 – 31 %
Continuous Duty
Must de-rate Must de-rate 24-hour capable
Maintenance Interval
100 – 200 hours
100 – 200 hours
2,500 -10,000 hours
Service Life of Genset
1,000 – 5,000 hours
2,000 – 8,000 hours
30,000-60,000 hours
Current Rural Hybrid System
Propane genset is in white box
Grey box is new Xantrexhybrid system controller with inverters
New Xantrex Hybrid System Controller
New SMA “Sunny Island” Inverter
High overload and Surge capacity
Automatic generator starting
DC & AC coupling built in
Output load shedding!
Gaia Advanced Hybrid System Controller w/ Large-capacity Battery Storage
Cost Advantages w/ Hybrid System
Gensets have a lowinitial cost, buthigh O&M costs
Renewables have high initial costs with low O&M costs
The right combination of renewables and propane genset provides the lowest system cost, and highest reliability
Initial CostOperating
Cost
+
Actual Output from HOMER Optimization Model
http://www.nrel.gov/homer
HOMER is a computer model that simplifies the task of evaluating design options for both off-grid and grid-connected power systems for remote, stand-alone, and distributed generation (DG) applications. In 2001, identified hybrid systems optimal over solar only. Includes a web link to site specific solar data.
Sample Hybrid System Costs
Propane genset onlySolar system onlyCurrent hybrid
Higher cost genset, no optimization, subsidies, or cost savings for no pole & wire
Optimized hybrid sitew/CHP
$1.58 per kW$ .95 per kW$ .72 per kW
$ .20 - .40 per kW
CHP System Advantages
• Regular gensets produce electricity – don’t utilize “waste-heat”
• CHP systems start with advanced propane engines w/ 50% better efficiency
• 2-3 units of heat energy for every unit of electrical energy produced
• CHP systems typically twice as efficient as central electrical production
• Lower energy cost and CO2 output
New Honda 1.2 kW m-CHP System
• UL listed propane system• PERC home demo in MA• Target home heating
market• Provides heat and
electricity• Can provide all home
electricity needs• Replace conventional
furnaces• Jointly developing off-
grid& back-up system(adding storage)
1.2kW m-CHP 1-cyl Liquid-cooled Genset Module
New 5kW CHP System
Marathon HD Power Generators in a Hybrid Residential System
• Minotaur 2.5 & 5 kW gensets available now
• Full time, prime power, high efficiency systems
• 5 kW ecopower CHP UL listed and available now
• ecoisland developed, UL listing target is early 2008
• Distribution network in development
Testing for Yanmar 5 kW CHP System
• Testing at GTI is complete• Picture is 5 kW propane unit in test cell• Results excellent• Net output: 4.64 kW• Elec. Efficiency: 26.3% LHV, highest system efficiency tested to date•Noise extremely low: 51 dB
Items CP10VB1
Rated output kW 9.9
Phase / voltage V Single / AC 100/200
Grid connecting system - Inverter
Heat recovery kW 16.8
Efficiency
Generating efficiency
% (LHV) 31.5
Heat recovery rate
% (LHV) 53.5
Overall efficiency
% (LHV) 85.0
Dimensions W x D x H mm 1470x800x1790
Engine - 4 cycle gas engine*
Generator - Permanent magnet
Net weight kg 790
Operating sound level dB(A) 54
Maintenance interval hours 10,000
9.9kW Advanced CHP System Specs
Rationale for Hybrid Market Opportunity
• Electric power is increasingly needed to improve the quality of life around the world
• Power needs at remote sites are increasing
• Remote Power costs are extremely high
• Renewable power emphasis is increasing
• Emphasis on lowering CO2 emissions is “huge”
• DG is a lead item in future market development potential and gallons
How Do Hybrid Systems and Propane Support the On-Site Power Market
• Propane is a reliable & clean fuel for power generation
• New propane small genset technology leapfrogs diesel as the premium fuel in efficiency, maintenance and longevity
• Hybrid systems generate power more efficiently and for lower cost than other alternatives
• Propane hybrids maximize the performance of renwables for sustainability into the future
For More Information Contact
Larry OsgoodDistributed Generation Program [email protected]
Greg KerrDirector of Research and [email protected]
Hybrid System Fact Sheet and more at:www.propanecouncil.org/rd