Building 65 Pellet Fired Steam Plant Bar Harbor, ME By Norm Burdzel, PE Facilities Engineer, The Jackson Laboratory Tony Davis, PE Mechanical Engineer, Allied Engineering
JAX Oil Load, 1.6M GPY 14000 12000 10000 8000 6000 4000 2000 0 30-Nov 19-Nov 8-Nov 28-Oct 17-Oct 6-Oct 25-Sep 14-Sep 3-Sep 23-Aug 12-Aug 1-Aug 21-Jul 10-Jul 29-Jun 18-Jun 7-Jun 27-May 16-May 5-May 24-Apr 13-Apr Daily Usage (gallons) 0/02/04 22-Mar 11-Mar 29-Feb 18-Feb 7-Feb 27-Jan 16-Jan 5-Jan 25-Dec 14-Dec 3-Dec Date 2004-2005 2005-2006
JAX Steam Demand 70000 60000 50000 40000 PPH 30000 20000 Campus PPH Pellet 40,000 max PPH 10000 0-10000 0 2000 4000 6000 8000 10000 Hour
Project Options, IWF International Wood Fuels initial proposal. We build it, sell you steam, you own it in 10 years. Grate fired technology Grate firing never tested with pellets Potential slow reaction to JAX steam loads Efficiency Ash handling Maintenance Only 10% less than the cost of oil Single fuel only 800-1000 HP
Project Options: Pizzagalli Powdered/pulverized technology Proven in Sweden Quick reaction to JAX steam loads Efficiency similar to Gas and Oil Simplified ash handling Fixed price pellet contract for 5 years. Guaranteed pellet quality Maine suppliers Pellet cost less much less than oil 6:1 turn down 1200 HP, Future Tri fuel
Efficiency Maine/DOE Grant ARRA dollars Only for shovel ready projects $1 million awarded Based on Carbon Reduction/Carbon Neutral Technologies 10,000 tons of pellets per year. Reduce campus CO 2 emissions by 13,430 short tons annually (80% reduction), (134,300 short tons over a 10-year period) Trigger an Environmental Assessment Found to have no significant impact
Project Highlights Guaranteed Maximum Price design build contract Project cost of $4.5 Million without Grant Project payback of 5-6 years with oil at $2.25/gallon modeled with a 3% escalation over 10 years Petrokraft Swedish technology Efficiency of 84%+, Complete Combustion Ash to dumpster 300 PSI for future turbine Meet all emissions targets with Bag House, no ESP required. Pellets with oil for ignition purposes only.
Project Highlights - Turbine Efficiency Maine Grant received for 600 kw Turbine. Grant value 50% of $730,000 Turbosteam chosen as the equipment vendor Simple payback of 2.5 years with Grant Reduce campus electrical energy load by 8-9% Cost of electricity $0.03/kWh
Project Schematic
Project Schematic
Project Successes Pellet cost of $175/Ton delivered, equal to oil at about $1.75/Gallon Fixed Pellet contract for 5 years. Cost of $200/Ton at year 5. Saved $1.4-$1.5 Mil to date over oil Has provided 75% of the steam to campus Pellet unloading and delivery is reliable and efficient. Maine based businesses and Vendors Ash disposal for fertilizer use at no cost. Efficiency confirmed 84% @ 85 PSI steam production Met air emissions targets Trending and logging through BMS Complete Combustion
Project Difficulties/Challenges Pellet consistency/variability Powder production consistency (frequent mill adjustments) Ash build up in vessel, requires 60 day clean out/vacuum service. Frequent soot blow down to remove ash Recommend automated system Efficiency not confirmed at 300 PSI, Max output obtained is 35,000 PPH (steam meter) Additional Operator on staff required Burner reliability on firing with two burners. Highly recommend consideration of one burner per vessel with this technology. Flame scanners Powder delivery complexity Flame outs due to opposite burner influence
Project Equipment Reliability Bag house bag failure and housing corrosion, warranty repair Powder filter bag bridging, bags replaced Rotary valve on baghouse replaced twice. Final version with graphite vanes solved noise issue and has been reliable. warranty repair Pellet conveyors of HMWP shells are worn through and currently under replacement warranty Steam meter unreliable. Currently using feedwater meter. Recommend bag house bypass for soot blowing. Tuning complex. Petrokraft technicians currently on site for 7-14 days per month. Highly recommend oil service brought to burner for mix firing when required and powder quality issues arise. Turbine punch list and support from vendor.
Project Photos General Site
Project Photos Fuel Unloading and Ash
Pellet Delivery
Project Photos Emissions Controls Bag House Leak Detection System Employed
Project Photos Mill Room Pellet Unloading Compressor, 200 HP Hammer Mills
Project Photos Mill Room
Project Photos Burners Petro Demo Burner, Jax Burners, Controls Panels and Conveyor
Project Photos Boiler, Economizer and Deaerator
Project Photos, Controls
Project Controls
Project Controls
Project Control Room
Project Photos Turbine
Project Design, Tony Davis
Questions? norm.burdzel@jax.org 207-288-6142