Fuel Switching For A Small Boiler Operator Using

1
Fuel Switching For A Small Boiler Operator Using
6 Fuel Oil On An Interruptible Natural Gas Supply

• James H. Connolly, P.E.
• Hoffmann-La Roche Inc.

2
Scope Of Main Energy Operations

• 2 Train Cogeneration With Supplemental Fired Heat
  Recovery Steam Generators. Natural Gas Fired, 2
  Fuel Oil Backup. Peak Boiler Capacity
  Approximately 112 MMBTU/hr Including Waste Heat
  From Turbines.
• 4 Boilers, 90 to 186 MMBTU/hr Each.

3
Energy Center Operation

• Summertime Cogeneration With One Boiler In Low
  Fire Swing Mode.
• Wintertime 4 Boilers Carried Site Through Winter
  2003 2004 Without Cogeneration During
  Cogeneration Repowering. Largest Boiler
  Essentially Used Exclusively During Winter
  Months.

4
5 Year Boiler Energy Profile

• Based On Gross BTUs
• Average 77 Natural Gas, 23 Oil
• Peak Oil Use 50 Natural Gas, 50 Oil
• Low Oil Use 99.5 Natural Gas, 0.5 Oil
• Using Current Energy Demand, Operational Ability
  Is 100 On Either Fuel For Boiler Operations (Not
  The Case When Permitted In 1990s).

5
6 Fuel Oil Use Vs. Allowable

• Permit Limit For The Entire Boilerhouse 4,233,000
  Gallons Per Year (Smallest Boiler Can Burn gt600
  GPH).
• Peak Oil Use 2000 2004 1,126,300 Gallons.
• Oil Use Occurs Chiefly When Temperatures Drop
  Below 20 Degrees F.

6
Emission Reduction Basis

• SO2 NJAC 727-9.2 Table 1, Zone 4.
• NOx NJAC 727 19.7 Table 4 and Table 5.
• CO/VOC Assume Unchanged NJAC 727-16.8.
• PM/PM10/PM2.5 Original Basis Assume Unchanged
  Due To Insufficient Data. Refined Basis Worse
  AP-42 Ratios

7
Original Emission Reduction Estimate

• Based On Peak Allowable Fuel Use
• SO2 31.7 TPY
• NOx 32.0 TPY
• (Estimates not adjusted for 8.9 higher gross
  heat value of 6 fuel oil, used permit/historical
  fuel volumes)

8
Refined Emission Reduction Estimate

• Based On Peak Allowable Fuel Use
• SO2 28.9 TPY
• NOx 32.0 TPY
• PM 7.9 TPY
• (Estimates adjusted for 8.9 higher gross heat
  value of 6 fuel oil, used permit/historical fuel
  volumes)

9
Original Emission Reduction Estimate

• Based On Peak Actual Fuel Use During Last 5
  Reporting Years
• SO2 8.4 TPY
• NOx 4.3 TPY
• (Estimates not adjusted for 8.9 higher gross
  heat value of 6 fuel oil, used permit/historical
  fuel volumes)

10
Refined Emission Reduction Estimate

• Based On Peak Actual Fuel Use During Last 5
  Reporting Years
• SO2 7.7 TPY
• NOx 4.3 TPY
• PM 2.1 TPY
• (Estimates adjusted for 8.9 higher gross heat
  value of 6 fuel oil, used permit/historical fuel
  volumes)

11
Burner/Fuel Infrastructure Retrofit Cost Estimate
Submitted To NJDEP

• Based On Peak Allowable Fuel Use
• 35,000/TPY (Corrected) Emission Reduction.
• Based On Peak Actual Fuel Use For Last 5 Years
• 173,000/TPY Emission Reduction.

12
Burner/Fuel Infrastructure Retrofit Cost
(Emission) Estimate Refined

• Based On Peak Allowable Fuel Use
• 33,000/TPY Emission Reduction.
• Based On Peak Actual Fuel Use For Last 5 Years
• 156,000/TPY Emission Reduction.