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• Reciprocating engine CHP systems in the 300 kW to 1 MW size range typically cost between $2,500/kW and $4,000/kW. Larger engine systems over 1 MW in size tend to range from $2,000/kW to $3,000/kW.31 • Combustion turbine CHP systems are generally the least expensive option on a per-kW basis, ranging between $1,800/kW and $2,800/kW.32 • In general, fuel cell systems are the highest cost option, at $5,000/kW to $6,000/kW, even for large gensets greater than 1 MW.33 Using the cost data points shown in Table 10, the analysis developed size ranges and costs for the different prime movers for use in the cost-to-generate estimates. Specifications for the prime movers, such as maintenance costs, efficiencies, and system availability (used to estimate down time), were also estimated based on manufacturer data. The results are presented in Table 11. Table 11: Prime Mover Price and Performance Specifications for Use in Economic Potential Model Prime Mover Min Size (kW) Max Size (kW) Modeled Installed Cost ($/kW) Maintenance ($/kWh)* Thermal Output (Btu/kWh) Electric Efficiency (%) CHP Efficiency (%) Small RichBurn 30 Engine Microturbine 30 RichBurn 100 Engine Fuel Cell 200 Small Lean 300 Burn Engine LeanBurn 1,000 Engine 100 4,500 250 4,000 300 3,600 2,000 5,500 900 3,200 4,800 2,500 0.03 5,800 28 76 0.025 3,900 26 55 0.025 5,500 29 76 0.03 2,700 42 76 0.02 4,000 32 71 0.016 3,400 38 75 Combustion 4,000 Turbine Note: All equipment and maintenance costs include gas pretreatment. Electric and CHP efficiencies are based on HHV of the digester gas supplied. * Maintenance costs for WWTFs using CHP can vary considerably. During the interviews of WWTF operators with CHP installations (see Section 5), it was found that some facilities have maintenance costs as high as 7 cents per kWh, primarily due to excessive contaminants in the digester gas leading to very high fuel treatment costs. Other sites were able to keep maintenance costs down due to cleaner digester gas and ideal maintenance strategies. As a result, the maintenance costs in Table 11 should be seen as estimates and are not intended to indicate what any individual site will experience. The analysis used the CHP prime mover price and performance specification data in Table 11 and the thermal energy requirement for anaerobic digesters data in Table 9 to develop cost-to generate estimates for CHP at WWTFs. Tables 12 through 14 present the cost-to-generate estimates for the three digester gas utilization cases: • Table 12 presents the cost-to-generate results for Case 1. This case assumes the site uses digester gas in its boiler to provide digester and space heating prior to CHP; therefore, no 31 Some smaller rich-burn engine systems have been employed at smaller WWTFs, but they tend to be costly and do not offer the benefits of lean-burn technology in this smaller (under 300 kW) size. Rich-burn engines tend to produce more emissions and have lower electric efficiencies than their lean-burn counterparts, so deployment of rich-burn engines has declined in recent years as lean-burn engines have been produced at increasingly smaller sizes. 32 Combustion turbines are mostly limited to WWTF applications 4 MW or larger in size. 33 Some states (e.g., Connecticut) offer incentives for fuel cell installations, which can help lower costs. 20 16,000 2,100 0.012 3,900 35 75PDF Image | Combined Heat and Power at Wastewater Treatment Facilities
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