High Efficiency CoGen System

Lighthouse Utility Solutions, Inc. of Cincinnati, OH, USA (513-708-4420) has developed a new version of the "good, old" CoGeneration package that operates at an annual thermal efficiency of 99%. During warm weather, it operates at over 100% (based on fuel input) because the leaving exhaust will be cooler than the entering combustion air. Impressive since "current" CoGeneration systems typically operate at 65-70% thermal efficiency (60% is the minimum acceptable for Federal grants).

Each MODULAR unit produces 300 kVA of 480 VAC, 3-phase power plus about 2-million BTUH of recoverable heat that makes a combination of high temperature hot water (can be flashed to steam at up to 150 PSIG) and hot water (up to 220F).

Because of the high thermal efficiency, the unit essentially matches or beats a normal steam boiler for thermal efficiency, so the electricity is essentially free. The unit also makes 380,000 gallons of near-potable water from the condensed exhaust.

The equipment can operate on natural or LP gas or an add-on module will vaporize liquid fuels like fuel oil. Additionally, it can also run on RENEWABLE energy inputs like landfill gas, digester methane or vaporized bio-diesel, ethanol or bio-kerosene.

Environmental benefits, beyond renewable fuel use, include 80% reduction in CO2 releases and 95% reduction in NOx, compared to "normal" electricity production and thermal system operations.

The two modules (generator and thermal recovery) are about 90 inches tall, 84 inches wide and 168 inches long. The liquid vaporizer module adds another 60 inches length to the thermal recovery unit. The units are designed to mount on 6" high concrete pads but multiple-unit modules can be installed using a structural framework.

Each standard system costs about $2500 per kVA ($748,500) and qualifies for the current Federal Renewable Energy Grants of 10% of the TOTAL installed cost. Several states also offer some form of tax relief or rebates for further final cost reduction. It typically has a payback of about 2 years or less.

ADDITIONALLY, those systems using renewable bio-mass fuels also qualify for the Federal Renewable Electricity Production Tax Credit that is $0.022 per kWh (that is $57,816 annually PER MODULE) and the credit is in place for 10 years (unused credits can be carried forward for 20 years).