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Cogeneration at Roche, Nutley, New Jersey
Climate Leaders Partners Meeting
Chicago, Illinois
October 7, 2008
Roche’s Climate Leaders Activities
• Original Goal:
– 10% GHG Reduction by 2008 vs. 2001 (Absolute)
– Achieved 10.8% Reduction by 2006
• Second Goal:
– 15% GHG Reduction by 2010 vs. 2001 (Absolute)
– Achieved 11.6% Reduction by 2007
Why Cogeneration at Nutley?
• Need to reduce and control energy costs
• Corporate commitment to sustainability
• Good fit to electric and steam loads
• Strong internal technical resources
Original Cogeneration Plant
(mid 1980’s)
• (3) Turbines @ 3.8
MW each
• 4th Engine for Spare
• Gas Compressor
• Base Loaded
• Steaming Range: 90-
135klb/hr (Constant
Duct Firing)
The Early Years
(mid-1980’s to mid-1990’s)
• Reliable Engine Performance
• Reduced Operating Costs
• Need to Run Duct Burners for CO Control
• Gas Compressor Headaches
• New High Pressure Gas Service
• Orphaned Engines
The Honeymoon Ends
(late 1990’s)
• Reduction in Plant Loads (especially summer steam)
• Steam Venting
• SUT, Exit Fees and Other Attacks
• Engine Problems…………..
ORIGINAL ENGINES NEAR RETIREMENT
•OLDER ENGINES
•POOR AVAILABILITY
•HIGH MAINTENANCE COSTS
AVAILABILITY BELOW BENCHMARKS MAINTENANCE COSTS ABOVE
BENCHMARKS
100.0% $0.0250
95.0% $0.0200
Availability
90.0% $0.0150
$/kWh
85.0% $0.0100
80.0% $0.0050
75.0% $-
E
0
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E
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S
LS
0
60
S
H
LS
M
M
50
ER
YC
50
YC
UG
ER
UG
O
O
US
IL
IL
US
TR
TR
LM
LM
EY
RO
EY
RO
O
O
M
M
UR
UR
PL
PL
LS
LS
M
M
EN
HE
EN
HE
S
S
TA
TA
L
/A
LL
LL
/A
L
NG
NG
LD
LD
C
C
TO
TO
BB
BB
RO
RO
RO
RO
R
R
RI
RI
A
A
IS
LA
IS
LA
HE
A
A
HE
M
M
BR
BR
SO
SO
SC
SC
To Cogenerate or Not to Cogenerate
(The Multi-Million Dollar Question)
• Original Plant was Approaching Economic
Obsolescence
• Modernizing Required Large Capital Investment
• After Extensive Analysis…No Better Way to Reduce
Energy, Carbon and Dollars
• Decision in 2002 to Repower
Repowering Project
• Shutdown 12/03
• 2 New Turbine-Gen Sets
• 5.2 MW Each
• Kept Old Exhaust Train
• Restart 5/04
Cogeneration Today
• High Availability
• Service Contract/Engine Overhaul
• Black Start/Island Mode Capable
• Inlet Air Cooling
• Ease of Operation
• New Absorption Chillers
• Optional Duct Burning
• Electrical Load Following
• Impacts to Energy Procurement
Cogeneration:
What It Takes To Win
• Careful Feasibility Assessment
• Long-Term Commitment
• Management Focus
• Attention to Detail
• Regulatory/Legislative Alertness
• Market Attention
Not for Casual Players
Cogeneration’s Big Payoff
• Reduced Operating Costs
• Better Budget Control
• Greater Energy Efficiency
• Improved Reliability
• Decreased Greenhouse Gas Emissions
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