Eastman Chemical Company’s Kingsport, Tennessee, Campus plant (pictured) was recognised for its 200 MW CHP system, which includes 17 GE steam turbine generators. The Kingsport industrial campus, one of the largest chemical manufacturing sites in North America, employs nearly 7000 people and manufactures chemicals, fibres, and plastics.
Seventeen boilers produce steam to support manufacturing processes, help meet the space heating/cooling needs of 550 buildings, and drive 17 GE and two ABB steam turbine generators with a combined design output of 200 MW. With an operating efficiency of more than 78%, the predominantly coal-fired system requires approximately 14% less fuel than grid-supplied electricity and conventional steam production, saving Eastman Chemical approximately US$45 million per year.
Janssen Research & Development, LLC, one of the Janssen Pharmaceutical Companies of Johnson & Johnson, was granted an award for its 3.8 MW CHP system, powered by a Caterpillar lean-burn low-emissions reciprocating natural gas generator set. The system supplies 60% of the annual power needs for the site and approximately 40% of the thermal energy used to support R&D operations and heat, cool, and dehumidify the facility's buildings.
With an operating efficiency of more than 62%, the system requires approximately 29% less fuel than grid-supplied electricity and conventional steam production, saving approximately $1.1 million per year.
Merck’s CoGen3 CHP system at its West Point facility was also recognised by the EPA. A pharmaceutical and vaccine manufacturing, R&D and warehouse and distribution centre, the project is powered by a 38 MW GE 6B heavy-duty gas turbine and recovers heat to produce steam to heat, cool and dehumidify approximately 7 million square feet of manufacturing, laboratory and office space.
The system, designed by Burns & Roe, is the third CHP system that Merck has installed at the 400-acre West Point, Pennsylvania campus. With an operating efficiency of more than 75%, the natural gas-fired system requires approximately 30% less fuel than grid-supplied electricity and conventional steam production.