Blue Box Technology’s BBT 500 – its first commercial product offering – has been specifically designed for use in high heat industries. The system generates a net power output of 500 kW in a self-sustaining cycle. Its only energy source is a parasitic use of waste heat.
In designing the BBT 500 system, Blue Box Technology has been conscious of the need to get past the impediments of developing on-site generation in industrial settings, particularly where the waste heat is not needed to support other processes.
The BBT 500 overcomes the most common problems and hesitations for companies considering waste heat solutions. With a BBT 500, the company benefits as follows:
- Production and processes are left undisturbed
- Gen-set is a standardized module rather than a customized ‘one-off’ system
- Waste heat does not become a reason for being in business
- Secondary need for steam or hot water not required for financial feasibility, etc.
- Operation risks not expanded – no fluids and pumps required
- Financial risks are minimized – no unforeseen installation costs and downtimes
- Low capital cost per kW compared to other options
The BBT 500 meets the needs of cost-conscious, competitive industries. It is a standardized, compact, skid-mounted unit. All the major components are tried and true industrial equipment with long track records of performance. The only customization required for any installation is simply in ducting the flow of waste heat through the BBT 500 skid system.
Blue Box Technology’s proprietary rights for the BBT 500 are process based. They are derived from the intellectual property underlying the integration of the standardized equipment into a power generation technology solution without any need for fossil fuel combustion.
How BBT 500 Works
Blue Box Technology’s BBT 500 system generates a net output of 500 kW of electricity through a continuous heat exchange cycle that drives a net energy gain. As show in the figure below, there are three main ‘off-the-shelf’ components for technological simplicity – compressor, turbine and generator.
In the BBT 500 process, a compressor blows waste heat through a turbine, with the turbine output driving the generator and supporting the electric load to run the compressor.
A comparison with a gas-fired turbine is helpful. Where natural gas is used to create heat for the gas turbine, the BBT 500 simply makes use of existing waste heat to “fuel” the self-sustaining cycle of compressor, turbine and generator. As a formula, the net electricity generation output equals the gross turbine output minus the compressor load. As a rough measure, the turbine output is split one-third to the generator an two-thirds to the compressor.
The uniqueness of Blue Box Technology’s BBT 500 is that it is a non-hazardous process requiring no combustion or heat conditioning. All the major components are connected to the same drive train. Minimal maintenance is required and can be performed during existing plant maintenance schedules.
Blue Box Technology’s BBT 500 is an industrial workhorse for any high heat industry. Besides delivering worry free behind-the-meter power generation, the BBT 500 has the following advantages in any application:
- Capable of displacing more than 4 million kWh of electricity cost per year (500 kW times 8,760 hours a year less maintenance hours)
- Lowers per kW monthly wires capacity / demand tariff
- No ‘gen-set’ customization – stackable 500 kW skid modules
- Small footprint – easy transportation, easy installation
- No fluids, no fluid related engineering and operational issues
- Up to 98% up times reliably achievable – minimal maintenance
- 20-year design life
- Low capital and operating cost per installed kW
- No combustion, no fuel required
Industry / Plant Specific Advantages
Blue Box Technology’s BBT 500 is also able to deliver many additional cost and operational benefits depending on the industry and plant processes. These can include:
- Savings on Cooling Waste Heat – Many companies need to cool their waste heat with water or a brine. The BBT 500’s parasitic use of waste heat returns a lower waste heat temperature at the end of its process. This lowers the volume and cost of water or brine that needs to be procured.
- Savings on Fueling Furnaces – Following BBT 500’s use of waste heat for power generation, the residual waste heat can be channeled to the company’s production or process oven, lowering the cost of fuel for heating the oven. This additional advantage may be eligible for natural gas conservation incentives.
Blue Box Technology’s BBT 500 will work in a wide range of high heat industries, but most certainly in the following:
- Chemicals and petrochemicals
- Foundries, furnaces, heat treating, cement and lime kilns, steel mills
- Glass and insulation
- Ore and mineral processing
Technical Requirements and Feasibility Studies
The technical requirements for Blue Box Technology’s BBT 500 are limited in number. These are generally met in any high heat industry. When these are combined with a few plant specific details, Blue Box Technology can readily produce a technical assessment and financial feasibility study. This preliminarily work would be done at Blue Box Technology’s expense and under a mutual Non-Disclosure Agreement.
The information requirements for the technical assessment and financial feasibility study are as follows:
- Temperature – requires 1200°F (650°C) or higher exhaust heat
- Flow Rate – requires continuous heat flow
- Heat and flow (CFM) technical study
- Simple Plant Process Diagram (for high heat components only)
- Customer cost of electricity – cents / kWh
This minimal degree of information sharing is all that is required to get started. Blue Box Technology can determine the technical feasibility, the financial payback period and the long-term value of the energy savings. The investment payback can be under two years depending on hours of operation and eligibility for incentives.
If a decision is made to proceed, the only remaining technical requirement is a Connection Impact Assessment. This is done in conjunction with your local utility provider. Other requirements may be required to receive approvals for incentives.
Blue Box Technology’s BBT 500 is valuable to the modern energy system and to climate change objectives in many ways. While objectives vary by jurisdiction, the general benefits behind many jurisdictional benefits are met as follows:
- Lowers grid level peak demand
- Lowers company peak demand
- Lowers grid energy consumption
- Lowers company energy consumption
- Supports distributed energy and smart grid objectives
- Supports behind-the-meter (behind-the-fence) generation objectives
- Contributes to lower GHG emissions
- Can lower natural gas consumption in some industrial applications
- Can lower water consumption in some industrial applications
Blue Box Technology would be pleased to discuss with you how your company can take advantage of incentives in your company’s jurisdiction. Please use the Contact Us page to inquire.
In Ontario, Canada, Blue Box Technology’s BBT 500 is eligible for very attractive incentives designed to support energy conservation objectives for both energy (consumption) and capacity (demand). Both are sponsored by the IESO (Independent Electricity System Operator).
Reduced Energy Consumption Incentive
The BBT 500 meets the criteria for Waste Energy Recovery systems under the IESO ‘behind-the-meter’ electricity generation program. This is true for customers connected to LDCs (local distribution companies) under the IESO’s saveONenergy Process and Systems Upgrade Program. It is also the case for the IESO’s Industrial Accelerator Program for industrial direct connect customers (transmission connected).
Under both the saveONenergy and Industrial Accelerator programs, the BBT 500 can be eligible for more than $800,000 in capital incentives per unit.
The capital incentive is based on the lesser of CDN$0.20/kWh ($200/MWh) of annual savings or 70% of project costs. If it were to run 7 x 52 x 24, the BBT 500 system would generate 4,380,000 kWh and be eligible for up to $876,000.
When the capital incentive is added to the energy savings and the wires tariff savings, the payback can be under two years in length.
The capital incentive is provided up front during construction as costs are incurred, but is subject to an initial technical review and to a measurement and verification audit after one year.
The saveONenergy specific program incentive details can be found here:
The Industrial Accelerator specific program incentive details can be found here:
Engineering study incentives are available up to $50,000, where required and approved by the LDC or the IESO. The engineering study incentive is deducted from above financial incentive.
Reduced Energy Demand Incentive
The IESO’s Industrial Conservation Incentive or ICI is an incentive program tailored to commercial and industrial customers. All customers with a peak demand above 1 MW (1,000 kW) are eligible. Certain manufacturing and greenhouses customers greater than 500 kW are also eligible.
ICI registered customers benefit when they lower their company peak demand on specific high system peak demand days. To the degree the company contributes to lowering the system peak, the company benefits by lowering its Ontario’s Global Adjustment payments throughout the year. Please see the program details in the link below for specific terms.
The BBT 500 system, by generating 500 kW behind-the-meter, can make a significant contribution to lowering a company’s Global Adjustment charge throughout the entire year. Where this is the case, the savings on the Global Adjustment payments accelerate the payback period for the BBT 500.
Please use the Contact Us page to inquire. We will be happy to explore the incentive possibilities in your jurisdiction with you.