Fall 2001 Issue
Fueling the Future
New Natural Gas Technologies on the Horizon
By Charles Rampey, P.E., CME
We all know that natural gas is a clean-burning, highly efficient fuel used in many manufacturing applications. But new and exciting technological breakthroughs in the use of this fuel may create significant opportunities for manufacturers. Much research is being conducted to discover more about the many applications of natural gas, specifically in the world of manufacturing.
The Industrial Center is a non-profit commercialization and marketing organization representing major natural gas pipelines and distribution companies. Its mission is to accelerate the acceptance of new gas-fueled technologies in industrial applications. The Industrial Center recently awarded a grant to SCMEP to help identify and promote the use of new gas-fueled technology to the South Carolina manufacturing community. Under the grant, SCMEP will become knowledgeable about new technologies that are available and develop an assessment tool to determine the value of implementing new technology to individual manufacturers. Beyond fuel efficiencies and cost savings, SCMEP expects to find other benefits for South Carolina companies.
Initial research under the grant was done in conjunction with the Gas Technology Institute to understand the new technologies that are being developed and introduced to the marketplace. SCMEP discovered several interesting applications that are in various stages of development and commercialization. Some of these new technologies are:
Gas Cooling - Gas cooling takes three basic forms, each suited to specific purposes. All three take advantage of the affordability and clean-burning qualities of natural gas and provide substantial advantages over conventional electric cooling.
- Gas engine-driven chillers work on the same cooling principle as electric chillers; however, instead of an electric motor driving the compressor, a gas-fueled engine does the job. Engine-driven chillers have the advantage of producing heat that can be recovered to heat water or building spaces.
- Absorption chillers, like engine-driven chillers, produce cooling through a cycle of condensation and evaporation. Instead of using a mechanical compressor, an absorption chiller uses a heat source such as a direct flame, steam or hot water to create a high-pressure refrigerant vapor by boiling it out of an absorbent solution. Absorption chillers are extremely clean, highly efficient and simple to operate and maintain.
- Desiccant dehumidification is a proven technology for environments where high humidity causes problems and increases costs for refrigeration systems. In such a system, air passes over a desiccant material that attracts moisture. A gas-fired chiller then cools the drier air. Gas heat regenerates the desiccant by driving off moisture, which is vented to the outside.
Combustion Technology - Several new applications address industrial boilers, process heating needs, waste processing and power generation, and are targeted toward reduced emissions and lower operating costs.
- Oscillating combustion is a simple retrofit solution for industrial furnaces equipped with conventional burners. Not only does it increase heat transfer by 5% to 10%, it reduces NOx emissions by 40% to 70%.
- Infrared (IR) heating with natural gas can optimize the operation of ovens and dryers used in processing paper, plastics, food, textiles and painted products.
- Flat radiant panels are a new technology that can be used in heat-treating furnaces and reheat furnaces. The process virtually eliminates the oxidation that is prevalent in direct flame treatment or in reheat furnaces.
- Forced Internal Recirculation (FIR) burners and Cyclonic burners promote more efficient combustion and reduce NOx emissions.
Distributed Generation - Recent changes in the electric power industry as it moves toward competition have created opportunities for natural gas. Power shortages, rolling blackouts and rising prices in California are the clearest signals of fundamental change in the making. Distributed generation using natural gas-fired generators in manufacturing facilities is gaining favor as a way to address supply issues and shield against seasonal price volatility.
Microturbines - Designed for on-site generation of electricity, microturbines are emerging as an alternate customer choice for certain applications in a deregulated electricity market. These applications include distributed generation, peak shaving, load management, cogeneration and standby power. Their key attributes are low emissions and low maintenance. Advantages include more control of power costs, reliability and power quality.
If you would like more detailed information about any of the technologies mentioned above, or if you have a gas-fired application you would like to have evaluated, please contact Vivian Harper at 803-252-6976 ext. 229 or Charles Rampey at 803-331-9410.
