A1 Energy - Blog #chpA1 Energy - Blog #chphttps://www.a1energy.net/blogs/tag/chpTue, 31 Mar 2026 12:43:54 -0700http://zoho.com/sites/<![CDATA[Overview of CHP (Combined Heat & Power)]]>https://www.a1energy.net/blogs/post/Overview-of-CHP-Combined-Heat-PowerPut simply, CHP is using a single fuel source i.e. natural gas to generate electricity. The result is improved fuel efficiency compared to pulling electric]]>
combined heat & power system


Finding cost-effective, sustainable energy is more than just a buzzword, and CHP may deliver the answer. Combined heat and power systems use a single fuel source to provide heat and electricity for a building, typically facilities with a consistent, ongoing thermal load.


CHP Systems:

  • Have 70%-80% efficient systems compared to 50% for standard systems
  • Meet sustainability goals
  • Provide reliable onsite energy generation
  • Reduce emissions and energy costs

What is CHP or Cogeneration?

Cogeneration systems reclaim excess heat from electric power generation. The most common fuel source is natural gas, although diesel, coal, and biomass may be used, too. Some systems can harvest geothermal or nuclear power. The systems are designed to capture the byproduct heat, usually steam, and use it within the host site's facility.

Additionally, newer CHP systems provide power back-ups in the event of an outage, ever more critical as the grid becomes more unreliable.

CHP process A1 Energy

Cost-Effectiveness of CHP Systems

As businesses and governments seek energy efficient technology, and with the current price of oil burgeoning, finding energy sources that are both cheaper and more sustainable can help emerging markets grow. In fact, the Department of Energy conducted a study that identified several market conditions currently contributing to CHP growth:

  • Lower energy operating costs
  • Resiliency initiatives
  • CHP-friendly market regulations
  • Utility support
  • Federal and state policies and incentives
  • Project replaceability

Plus, as we mentioned above, cogeneration power systems reduce the strain on the electric power grid. One needs only to look at the state of the Texas power grid during an unexpected snowstorm in February of 2020 to see how easily a power grid can be overwhelmed. Opting for CHP systems instead of separate heating and electrical systems can ease that burden nationwide.

CHP systems have lower greenhouse gas and other harmful emissions and may be a viable option for developing new transmission and distribution infrastructure for clean energy.

DOE Analysis of CHP Systems

CHP technologies involve either a "topping cycle" or "bottoming cycle." Topping cycles, the most common use, burn fuel to create electricity. Part of the generated heat converts to thermal energy, which is then used for heating water, space heating, or industrial process steam.

The bottoming cycle is more common in large-scale industrial applications and uses fuel for industrial processes, such as in a furnace or kiln, and captures the waste from the heat for power production.

Eliminating the wasted heat and instead redirecting it into efficient usage drops operating costs for businesses and results in a more sustainable production cycle. Some other points to consider from the DOE report:

  • "Across all CHP categories, there is estimated to be more than 240 GW of technical potential at over 291,000 sites within the U.S."
  • "In contrast to the existing facilities with installed CHP, which are heavily concentrated at large industrial and manufacturing facilities, a significant portion of the remaining technical potential for on-site CHP in the U.S. is located in commercial facilities."

The Rise of Modern CHP

Using waste heat for power generation isn't a new trick. In 1882, Thomas Edison produced both electricity and excess steam to heat buildings close to his Pearl Street Station. At the turn of the 20th century, early electricity providers sold steam to local customers for industrial use or heating homes. Because steam can't be transported over long distances, this early CHP was limited to immediate local areas.

As the 20th century progressed, some manufacturing sectors used bottom-cycle CHP to turn exhaust into electricity, such as chemical plants, food processors, and paper mills. However, CHP remained largely underutilized until the Arab oil embargo in the 1970s. The electrical conservation plan of President Carter led to a shift in power generation, and non-utility generators (NUGs) rapidly emerged. The new CHP technologies changed how electricity could be sold and resulted in large-scale cogeneration.

female energy consultant

Talk With Our CHP Team

Our CHP Team will conduct a review of your facility to see if CHP is right for you.  Work with a trusted partner on your CHP project.

SCHEDULE A CALL

The Future of CHP

The Department of Energy has a long-standing goal of having a 20% generating capacity in the U.S. from CHP sources. Partnerships between the DOE and CHP "promote and assist in transforming the market for CHP, waste heat to power, and district energy technologies/concepts throughout the United States."

Microgrids, especially benefit from CHP, which can solve reliability and cost issues. Additional efficiency, environmental, and cost benefits from combining power creation with heating and cooling make CHP systems increasingly desirable.

Takeaway - New Opportunities for CHP

CHP systems are developing rapidly throughout the world, including emerging nations. Russia is the most aggressive developer, with the EU close behind. India, on the cusp of rapid development, is another ripe candidate for CHP, leveraging the sugar industry byproducts for energy. Stateside, developers and local municipalities can benefit from CHP systems and microgrids, preserving the integrity of the grid and reducing heating and cooling costs even as electrical demands increase.

]]>Mon, 15 Nov 2021 15:05:00 -0500<![CDATA[The Benefits of CHP for Food Manufacturers]]>https://www.a1energy.net/blogs/post/The-Benefits-of-CHP-for-Food-ManufacturersFood manufacturers have massive energy requirements and by utilizing sustainable practices like combined heat and power can optimize their energy dollars]]>

Industrial food manufacturers are known to use an incredible amount of energy when it comes to operating their facilities. Whether it is electric or thermal energy , food manufacturers depend on having enough precisely when they need it in order to operate smoothly. This need for a large amount of energy comes at both a great financial and emissions cost.


For that exact reason, major food manufacturers across the country are always looking for new and meaningful ways to either decrease their energy needs – or rather, make their energy usage more efficient – so that they can optimize the energy dollars spent and improve the bottom line.


That is why many food manufacturers evaluate and implement combined heat and power (CHP), also known as cogeneration. Adding a CHP system to a food processor facility is one of the best ways to take advantage of top technologies in order to see a business prosper.

How it Works

CHP is an energy efficient process that generates electricity and captures the heat that would otherwise be wasted to provide useful thermal energy- such as steam or hot water- that can be used for space heating, cooling, domestic hot water and industrial processes.


There are two common configurations of CHP –


    • Combustion turbine, or reciprocating engine, with heat recovery unit


    • Steam boiler with steam turbine.


A reciprocating engine with a heat recovery unit burns a fuel (natural gas, diesel, or biogas) to produce electricity and use heat recovery devices to capture the the exhaust and jacket heat from the engine.  This heat is converted into useful thermal energy, usually in the form of steam and/or hot water.


A combustion turbine is typically a simple cycle gas turbine to produce electricity and a heat recovery boiler to recover exhaust heat and turn to steam.


Steam turbines use a separate heat source and do not directly convert fuel to electricity.  The steam is transferred from the boiler to the turbine through high pressure steam that in turn powers the turbine and generator to produce the electricity.  These systems can use a variety of fuels, such as natural gas, oil, biomass, and coal and often are used in large utility plants. 

Absorption chillers are often designed into a CHP project.  The chillers can be exhaust fired using thermal energy recovered from the (CHP) prime movers. (e.g., reciprocating engines, microturbines, and combustion turbines)

Overview of Benefits

There are many benefits of combined heat and power for food manufacturers, here is a quick overview of what you can expect:


    ● Your system’s enhanced operational efficiency will dramatically decrease overhead costs


    ● You will reduce waste and further increase energy efficiency


    ● You will gain newfound and improved energy independence by moving a portion of your energy needs off the grid and decrease your carbon emissions


    ● You will potentially have the opportunity to improve other infrastructure


    ● You will gain increase energy resiliency and help ease congestion of the grid


    ● You will minimize energy cost risks based on fluctuations in the future markets


    ● You will enjoy greater economic stability and independence


As you can clearly see, all of these benefits will not only have the potential to have a positive impact on your business, but also your peace of mind going forward.
The Benefits of CHP for Food Manufacturers
Overall, the main reason why food manufacturers turn to combined heat and power is because it can help decrease both your carbon emissions and energy costs.  Believe it or not, when it comes to total emissions, a food processor that is using CHP will be generating both electric and thermal energy at a combined efficiency of up to 85%.  Competitors without CHP, getting electricity from the grid and generating heat the traditional way typically run at a combined efficiency of around 55-60%.


You will enjoy an increased level of energy stability thanks to your business no longer fully relying on the grid.


In the end, it is quite clear why combined heat and power should be a consideration for all food manufacturers .
]]>Fri, 21 Aug 2020 11:36:51 -0400<![CDATA[Microgrids: Where Sustainability and Resiliency Meet]]>https://www.a1energy.net/blogs/post/Microgrids-Where-Sustainability-and-Resiliency-MeetMicrogrids of the modern era are tough, tactical, and efficient - and they highlight the importance of localized distribution.]]>
Microgrids: Where Sustainability and Resiliency Meet

Microgrids of the modern era are tough, tactical, and efficient - and they highlight the importance of localized distribution.

The US is home to thousands of microgrids in both operational and planning phases. Some are basic while others are more advanced, but they all have one thing in common. They deliver a sense of security to commercial, industrial and residential communities by offering power when the big grids fail.


Microgrids — small-scale distributed energy grids — are more consistent and resilient than large, centralized grids. Unlike wind power, they work even when the wind doesn't blow. And they're sustainable, something that can help companies solidify efficiency metrics in a restrictive market.

What are Microgrids?

In short, microgrids are freestanding grids that are independent of larger, regional grids. While many can be integrated within these larger frameworks, they don't rely on them. When the going gets tough, a microgrid's control system flips a switch that tells it to decentralize itself. This allows the microgrid to reap the benefits of its own power, without succumbing to widespread failure.

How Microgrids Augment the Industrial Setting

Resiliency

Similar to decentralized currency, microgrids are an independent energy solution. They don't have to rely on larger energy platforms to function, though they're able to integrate with regional power grids to provide a more robust grid system in a particular area. 


Microgrids exist on a small scale, though systems of microgrids — as well as microgrids connected to regional power grids — have impressive capacity. When it's time to go independent, they "island" off, giving microgrid-run communities or facilities the upperhand in the wake of brownouts. For industrial and commercial locations who can't afford to ride out outages, this is an empowering reality.


Sustainability

In practice, most of the world's microgrids rely on diesel generators. But with more stringent environmental regulations in place, the times are a-changin'. The US primarily uses natural gas and combined-heat-and-power (CHP). Moreover, experts expect solar photovoltaics (PV) to account for 19.5% of the global volume of microgrids by the end of 2025. 


Microgrids are especially relevant in regions hit hard by climate change. Heightened rates of natural disasters make energy resiliency even more important — and to resolve outages in an efficient way only makes sense. 


Because of microgrids' ability to integrate with various power sources, it proves to be a flexible baseline for localized, efficient energy to come.

Sustainable city with microgrid

CHP Generators Rescue Energy to Enhance Microgrid Setups

CHP generators work in tandem with microgrids to make decentralized energy generation even more efficient and useful.


Because of the three laws of thermodynamics, waste heat is inevitable. CHP systems capture waste heat and transform it into thermal energy. When CHP generators work their magic on microgrids, they generate additional energy while simultaneously cooling the system. 


Wind is a magnificent act of nature, but there's one caveat: it's volatile. No wind, no power. Beside that, wind power maxes out at 40% of its potential energy output. When working in conjunction with CHP generators, microgrids can boost wind's potential energy output to upwards of 90%. US microgrids are more likely to utilize solar PV and natural gas. Still, it goes to show just how effective CHP is in capturing lost energy and lost money, regardless of the resource at hand.


In such a valuable partnership, CHP generators and microgrids work to boost efficiency and reduce net operating costs in any industrial setting.


The Critical Compatibility of Microgrids and Solar PV

An increasing number of microgrids are relying on solar PV, primarily as an additional generating source when other power is down.


On their own, solar panels cannot keep the lights on when the grid fails during an outage. Even when an industrial building has solar panels, that building still requires voltage from the grid to power the facility. But when a microgrid itself is fitted with solar capability, it can island itself to generate power during a storm or other unexpected event.


A microgrid can include multiple energy sources, but solar PV is an increasingly relevant part of the picture. As a result, many solar PV projects are now being built with future microgrid compatibility in mind, even before any grid planning takes place.

Adaptability Through Battery Storage

Thermal, fuel cell and other forms of battery storage make microgrids even more efficient and diverse. When retrofitted with battery storage, they become a wildly resilient source of localized energy deployment. CHP- or solar-generated power can be stored for later use to fill in gaps during outages or fluctuations.


On their own, microgrids are a form of energy security. But depending on a company's resiliency goals, that additional padding in the form of battery storage could be a necessary investment. Most microgrids are only partially resilient. Energy storage firms things up, meaning facilities can seamlessly reconnect to utility as soon as it's safe to do so.

Why Microgrids Now?

In the midst of a swiftly changing world, energy resiliency can literally be a matter of life or death. Industrial facilities like hospitals, and commercial buildings like senior living centers, require energy to make use of available treatments and technologies.


At the same time, increased efficiency can build critical wiggle room into the bottom line. When you don't know what kind of investments you'll need to make next, efficiency makes all the difference. A thoughtful microgrid system delivers resiliency and sustainability to communities across the country; if that's not important in 2020, we don't know what is.


A1 Energy is a solutions-driven team of experts providing results in the form of solar PV, CHP and more. From feasibility studies to operation and maintenance, we support industrial clients seeking a more resilient, more efficient operation.

Resources:

https://www.grandviewresearch.com/industry-analysis/microgrid-market

https://courses.lumenlearning.com/introchem/chapter/the-three-laws-of-thermodynamics/

https://www.distributedenergy.com/microgrids/article/13034342/chp-and-microgridsa-profitable-pair#:~:text=Two%20such%20energy%20delivery%20technologies,to%20a%20group%20of%20users

https://www.nrel.gov/docs/fy18osti/70122.pdf

https://microgridknowledge.com/energy-storage-microgrid/


]]>Tue, 28 Jul 2020 09:48:27 -0400<![CDATA[A1 and Cleveland Bros. Install 4MW CHP at CarbonLITE]]>https://www.a1energy.net/blogs/post/carbonlite-4MW-CHP-Reading-PAA1 Energy and Cleveland Brothers Install a 4MW CHP System at the new CarbonLITE Facility in Reading, PA to meet sustainable energy goals.]]>

In 2017, China announced a new policy to restrict the import of various solid waste and raw materials, including plastics such as PET, PE, PVC, and PS. Since the implementation of material restriction, much of the U.S. has been at a standstill with PET (polyethylene terephthalate) plastic processing. The need for domestic PET processing plants has skyrocketed since cities and state governments have created laws to fix the plastic waste issue. 


Much of the PET that once went to China is now stagnant in our waste stream or shipped to the few Southeast Asian countries still accepting plastic for incineration. With the production of PET plastic now at 3.1 million tons in the U.S., companies like CarbonLITE are expanding PET plastic processing facilities to help handle some of these recyclables domestically. 


CarbonLITE, a Riverside, California facility founded by Leon Farahnik, is now expanding to Berks County, PA. The organization is one of the few plastic processing plants in the U.S. to make food-grade PET plastic so that it can be reincorporated into the system again. The final location was based on proximity to major customers.


CarbonLITE converts used plastic bottles made of PET into a resin. The resin is then used to create new PET bottles. It's CarbonLITE's 6-step recovery process that makes it possible for food grade PET to be turned into new bottles. Most PET plastic is typically downcycled into fabric fibers, carpets, and polyester. 


The new facility will be investing in combined heat and power (“CHP”) to power the energy-intensive plastic processing at the plant. 

combined heat and power process

A1 Energy and Cleveland Brothers have partnered to manage and execute the addition of 4MW of cogeneration power to the new facility. The new facility will use a combination of local utility power and power generated from the new CHP system. Blue Rock Construction, Inc. (based in Allentown, PA), in partnership with Brasler Properties and Endurance Real Estate Group, is the general contractor responsible for the new facility's build-out. Kupper Engineering, of Ambler, PA is providing electrical, mechanical, and plumbing engineering services. In addition, Kupper Engineering is providing interconnection application services to Met-Ed for the use of three 1,475kW natural gas gensets in CHP mode rated to operate in parallel with Met-Ed's system, as well as engineering services for a new 15kV service and distribution line.


What is CHP? 


Combined Heat & Power (CHP) systems are an efficient solution for meeting facility energy needs. CHP systems achieve over 80% fuel efficiency compared to traditional methods of buying grid supplied electricity and generating steam or hot water in boilers. The higher fuel efficiency leads to both energy savings and reduced environmental footprint for the CHP adoptee. And for energy users concerned about reliability, CHP can be configured for black start/island mode operation for increased reliability during utility outages. With both turnkey and third-party Power Purchase Agreement (“PPA”) solutions now available, and the increased awareness of its many benefits, industrial adoption of CHP is on the rise.  


About A1 Energy


A1 Energy is a leader in energy consulting services committed to developing and delivering creative solutions to optimize energy efficiency, reliability, and sustainability for our clients. We combine our in-depth industry knowledge and financial expertise to dramatically lower energy costs and meet sustainability measures for our clients. We support government agencies, industrial, and commercial clients in achieving energy efficiency through reduced demand, strategic procurement, and renewable energy sources. Stay informed on new energy projects on Linkedin and Twitter. 


About Cleveland Brothers Equipment Co., Inc. 


Founded in 1948, Cleveland Brothers Equipment Co., Inc. is the exclusive Cat® dealer of western and central Pennsylvania, northern West Virginia and western Maryland, providing new, used and rental equipment and machinery, parts and service. Cleveland Brothers supplies a vast variety of solutions and products, including industrial diesel and gas engines and generators, air compressors and boosters, oil and gas machinery, construction equipment and much more, in addition to full truck service for all makes and models. With 26 locations, customers have access to all of the parts and equipment needed to get the job done, backed by industry-leading technicians and staff. For more information, please visit www.ClevelandBrothers.com.

Resources: 

https://www.a1energy.net/energy-generation 

https://www.clevelandbrothers.com 

https://advances.sciencemag.org/content/4/6/eaa t0131 

https://www.mcall.com/business/mc-biz-carbonlite-bottle-recycling-plant-berks-county-20190514 -6xsw47xo6rbkhlbfro77hkcu7u-story.html

https://everydayrecycler.com/rpet-plastic/

https://www.ptonline.com/articles/carbonlite-to-open-new-pet-recycling-plant-in-pennsylvania

]]>Tue, 09 Jun 2020 15:53:10 -0400<![CDATA[PA Legislative CHP Update]]>https://www.a1energy.net/blogs/post/PA-Legislative-CHP-UpdateGuest post by Robert Barkanic P.E., The Barkanic Group Combined heat and power (CHP) is an efficient and clean approach to generating electric power an ]]>
Guest post by Robert Barkanic P.E., The Barkanic Group



Combined heat and power (CHP) is an efficient and clean approach to generating electric power and useful thermal energy from a single fuel source. Rather than buying electricity from a distribution company or a retail supplier, and separately combusting oil, gas or coal in an on-site boiler to produce steam or hot water, an industrial or commercial facility can use CHP to provide both services in one, energy-efficient step. The benefits of CHP are clear; improving competitiveness, reducing energy operating costs by becoming more energy efficient, and reducing environmental pollution such as greenhouse gasses, oxides of nitrogen and sulfur dioxide emissions.


Pennsylvania is already embracing CHP with over 7500 MW’s of capacity at over 12,000 sites, and the potential for more is significant. Sites range from nursing homes and hospitals to colleges and universities, to food processors and other agricultural applications to chemical, metals processing and pulp and paper to correctional facilities.


According to a 2016 DOE Study there exists close to 11,000 MW of CHP potential in Pennsylvania alone. Across the country that number is over 240,000 MW.


The state legislature, recognizing the benefits of CHP, both economic and environmental, passed the Alternative Energy Investment Act.  This Act was signed into law in July 2008 and provides for grants and loans for the utilization, development and construction of alternative and clean energy projects in the state, including CHP.   


The Pennsylvania Public Utility Commission is encouraging Electric Distribution and Natural Gas Distribution companies to support the development of CHP projects by reducing the barriers to entry within their service territories and by, for example, helping identify the federal and state incentives and funding programs available.  The PUC is also requiring the utilities to report biennially on their proposed plans to encourage CHP development including the identification of any barriers and their recommendations to reduce or eliminate them, identification of CHP systems that are or have been interconnected to the system, an estimate of the annual energy and financial savings that customers may experience over the life of the CHP system, benefits to the distribution system, the costs associated with interconnection and efforts to facilitate the ability for larger CHP systems and those not captured under the net metering regulations to meet applicable interconnection standards, to name a few.  These reports will highlight the good work that is going on in Pennsylvania and the opportunities to improve the administrative systems to enhance CHP implementation.   


So regardless of whether your interest is lowering your operating costs or environmental emissions or increasing the resiliency of your facility you should consider investigating a CHP project at your site.   


Industrial manufacturing facilities in the Chemical industry, metals processing and petroleum industry as well as the food processing industry, governmental and commercial buildings have all benefitted from CHP.  Isn’t it time you consider doing the same?  To talk about CHP opportunities at your facility please contact A1 Energy.   


Combined Heat and Power Technical Potential in the United States, US Department of Energy, March 2016

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