where the heat in the exhaust steam is wasted in the condenser. The cogeneration plant can be sized to meet
or exceed the plant electricity requirement, depending on whether the export of electricity is an
attractive use of capital. This “make or buy” scenario gives chemical producers strong leverage
when negotiating electric power contracts and they are usually able to purchase electricity at or
close to wholesale prices. Wholesale electricity prices vary regionally (see www.eia.gov for details),
but are typically about $0.06/kWh in North America at the time of writing.
The voltage at which the supply is taken or generated will depend on the demand. In the United
States, power is usually transmitted over long distances at 135, 220, 550, or 750 kV. Local substations
step the power down to 35 to 69 kV for medium voltage transmission and then to 4 to 15 kV local distribution
lines. Transformers at the plant are used to step down the power to the supply voltages used
on site. Most motors and other process equipment run on 208 V three-phase power, while 120/240 V
single-phase power is used for offices, labs, and control rooms.
On any site it is always worth considering driving large compressors and pumps with steam
turbines instead of electric motors and using the exhaust steam for local process heating.
Electric power is rarely used for heating in large-scale chemical plants, although it is often used
in smaller batch processes that handle nonflammable materials, such as biological processes. The
main disadvantages of electrical heating for large-scale processes are:
• Heat from electricity is typically two to three times more expensive than heat from fuels, because
of the thermodynamic inefficiency of power generation.
• Electric heating requires very high power draws that would substantially increase the electrical
infrastructure costs of the site.
• Electric heating apparatus is expensive, requires high maintenance, and must comply with
stringent safety requirements when used in areas where flammable materials may be present.
• Electric heaters are intrinsically less safe than steam systems. The maximum temperature that a
steam heater can reach is the temperature of the steam. The maximum temperature of an electric
where the heat in the exhaust steam is wasted in the condenser. The cogeneration plant can be sized to meet
or exceed the plant electricity requirement, depending on whether the export of electricity is an
attractive use of capital. This “make or buy” scenario gives chemical producers strong leverage
when negotiating electric power contracts and they are usually able to purchase electricity at or
close to wholesale prices. Wholesale electricity prices vary regionally (see www.eia.gov for details),
but are typically about $0.06/kWh in North America at the time of writing.
The voltage at which the supply is taken or generated will depend on the demand. In the United
States, power is usually transmitted over long distances at 135, 220, 550, or 750 kV. Local substations
step the power down to 35 to 69 kV for medium voltage transmission and then to 4 to 15 kV local distribution
lines. Transformers at the plant are used to step down the power to the supply voltages used
on site. Most motors and other process equipment run on 208 V three-phase power, while 120/240 V
single-phase power is used for offices, labs, and control rooms.
On any site it is always worth considering driving large compressors and pumps with steam
turbines instead of electric motors and using the exhaust steam for local process heating.
Electric power is rarely used for heating in large-scale chemical plants, although it is often used
in smaller batch processes that handle nonflammable materials, such as biological processes. The
main disadvantages of electrical heating for large-scale processes are:
• Heat from electricity is typically two to three times more expensive than heat from fuels, because
of the thermodynamic inefficiency of power generation.
• Electric heating requires very high power draws that would substantially increase the electrical
infrastructure costs of the site.
• Electric heating apparatus is expensive, requires high maintenance, and must comply with
stringent safety requirements when used in areas where flammable materials may be present.
• Electric heaters are intrinsically less safe than steam systems. The maximum temperature that a
steam heater can reach is the temperature of the steam. The maximum temperature of an electric
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