Using Energy More Efficiently

  • The Sappi paper mill in Cloquet Minnesota produces most of the electricity it needs, using steam that also powers the industrial process. Sappi can even sell power when demand is high. Electric co-generation is enjoying a come-back. (Photo by Stephanie Hemphill)

More and mores states are establishing a “renewable energy standard”
for their electric utilities. So far, wind power is producing the bulk
of renewable energy. But there are other sources. Some are brand new.
Others have been around for a long time. Stephanie Hemphill reports:

Transcript

More and mores states are establishing a “renewable energy standard”
for their electric utilities. So far, wind power is producing the bulk
of renewable energy. But there are other sources. Some are brand new.
Others have been around for a long time. Stephanie Hemphill reports:


The first thing to know about electricity is that making it can be
incredibly inefficient.


In a conventional power plant, burning fuel turns water into steam.
The steam drives a turbine, which spins the generator. Only about a
third of the energy in the original fuel is converted to electricity.
Two thirds goes up the smokestack in the form of heat.


“Every time you convert energy from one form to another, you lose
something. That’s just the way it is, ’cause nothing’s perfect.”


Dwight Anderson works for Minnesota Power. He’s lived with that
inefficiency for his whole working life. Now, he’s trying to wring
more electric power out of every bit of fuel.


He’s high on something called co-generation. The basic idea is to
harness the heat or steam that normally goes up the smokestack.
There’s a good example of co-generation at the Sappi paper mill in
Cloquet, in northern Minnesota. Like many paper mills, Sappi makes
most of the electricity it needs.


Engineering Manager Rick Morgan points to a mountain of wood chips:


“We have about 20,000 tons of biomass stored.”


That’ll last less than a month. The plant uses 53,000 watts, enough to
power a small city.


Inside the sprawling buildings, there are several electric generators.
One of them is fueled by a recovery boiler, which burns the byproducts
of the paper-making process, to run steam through a turbine.


“…The actual turbine is manufactured in Czechoslovakia and the generator’s
made in Vestros, Sweden.”


Higher pressure steam spins the turbine to produce electricity. The
waste steam from the same boiler goes to the pulp dryer, the paper
machines, and other parts of the process.


Back in his office, Rick Morgan says energy is the fourth largest
expense for paper mills:


“If you can’t control energy costs in this business, you can’t be in
business.”


The main product here is paper, but sometimes Sappi sells electricity
too. That happened during a recent cold snap:


“The electric demand increases and the costs go higher and higher, to
the point that it’s financially feasible for us to generate power for
Minnesota Power.”


Opportunities to produce electricity turn up in some surprising places.
Like along natural gas pipelines. The pressure has to be boosted
periodically as the gas travels through the pipe. Compressors fueled
by the natural gas do that work, and normally they vent off waste heat.


But now in South Dakota, the waste heat is fueling small power plants.
They look like the barns and silos of a farm. The generator itself is
about the size of a truck.


Basin Electric Power Coop spokesman Daryl Hill says the plants are
owned and operated by an Israeli company, and the co-op buys the power:


“We get basically 22 megawatts of baseload for little investment.”


Other countries are leading in these approaches because their fuel
prices have been so high. As prices go up in the U.S., power producers
are finding ways to use more efficient technologies, and they’re
returning to old-fashioned ideas like combined heat and power. This is
a form of co-generation that was once common across the country.


A central electric plant uses its waste steam to heat buildings. Of
course, most people don’t want to live next to a coal-fired power
plant. But Neal Elliott, with the American Council for an Energy-
Efficient Economy, says with combined heat and power, cleaner fuels,
like natural gas, can become competitive:


“Use natural gas, but use it much more efficiently. And instead of
throwing more than half of the fuel value away, let’s do it with co-
gen.”


Elliott says combined heat and power and other forms of co-generation
could provide 20% of America’s electricity needs, and save on heating
fuel at the same time. And he says recovered energy generation like
along the natural gas pipelines could provide another 20%.


For the Environment Report, I’m Stephanie Hemphill.

Related Links

Powerline Generates Controversy

No one likes the idea of a major powerline running through their
backyard. But a proposed bulk transmission line in Wisconsin is
generating more than the usual amount of controversy. The Great Lakes
Radio Consortium’s Stephanie Hemphill reports:

Transcript

No one likes the idea of a major power line running through their backyard.
But a proposed bulk transmission line in Wisconsin is generating more than
the usual amount of controversy. The Great Lakes Radio Consortium’s
Stephanie Hemphill reports:


Steve Olson will never forget the night of June 25, 1998. He was working
the overnight shift at Minnesota power’s control center when something went
very wrong.


“I really didn’t know exactly what was going on at the time but I knew it was
serious. I knew it was something bigger than Minnesota power. It’s within
a matter of a minute or two we had half a dozen lines opening.”


The open lines meant the electric grid was breaking apart. The grid
connects Minnesota power to eight states and three Canadian provinces.
lightning strikes in Wisconsin – 200 miles away – caused the breakup. Over
40,000 people lost power.


John Heino is a spokesman for Minnesota power. He says that kind of
situation is one step away from a regional blackout.


“Normally this system is designed to work together so neighboring states and
systems can support each other, but in that situation, it just breaks up
into pieces and there’s no guarantee the power plants in that area are
enough to supply the load that’s left.”


The near miss convinced Minnesota power to do something to shore up the weak
link in the regional electric grid.


The Duluth-based company joined with Wisconsin Public Service to propose a
345-kilovolt transmission line from Duluth Minnesota to Wausau Wisconsin.
It would tap into cheap coal and hydro power from western Minnesota and
Manitoba. Heino says the new link would lighten the load on existing lines
and make service more reliable.


“With all these sources to the north and the west, and you have the Twin
Cities, Milwaukee and Chicago, to the south and the east, so there’s this
general day in and day out tendency for the power to flow to the south and
the east.”


The plan has attracted a lot of opposition along the proposed route. Eight
counties and over fifty local governments have gone on record against it.

Opponents worry about property values, loss of farmland, and health issues.


(sound of meeting)


At a recent meeting in superior Wisconsin, nearly 200 angry people showed up
to confront Minnesota power officials.


Person 1: “Both of these proposed routes would go through our property. We sunk our
life savings into it and we thought we could protect it. Lo and behold,
what did we know?”


Person 2: “As far as I’m concerned, this is a dinosaur. We’re looking at smaller
leading edge technologies that are more adapted to local generation.


Person 3: “I have a very nice neighbor and the power line is going across his land

and
he said to me, if it comes across my land, I’ll shoot’em.


Some Wisconsin farmers oppose the line because of problems they’re having
with other electric lines. Debbie Beyrl says ground currents have made her
cows sick. That’s reduced milk production and made it harder to keep the
business going. She’s also worried about her family’s health.


“I worry about my kids because they’re in the barn helping us. And I think
it’ll put us out of business, not that we’d want to quit but I think it
would finish us off, yeah.”


Power company officials say ground currents are caused by improper wiring or
local distribution lines, not large transmission lines.


But environmentalists question the need for the line. Chris Laforge sells
wind and solar electric generating systems. He says utilities could avoid
building expensive power lines by using alternative systems.


“It’s a perfect match. Distributed photovoltaic generation on rooftops of
large buildings can meet peak air conditioning demand because electricity
gets made right when you need it.”


Power companies say there’s great potential in alternative technologies, but
the current need is acute. Jim Loock is the chief electrical engineer
at the Wisconsin Public Service Commission. That agency has the authority
to approve the line.


“Our electrical system is growing at 2-3% a year, so we need 200-300
megawatts of additional supply every year. That’s why we say part of the
equation is energy conservation and demand side management, we feel strongly
that the consumer needs to conserve energy and use it as wisely as possible.”


Hearings are scheduled this month in Minnesota and this summer in Wisconsin.
if approved, construction could start in September 2001.


For the Great Lakes Radio Consortium, I’m Stephanie Hemphill.