Hexion CHP Project

Abstract

Built in 1998 in South Glens Falls, New York, the Hexion Chemical plant can produce up to 200 million pounds of formaldehyde per year. The formaldehyde is produced by combining methanol with air in the presence of a catalyst. Heat is recovered from the exothermic reaction through a heat transfer fluid jacket around the reactor vessel that controls reaction temperature and transfers heat to a secondary water/steam loop. Until 2004, most of the heat entrained in the steam was vented to the atmosphere via a condenser. Since that time, a turbine-generator system, designed by Turbosteam recovers this waste heat to produce up to 451 kilowatts of electricity. This innovative combined heat and power (CHP) system uses no fuel and produces zero emissions. The CHP system is equivalent to annually reducing carbon dioxide emissions by more than 2,700 tons. The EPA and DOE have recognized the project with an EPA CHP Certificate of Recognition. The project has been operating successfully since early 2004.