USC’s biomass plant debacle
How the university’s green dream went bust after three ‘potentially lethal accidents’ and a host of other problems
By WAYNE WASHINGTON (The State Newspaper)

On June 28, 2009, an explosion rocked the biomass-fueled power plant on the campus of the University of South Carolina.
The force of the blast sent a metal panel some 60 feet toward the control office of the plant at Whaley and Sumter streets, according to documents obtained from USC by The State newspaper through a Freedom of Information Act request.
No one was hurt, but USC officials were concerned enough about the “potentially lethal accident” that they ordered an independent safety review and, in a strongly worded letter to the company that had built the plant, made it clear that university staff would not be allowed back into the building until the review was completed.
The blast underscored what some USC officials privately grumbled about for years: That the plant has been a $20 million disaster, a money pit that was poorly planned and built by a company that had never constructed such a cutting-edge “green energy” power plant before.
Interviews with USC officials and a spokeswoman for the company as well as a review of more than 1,800 pages of documents show that:
• USC, whose officials touted the plant “as the cat’s meow” before its startup in December 2007, closed it in March of this year after it had been shut down more than three dozen times. In one two-year period, the plant only provided steam – its purpose – on 98 out of 534 days, according to a USC review.
• There was no separate bidding process for the construction of the plant. The firm that built it, Johnson Controls Inc. of Wisconsin, was the only firm that included the construction of a biomass plant as part of its effort to win a competitively bid energy services contract. JCI won that $33.6 million energy services contract, then alone negotiated with USC the added cost of the biomass plant.
• USC paid JCI an additional $19.6 million for the plant. The university was to get its money back in energy savings or payments from JCI. So far, JCI has paid USC $4.3 million because the plant did not perform as promised. As things stand now, USC will recoup its $19.6 million investment by 2020 from payments by JCI.
• Despite a relationship that was, at one point, so acrimonious that USC hired outside legal counsel, the university continues to work with JCI. One option that USC now is considering is putting natural gas-fired turbines in the closed biomass plant to produce power, and JCI may be involved, a USC official says.
• Most substantively, however, the biomass experience led USC to change its structure of governance, giving a reformulated committee of its board of trustees responsibility for overseeing and vetting projects.
Now sitting idle, with spider webs and a thin film of dust replacing a plant’s hard-hat hustle and bustle, the biomass plant stands as a monument to the university’s failed push toward new, “green” technology, inadequate oversight and naïveté, some of its own officials acknowledge in internal documents.
The plant blemishes the legacy of the late Andrew Sorensen, the beloved, bow-tied president who was in charge of USC when the plant was conceived and constructed. And it also raises questions about whether USC’s revised system of oversight will be able to prevent future instances of idealism gone wrong that marred the biomass project from the beginning.
“A (expletive) mess with many layers,” is how William “Ted” Moore, a former USC vice president of finance and planning, described the plant in an email to Ed Walton, USC’s chief financial officer.
In another email, this one to USC president Harris Pastides, who succeeded Sorensen, Moore said: “The value of this thing may be scrap metal.”
That’s not the way JCI sees the project.
“We remain committed to the long-term success of the USC project, and the university has been supportive and appreciative of Johnson Controls’ efforts to fulfill its commitment,” said Karen Conrad, the company’s director of marketing communications.
Full story: http://www.thestate.com/2011/10/09/2001993/uscs-biomass-plant-debacle.html#ixzz1aKeVXkUU
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At least they finally (weeks late) complied with FOIA requests, unlike some public agencies we know:
About this story
More than 1,800 pages of records obtained by The State show the biomass project collapsed into delays, recriminations and frustration.
Click here to read excerpts of those documents
State senior reporter Wayne Washington requested documents, via the S.C. Freedom of Information Act, concerning USC’s biomass plant on June 29 from the University of South Carolina. That law allows public agencies 15 working days to respond to a request for public information.
University officials responded they would need additional time to fulfill the request. They also said, because USC is getting an increasing number of requests for public information, the university would exercise its legal right to charge for document production and copying.
USC supplied 1,816 pages of documents concerning the $20 million facility to The State Sept. 22, charging $255.80 to provide the information.
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h/t to WUWT reader Mike Whaley
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……of mice, and men.
Anyone else notice it is always the Marketing arm of any business that is driving green energy, and most “liberal” programs?
Ummmm, that’s “fraught,” Anthony.
/pedant
[Fixed, thanx. ~dbs, mod.]
Ah Johnson controls…that explains everything!
Alvin, I don’t “liberal” describes the problem. It crosses political lines and is somewhere in the vicinity of “criminal”.
More about this plant that uses wood chips to produce syngas can be found here: http://www.palletenterprise.com/articledatabase/view.asp?articleID=2841
— John Andrews
The link says this
Quote
On Friday, Kelly reiterated his belief in biomass as a new and important fuel source.
Unquote
Had they never heard of wood burning stoves. or boilers or such. Shakes head and leaves room
Seems consistent to me;
“The force of the blast sent a metal panel some 60 feet toward….”
AND
“cutting-edge “green energy” power plant”
Nothing says “cutting-edge” like a nice thin piece of metal (formerly known as a knife).
Cheers, Kevin.
Do a search for “biodiesel plant explosion” you might be amazed at how often this occurs. There was a local one in a rural neighborhood that caught fire 2 years ago. The residents didn’t realize what kind of chemicals were used there and how dangerous it was.
They’re pushing the green stuff so fast that common sense and engineering quality control are shoved to the side, if not ignored all together.
So USC has other properties sitting idle than the old Food Lion property in Goose Creek, which has turned into a local eye sore, vandal attractant, and over-all bad neighbor to have?
USC has been unresponsive to attempts by the local Mayor and the Crowfield Homeowners Assoc. to remedy this blight. The abandoned property sits in its own Berkeley County doughnut, surrounded by the City and un-answereable to City Zoning ordinances.
I was under the (apparently mistaken) impression that a schools goal was to educate rather than to dabble in real estate and energy sales.
Google industrial accidents and you will see this is EXTREMELY common across scores of industries. I can’t believe the crap that accounts for “news” on this web site.
I don’t think it is a problem with the biomass fuel. Biomass is not as explosive as Natural Gas or even oil. Don’t let the term biomass fool you; biomass = wood, corn cobs, rice hulls, charcoal, dried cow patties, etc. There are differences between how you fire different fuels but the commonality of the different technigues is the goal of a even temp across the boiler bed and adequate air flow. The explosion may have come from defective water tubes, pipes that carry hot water/steam away from the boiler to the turbine but that is conjecture on my part. I didn’t read the documents through the links so maybe it says in one of those say that a hunk of biomass fuel got caught in the turbine and exploded but I doubt it. Burning biomass fuel isn’t as dumb as putting wind turbines of soler panels all over. Eventually, biomass will be just another fuel.
The “green” industry seems almost to be a Section 8. Propped up by funding and subsidy.
Will the REAL green alternative energy please stand up!
We understand it isn’t easy being green. Just give us the best you can give. Here’s hoping for the best. And if you can produce it, the economy will support it.
If you can’t, then keep working at it. Meanwhile we will go after “green” hydrocarbons, like natural gas.
The real canary in the coal mine is not any subsidized or socialized prop at the taxpayers’ expense (such as Solyndra); rather, it would be T Boone Pickens.
He tried it. And moved on.
Natural gas…is our immediate future…until we can figure out something better.
Chris
Norfolk, VA, USA
“Drewski says:
October 9, 2011 at 8:20 pm
Google industrial accidents and you will see this is EXTREMELY common across scores of industries. I can’t believe the crap that accounts for “news” on this web site.”
Can you point me to links where you find non-“green” energy plants producing 98 out of 534 days of the year and said plants staying in business?
The reason it was posted was because of the attempted cover up, delay tactics, charging for info and wonderful results…
However I think everyone can agree that green tech failure is common place… so common that it should not be in use now or anytime soon.
[note: Drewski isn’t interested in discussion, only denigration. He has anger issues. Don’t feed the troll ~mod]
Was they a scrubba on it?
===========
We already have biomass fuel, it is called extracting methane from landfills. No fancy gizmos required. But apparently it does require political clout sometimes even to get that done.
Example: A city in a coastal California county has a landfill which generates methane. The California Coastal Commission allowed a pipeline to be built from the landfill to a private company to supply it with gas. The town also wants to build a second pipeline from the landfill to its water treatment plant … DENIED. Apparently a private company is capable of dumping cash in the right places to get its projects through the Commission but a city can’t.
This is even though the gas pipeline would parallel an existing pipeline that carries leachate from the landfill to the water treatment facility (leachate being water that leaches out of the landfill that is collected by a ring of wells around it). Apparently the leachate wells and treatment are mandated by state law so the commission has to allow that pipeline but there is no mandate from the state to allow the methane to be captured to power the treatment of the water.
I tried to find some permit documents online but haven’t found them yet. This is an informative article including gasifier system schematics, some project photos etc.:
http://www.nexterra.ca/PDF/BiomassMagMarch08FNLLogos.pdf
…sorry, as an former Okie, all I can say is that they should have hired John Zink Company!
I suppose looking up “meth lab explosions” will return similar results.
Well, no wonder it didn’t work. It appears that this technology includes a wood gasifier, per this link:
http://www.statelibrary.sc.gov/scedocs/B8595InE/000734.pdf
University of South Carolina to Add Waste Wood Gasification System
“The University of South Carolina will soon add a waste wood
gasification system to its central energy system, using existing waste
products from sawmills, logging and timber operations in the Midlands
to produce 60,000 pounds of steam per hour (about 85 percent of campus steam needs) and
approximately one megawatt of electricity.
The biomass energy plant will utilize one million tons of South Carolina homegrown energy over
20 years, saving students and taxpayers almost $2 million annually while improving air quality
through substantially reduced emissions of sulfur dioxides, nitrogen dioxides and particulate
matter.
About $1.5 million annually in wood waste expenditures will be pumped into the South Carolina
economy, displacing spending now going to oil and natural gas producers in Gulf States and
abroad. Furthermore, campus operations will be significantly protected from future oil and
natural gas supply disruptions, such as those occurring in late summer of 2005.”
The technology on such solid waste gasifiers is notoriously prone to equipment breakdown and having low on-stream factors, and this is well-known by engineers. U. South Carolina management should have done a better job of due diligence before approving the expenditures.
This reminds me very much of the stories I read about the Great Leap Forward in China under Mao. At this time steel production was the big thing and everyone in every walk of life was given a quota of steel to produce. University professors had to take turns pumping air into the university steel smelter and for raw material the peasants often had to melt down all their work tools and cooking pots. The steel produced was invariably of such low quality that it was quietly disposed of by the steel mills when it was delivered to them.
When I read it I could not imagine how society could become so nutty…
Its a problem with engineering design and lack of safeguards; not (inherently) with biomass. My job is heavily related to process safety for oil & gas plants, and for me, biomass is just another source of gas. Design it properly, and you can prevent explosions. Probably they didn’t (alternatively, they did but were unlucky).
Basically nothing to do with green as such. It’s just everyday engineering. In the real world s—t happens. Nuclear power plants melt down, oil wells spring a leak, gas refineries explode, ships sink, aeroplanes crash, methyl isocyanate escapes.
The technology here sounds like the gas generators attached to cars during the great war. Old tech in other words.
Gosh, they contracted for a company to build something that the company had never, before, built; and it didn’t work properly.
I jes can’t imagine.
South Carolina is a great place for pine trees. Why don’t they just burn turpentine?