Past Projects

Morris Cogeneration, LLC Summary:

Morris Cogeneration, LLC (“Morris”) is a 192-megawatt combined heat and power facility in Morris, Illinois acquired in a partnership between Ironclad Energy and Fengate Asset Management.   The Morris Cogeneration facility began commercial operations in 1998 and uses General Electric (GE) technology, including three combustion turbines and a steam turbine.  The steam and energy produced at the facility is sold to LyondellBasell for use at its Morris petrochemical plant and the PJM market.

Capacity 192MW and 1,000,000 lbs/hr steam Location Morris, IL COD 1998 QF Status Cogenerator Fuel Type Natural Gas Heat Rate ~8,150 Btu / kWh (steam adjusted) Technology GE Frame 6B (3), GE steam turbine, Deltak heat recovery steam generator Asset Management/O&M Ironclad Energy

Oyster Creek Cogen Summary:

A partnership between Ironclad Energy Management and Fengate Asset Management acquired Freeport Power Limited, a 440-megawatt combined heat and power facility in Freeport, Texas.  Also known as Oyster Creek Cogen and Dow “Power 8”, the facility began commercial operations in 1994 and uses General Electric (GE) turbine technology, including three combustion turbine-generators and a steam turbine-generator.  The steam and power produced by the facility are integrated into Dow’s Oyster Creek and Plant A complexes.

Capacity 440MW and 1,900,000 lbs/hr steam Location Freeport, TX COD 1994 QF Status Cogenerator Fuel Type Natural Gas Heat Rate ~8,821 Btu/kWh (steam adjusted) Technology GE Frame 7EA (3), ABB/Alstom steam turbine-generator,   Vogt heat recovery steam generators Asset Management/O&M Ironclad Energy / Dow

Ironclad Energy manages the utility infrastructure in Eastman Business Park (“EBP”), a 1,300 acre state of the art industrial park in Rochester and Greece, New York, and provides 14 critical utility services to all the companies located in EBP. The park’s reliable utility services and low costs are a core part of RED-ROCHESTER’s strategy and we are actively engaged in growing EBP. As the park’s utility volume grows, customers save more money based upon a profit sharing rate structure.

Less than 30 days after purchasing the energy assets within EBP in late 2016, we broke ground on a new $75M natural gas powerhouse and plan to retire the old coal powerhouse in early 2018. The short answer is this project dramatically improves air emissions while lowering customer costs thereby making EBP even more attractive to new industrial tenants that are looking to expand their operations. A snapshot of our operations in Rochester, NY are:

• 120 MW behind-the-meter tri-generation w/ grid interconnect and a 12.5 KV underground electrical cable network
• 1,600 KPPH of steam produced at 1,400 psi with site-wide distribution at 260, 140/70 & 10 PSIG and site-wide condensate return system
• 90 miles of largely above-ground distribution pipelines
• 50,000 TONS of chilled water capacity including 800 tons of 9-degree F brine capacity.
• 40,000 SCFM of compressed air
• 2,300 SCFM of nitrogen generation
• 36 Million Gallons a Day average hydraulic capacity (54 MGD max) with water intake from Lake Ontario (5 miles to the north) coupled with an underground sewage piping system and in house sewer treatment plant designed for industrial effluent
• 3,000 GPM of demineralized water capacity
• 400 GPM – ultra high purity water
• 400 GPM of reverse osmosis water capacity
• 3.5 & 12.5 Million Gallon reservoirs, distribution and pumping of industrial, process and fire water.

Ironclad focused on optimizing all aspects of RED Rochester.  Upon close, the team worked with the EPA to extend permitting requirements to allow for the construction of the $75M boiler house.  Within 30 days of the acquisition, construction commenced and the old coal boilerhouse was replaced 18 months later.  Following construction of the boilerhouse, Ironclad created an accretive project group who ultimately executed another40+ accretive projects to bring additional value.  The team worked with their customers to restructure the Utility Service Agreements to achieve better alignment with customers allowing for all parties to succeed with growth.  Working with the customers, the team brought in large new customers and helped existing customers expand to a point where new generation was needed.  The team then developed and constructed a new cogeneration facility on-site allowing for additional growth into the future and significantly better efficiency.

Stonepeak acquired a 100% ownership interest in Canal 1&2 from a subsidiary of GenOn Energy, Inc. in June 2018.  Canal 1 is a residual oil-filed unit that went into service in 1968 and Canal 2 dual-fuel unit that went into service in 1976, and together the units represent a total of 1,124 MW of oil and natural gas fired generating capacity.  The Canal 1, 2 & 3 site is located in Sandwich, Massachusetts on the Cape Cod Canal.

Together with Canal 3, Canal 1 & 2 form the 2^nd largest single-site fossil-fuel generation site in the region, allowing the Canal site to enjoy substantial economies of scale in the premier New England power market where existing resources benefit from higher on-peak and capacity prices relative to other regions and significant barriers to entry by new resources.

Canal 1 & 2 Summary:

CANAL 1 Capacity 565 MW Location Sandwich, MA COD 1968 Fuel Type Fuel Oil Heat Rate  9,019 Btu/kWh Technology Siemans Westinghouse Asset Management/O&M Ironclad Energy

CANAL 2 Capacity 559 MW Location Sandwich, MA COD 1976 Fuel Type Dual-Fuel (gas/fuel oil Heat Rate  9,790 Btu/kWh Technology Siemans Westinghouse Asset Management/O&M Ironclad Energy

Canal 3 is a 350 MW natural gas fired peaking facility developed by NRG Energy Inc. and later completed by Stonepeak Infrastructure Partners and Ironclad Energy Partners.  The project is co-located with Canal 1 & 2 in Sandwich, MA and utilizes best-in-class GE 7HA.02 technology with fast-start capability (full load < 10 minutes), advance emissions controls, and dual-fuel flexibility.  The project cost approximately $315 million to construct and was completed in 2019.

Canal 3 Summary:  Ironclad Energy Management, LLC (“Ironclad”) was the Owners representative during construction of facility acting as liaison to construction management team, EPC contractor, and major OEM suppliers. Fully commercialized Canal 3 to become a participating generator within ISO NE.

In addition, Ironclad developed the bidding strategy with Canal 3 as well as Canal 1&2 and managed the 50+mm gallon onsite No. 6 Oil and ULSD storage facility.

Capacity 333 MW Location Sandwich, MA COD 2019 Fuel Type Dual-Fuel (gas/ULSD) Heat Rate  9,200 Btu/kWh Technology GE 7HA.02 CT Asset Management/O&M Ironclad Energy

The Bucksport Generation Plant was aquired by Stonepeak Infrastructure Partners and is a 175 MW natural gas fired peaking facility utilizing GE 7FA.03 technology.  The plant is located in Bucksport, ME at the site of the former Verso paper mill, is primarily used for peaking and grid balancing in ISO New England, and was sold to JERA Americas Inc. in 2022.

Bucksport Summary:

Capacity 175 MW Location Bucksport, ME COD 2001 Fuel Type Dual-Fuel (gas/ULSD) Heat Rate  10,656 Btu/kWh Technology GE 7FA.03 Asset Management/O&M Ironclad Energy