Jenbacher gas engines a variety of efficient applications

Transcription

GE Energy
Jenbacher gas engines
a variety of efficient applications
Bucureşti, October 28, 2010
Thomas Elsenbruch
Global trends …
Population
Consumption
Energy security
Environment
… Create big challenges
2
GE Power & Water - Jenbacher gas engines
14.02.2011
Meeting big challenges … with big solutions
Reliability
Emissions
Gas
Biomass
Wind
Solar
Oil
Geothermal
Hydro
Natural gas
Efficient
C
o
n
v
e
r
s Driving Cost of Electricity Down
i
o
n
Efficiency
Diverse
Affordable, reliable & environmentally responsible
3
14.02.2011
Four types of gas engines
2
Type
Type
•
•
•
•
Electrical output
from 250 to 330KW
•
8 cylinder
•
1,500 rpm (50Hz) /
1,800 rpm (60Hz)
•
•
3
Type
Electrical output
from 500 to
1,100KW
4
V12, V16 and V20
cylinder
1,500 rpm (50Hz) /
1,800 rpm (60Hz)
•
Electrical output
from 800 to
1,500KW
Delivered engines:
more than 5,000
•
Since 1988 in the
product program
V12, V16 and V20
cylinder
•
1,500 rpm (50Hz) /
1,800 rpm (60Hz)
Delivered engines:
more than 850
•
Delivered engines:
more than 750
Since 1976 in the
product program
•
Since 2002 in the
product program
•
•
Type
6
•
Electrical output
from 1.5 to 4MW
•
V12, V16, V20 and
V24 cylinder
•
1,500 rpm (50Hz,
60Hz with gear-box)
•
Delivered engines:
more than 2,200
•
Since 1989 in the
product program
4
14.02.2011
Product Program 2010:
Biogas, Sewage Gas and Landfill Gas
3.500
Electrical output [kW]
Thermal output (70°/90°C) [kW]
2.000
(dry Exhaust gas; based on 5 % O2)
1.500
J 208
GS-B.L
J 312
GS-B.L
J 316
GS-B.L
J 412
GS-B.L
1190
1175
1065
1088
888
881
836
910
703
744
526
558
330
400
250
294
0
39%
625
680
1.000
500
40.8%
40.5%
1489
1468
42.2%
2737
2880
Natural gas standard
NOx ≤ 500 mg/Nm3
2190
2403
2.500
42.5%
1635
1802
3.000
J 320 J 416
J 420 J 612
J 616
J 620
GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L
5
14.02.2011
Three basic configurations – customized for each
customer’s requirements
• Generator sets
Reliable on-site power generation on demand
Energy independence
• Cogeneration systems
Combined generation of power and heat
Maximum efficiency in the conversion of energy with minimum emissions
• Container solutions
Maximum flexibility with fully functional containerized plant
Compact design and service oriented accessibility
6
14.02.2011
Jenbacher gas engines –
what makes the difference?
Details: „Gas engine concept“
Advantage:
“Cross flow” cylinder head
(external exhaust gas manifolds)
Clear separation of cold mixture inlet
and hot exhaust gas
Exactly defined thermal zones in the
cylinder head
Long cylinder head life time
Better accessibility to the exhaust gas
manifolds
8
14.02.2011
LEANOX® - Lean-burn combustion control
•Sensors in non critical measurement ranges (pressure, temperature, deposits...)
•Reliable and durable compliance with exhaust emission limit at changing
operational conditions (fuel gas compositions...)
•Controlled combustion and subsequently controlled stress of various
components (valves, cylinder heads, spark plugs...)
9
14.02.2011
LEANOX – Now impact from deposits
Oxidation of exhaust gas valve area
Si deposits on spark plug (Biogas/LFG)
No Sensor in hot & critical areas
No risk of deposits on sensors
No aging of sensor
10
14.02.2011
GE‘s Jenbacher SPARK PLUG
• Efficient & reliable combustion
• Low emission (NOx)
• Enables high specific output
‒ Low specific product cost
‒ Low specific service cost
11
14.02.2011
GE Jenbacher - reliable operation on biogas
• Biogas Gosdorf/AT achieved 8,740 out of 8,760 oph/y in ’05
• 99.8% Availability with Biogas
• average 98+% fleet reliability at Biogas (450+ units)
12
14.02.2011
DIA.NE® XT3 + WIN
Large screen (10.4’’ vs 5.7”)
Help system applicable
Customer and expert view
Improved trend function
Alarm display improved
Identical information at DIA.NE® WIN
User friendly
Asian characters possible
Easy navigation
13
14.02.2011
Biogas
• More than 1,500 Jenbacher biogas engines with an
electrical output of about 1,100 MW worldwide
• Anaerobic digestion produces fuel gas
• Renewable – from organic and animal waste
• 7,000 cows can power 1 MW plant
14
14.02.2011
GE‘s Jenbacher gas engine business offers
customized biogas solutions
(in case of food waste)
Jenbacher biogas-cogeneration units are core part of biogas plant, but
enhanced digester-technology needed
15
14.02.2011
Operational conditions of the fermentation
process
Dry matter concentration
• Temperature
- dry fermentation: 20 - 30%
- wet fermentation: 10 - 15%
• Absence of oxygen
• pH value from 6.5 to 7.5
- mesophile process: 35 - 40°C
- thermophile process: 50 - 55°C
• Retention time
- minimum 15 days
- range: 20 - 50 days
- common: 25 - 30 days
Gas mixture composition:
50 – 70% methane (CH4)
30 – 50% carbon dioxide (CO2)
waste wheat
waste bread
grease trap contents
corn-cob-mix
corn silage
grass silage
food waste
municipal biowaste
brewery
beet
grass cuttings
potato peelings
pig manure
cattle manure
minimum
variation
0
100
200
300
400
Standard m³ biogas / ton
500
600
700
16
14.02.2011
The whole Jenbacher biogas fleet:
400
400
350
350
300
300
250
250
200
200
150
150
100
100
50
50
0
0
MWel/a
#units/a
More than 1500 installed engines (1065 MW )
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
17
14.02.2011
Jenbacher - Biogas engines around the world
Installed in Biogas plants up to 31.12.2009:
• Germany
945 engines
• Italy
161 engines
• Austria
90 engines
• Netherlands
69 engines
• Denmark
46 engines
• Czech Rep.
40 engines
• Belgium
32 engines
• Spain
32 engines
• UK
11 engines
• Poland
8 engines
• Hungary
7 engines
• Slovakia
6 engines
•
•
•
•
Thailand
India
Indonesia
China
42 engines
37 engines
28 engines
5 engines
527 MW
130 MW
48 MW
72 MW
35 MW
28 MW
36 MW
30 MW
12 MW
6 MW
3 MW
6 MW
51 MW
32 MW
30 MW
5 MW
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14.02.2011
Investment and Cost of electricity basis
Investment costs – based on European figures:
Biomass preparation,
digester, Gas holder,…
25%
75%
Containerized
Cogeneration plant
1000 kWel. Plant - approx. 3,500– 4,000 € per kW
Initial cost of electricity – €cent/kWhel:
• 8000 operation hours per year
• Financing based on 10 years
Biomass input
95% manure
2/3 energy crops (Corn cost: 30 €/t)
palm oil mill effluent (Asia)
500 kW
1000 kW
~ 10
~ 15
~6
~8
~ 13
~4
19
14.02.2011
Biogas plant Kogel, Germany
No. of units and engine type:
Fuel:
Electrical output:
Thermal output:
Steam production:
Commissioning:
1 x JMC 420 GS-B.L
Biogas from food waste
1,413 kW
751 kW
3 bar(g) 1,037 kg/h steam production
Year 2002
20
14.02.2011
Biogas plant – Bösch Herisau/CH
No. of units and engine type:
Fuel:
Electrical output:
Thermal output:
Commissioning:
1 x JMS 320 GS-B.LC
Biogas from pig manure/slaughterhouse/ food waste
1,065 kW
21
1,115 kW
14.02.2011
March 2005
China’s first Chicken manurebiogas plant
Two Jenbacher biogas engines generate much needed energy
while helping to solve the farm’s waste problems: The farm
owns three million chickens, producing 220 tons of manure and
170 tons of wastewater each day.
22
14.02.2011
Sewage gas
• More than 460 Jenbacher sewage gas engines with an
electrical output of more than 330 MW worldwide
• Sewage fermentation produces fuel gas
• Waste water from city of half a million powers 1 MW plant
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14.02.2011
• Covers 100% of energy needed for sewage plant
Sewage Treatment Plant
Function Diagram Sludge Processing
Primary Sludge
High Loaded
Biology
Excess Sludge
Low Loaded Biology
Post-Thickener
Pre-Thickener
Mechanic
Thickener
MixingContainer
Chamber Filter Press
Raw Sludge
Digester
Sludge
24
14.02.2011
Utilization of Sewage Gas:
25
14.02.2011
Specific Sewage Gas Production:
• approx. 16.5 [liter/(population
equivalence; day)]
save value for simple process
• up to 20 - 25 [liter/(population
equivalence; day)]
optimized plant over long period
• up to 33 [liter/(population
equivalence; day)]
Example:
short term maximum for optimized
• 500.000 inhabitants
plants
• 1 person 20 liter gas per day
• 10.000 m³ sewage gas/ day
• LHV = 6 kWh/m3
• appr. 1,0 MWel
Source: Biogasvolume and Properties; U. Loll, ATV Seminar 2/99 Essen; Germany
26
14.02.2011
Experience in sewage gas operation
1988 – 2009
More than 450 engines installed (313 MW)
60
50
45
50
40
30
25
20
20
15
10
10
5
0
0
19
93
19
94
19
95
19
96
19
97
19
98
19
99
20
00
20
01
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
# Units / a
30
MWel / a
35
40
27
14.02.2011
Maximum power with waste water
After a record time major overhaul the plant is ideally equipped
for the next 60,000 operating hours: A J312 GS engine provides
electricity and heat for a facility that generates 120% of its
energy demand. The excess power is fed into the local grid.
28
14.02.2011
Landfill gas
• More than 1,350 Jenbacher landfill gas engines with an
electrical output of more than 1,300 MW worldwide
• Organic decomposition produces fuel gas
• 1 million tons of waste power 1 MW plant for more than 15 years
29
• Waste from US city of 1 million can power 8 MW
plant
14.02.2011
Experience in Landfillgas operation
1988 – 2009
80
80
60
60
40
40
20
20
0
0
[MWel]
100
20
09
100
20
07
120
20
05
120
20
03
140
20
01
140
19
99
160
19
97
160
19
95
180
19
93
180
19
91
# units
More than 1.500 engines installed (1.370 MW)
30
14.02.2011
Landfill gas is captured by wells and turned
into energy with Jenbacher gas engines
31
14.02.2011
Landfill gas project Maribor/SLO
GE’s Jenbacher Generator-Set in operation since 1998 with
one J312 engine producing 625 kWel.
32
14.02.2011
Landfill gas project Arpley/UK
Biggest landfill gas installation with 18 x JGC 320
with 18.6 MW el, in operation since 1999
33
14.02.2011
Optimized plant concepts for biogas
installations
Gas Requirements:
• gas pressure
• methane number
• gas temperature/relative Humidity
• heating value fluctuation
• contaminations
– Sulphur,
– Halogens,
– Ammonia,
– Silica …
35
14.02.2011
Gas Requirements:
• Gas temperature < 40°C
mixture temperature limited by rubber materials of gas train •relative humidity < 80%
(at every gas temperature)
condensate in gas supply –filter; pressure regulator; gas train,.....
–condensate in engine/intercooler 36
14.02.2011
Gas humidity / cooling:
Gas filter filled with condensate
water
Amounts of condensate water
are significant
Distance to dew-point to small
Taking measures upfront is
important
37
14.02.2011
Reduce humidity:
Gas pipe + pre heating second best
solution
Active humidity reduction best solution
Cooling system
biogas
soil
Gas compressor
Condensate trap
4Only reduction of rel humidity; works only
at a low gas temperature level
4Water content is not changed
4Avoid condensate drain off in
subsequent parts
Gas compressor
Condensate trap
4 Effective reduction of water
content
4 Reduce danger of having
condensate in the gas system
4 Reduce risk of corrosion!
4Gas cooling by gas pipe in soil helpful,
but no controlled condensate removal
38
14.02.2011
Optimum Layout of gas supply:
Condensate trap at the
lowest point
Condensate drain
below blower level
39
14.02.2011
CH4- Signal only helpful for engine start:
For optimized engine start behavior in case of LHV fluctuation :
Buffer tank
Flushing pipe
to boiler,
flare or
buffer tank
DIA.NE® XT : 4 gas types
CH4
signal for gas type selection 1.....4
gas train
40
14.02.2011
Gas Requirements
Sulfur:
H2S
< 700 mg/100% CH4
Standard maintenance schedule
Σ H2S < 2000 mg/100% CH4
„modified“ maintenance schedule
acidification of oil reduced Oil lubricity SOx + H2O corrosion deposits in exhaust gas heat exchanger, when temperature is
below dew point 41
14.02.2011
Gas Requirements TI 1000 – 0300
Sewage Treatment Plant
Sulfate deposits
exhaust gas temperature
below dew point
42
14.02.2011
Dew-point-line for SOx
170
Acid dew
dew-point [°C]
150
130
110
90
Cooling of exhaust gas not below 220°C (180°C) recommended!
70
≈ 100 ppm H2S in Fuel gas
(LHV = 6,5 kWh/Nm³)
50
0
10
20
30
40
50
Acid concentration in exhaust gas [mg SOX/m³]
43
14.02.2011
Oil Requirements
Biogas plant DK
Polymerization of oil
H2S approx. 3400 mg/100% CH4
oil change interval
exceeded by 100%
Sulfur
44
14.02.2011
H2S reduction:
Air dosing
Biological H2S reduction
biogas
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insert it again.
Air
4 allocation of air is important
4Consider max. air volume
4H2S reduction is not constant
4The additional air increase
corrosion activity
air water
4Saturate the water content of the
gas
4The additional air increase
corrosion activity
4H2S reduction is stable!
4Higher investment costs
45
14.02.2011
Solution special Biogas heat exchanger:
• Cooling down to 180°C or 220°C
• Exhaust gas heat exchanger without pipes at the bottom no condensate
around the pipes
• Big condensate trap (DN50) + falling condensate pipes
46
14.02.2011
Improve fuel gas quality for landfill gas
Activated carbon adsorber
Fuel gas cleaning system
• Sewage gas and landfill gas frequently
contain gaseous silicon compounds
• Quality of the gas has a big influence on
the availability of the gas engine
The GE solutions:
Automatic self-regenerating TSA
(Temperature Swing Adsorber)
• Prevents formation of silica in the engine
• Increases component lifetimes
• Ensures continuous operation over the engine life
47
14.02.2011
Installation surface:
Elastic elements
Sylomer strips
•Evenness < +/- 1,5 mm
•no foundation necessary
•dynamic load < 3% installation weight
48
14.02.2011
The variety of heat utilization concepts
Natural gas fueled CHP
• More than 4,200 natural gas fueled cogeneration units with an
• Highly efficient generation of power, heat and cooling
• Minimizes transmission losses
50
• Enhanced total efficiency – greater than 95% GE Power & Water - Jenbacher gas engines
14.02.2011
• Reduces fossil fuel use and greenhouse gas emissions
CHP prinicple
By the combustion of fuel inside the engine, mechanical and thermal power
is generated.
•The mechanical power is converted to electrical energy in the alternator
•The thermal output can be used via heat exchangers to heat up media
51
14.02.2011
The right engine for each individual output
requirement
Product line 2010 (50Hz)
4.500
4.000
4029
3865
45.4%
Electrical output [kW]
Thermal output (70°C/90°C) [kW]
2.000
1.500
0
1190
1201
888
901
1064
1190
835
988
625
731
500
39%
329
361
1.000
40.8%
1489
1502
43.4%
2674
2604
2.500
45.0%
2007
1952
Natural gas
NOx 500 mg/m3N
(Dry exhaust gas; based on 5% O2)
3.000
3349
3238
3.500
JMS 208 JMS 312 JMS 316 JMS 320 JMS 412 JMS 416 JMS 420 JMS 612 JMS 616 JMS 620 JMS 624
GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L GS-N.L
52
14.02.2011
Power plant output range
Product line 2009 (50Hz) – Natural gas NOX ≤ 500 mg/m³N
Electrical Efficiency up to 45% Thermal Efficiency up to 50%
Type 6
12 x J624
10 x J420
Type 4
8 x J320
Type 3
Pel (kW)
Electrical Output
Thermal Output
Additional benefits with multiple engine approach
• High fuel efficiency: engines constantly running at nominal load and efficiency
• Availability and reliability: stable electrical output
• Flexibility: scheduled maintenance in sequence
53
14.02.2011
Cogeneration of heat and power (CHP)
CHP systems utilize the waste heat incurred during engine
operation to generate overall plant efficiencies of more than 90%.
HE 1
Mixture intercooler
HE 2
Oil exchange heater
HE 3
Engine jacket water heat exchanger
HE 4
Exhaust gas heat exchanger
54
14.02.2011
Temperature levels of different heat sources
Min.
Max.
Danger
Engine Jacket water
57°C
95°C
Overheating
Lube oil
70°C
90°C
Viscosity
Intercooler
55°C
80°C
Condensation
Exhaust gas
(50°C)
220 (180)°C Acid dewpoint
Condensate!
55
14.02.2011
Recoverable Heat w/ Integration 70/90°C
56
14.02.2011
Heat utiliziation in Biogas-CHP
JMS 312 GS-B.L (C225)
Electr. Output:
Recov. Heat:
LT-IC heat:
526 kW
524 kW
23 kW
Therm. Efficiency: 40,3%
57
14.02.2011
Natural Gas – CHP/Trigen Segments
District Heating & Cooling
• Regions: Europe (specially EE), ME
• Incentives: Feed in tariffs
fuel tax exemptions
Supply of buildings
•Worldwide opportunity
•Incentives: Feed in tariffs
fuel tax exemptions
Utilities,
Municipal Utilities
Hospitals, Airports,
Shopping Malls,
Universities, Hotels
Industry
•Worldwide opportunity
•Incentives: Feed in tariffs,
fuel tax exemptions,
investment credits,
import duty exemptions
Textile, Chemical,
Food, Beverage,…*
*) Any industry where electricity & heat are significant portions of
the product cost (eg. textile, chemical industry, food industry…)
Industries with high pressure steam demand are NOT target
segments (e.g pulp & paper)
58
14.02.2011
Zelezara Skopje 30MW – 10 x JMS 620
180GWh
540GWh
720 GWh
166 000t CO2
370GWh
180 GWh
170GWh
~ 40% primary energy
savings
180GWh
430 GWh
80 GWh
85 000t CO2
170GWh
~ 50% savings in CO2 emissions
59
14.02.2011
Zelezara Skopje…
… requires about 300 GWh less primary energy
• equivalent to the energy contained in
180 000 barrels of oil
• equivalent to the energy contained in
40,000 tons of coal
… reduces CO2 emissions by 80,000 tons
• equivalent to the emissions of about
41,000 cars on European roads
• Equivalent to amount of CO2 absorbed
annually by 22 000 hectars of UK forest
(850 soccer fields)
Electricity for 45 000 European Households
Heat for 16 000 European Households
Annual comparison with the separate production of electricity on the European Grid and Heat by a natural gas fired boiler
60
14.02.2011
Helping Coca Cola to reduce CO2emissions
Coca-Cola Hellenic Bottling plants throughout Europe utilizing
GE Energy’s Jenbacher CHP engines, eliminating up to 40% of
their annual carbon dioxide emissions and reducing operational
costs by generating onsite heat and power.
61
14.02.2011
Cogeneration plant Altinmarka, Turkey
In the Cocoa production facility of Altinmarka in Turkey two JMC320
units running on natural gas provide 2 MW electrical and 2.3 MW
thermal output, 1.7 t/h as steam at 8 bar.
62
14.02.2011
Trigeneration with gas engines
• Operated with heat, utilizing inexpensive “excess energy”
• No moving parts in absorption chillers, no wear and therefore low maintenance
expenses
• Noiseless operation of the absorption system
• Low operating costs and life-cycle costs
• Water as refrigerant, no use of harmful substances for the atmosphere
63
14.02.2011
Maximum energy efficiency with
trigeneration at Cologne/Bonn Airport
Four of GE’s Jenbacher gas engines surpassed 200,000 operating
hours, and generated about 46,000 MWh of electricity annually
displacing the equivalent of 360,000* tons of CO2 since 1999.
64
14.02.2011
* According to the airports annual report 2007
Greenhouse application
• More than 500 Jenbacher CO2 fertilization plants with an
• Powers artificial lighting
• Provides heat for greenhouses
• Cleaned exhaust used as fertilizer
• Overall stronger plant growth
65
14.02.2011
Heat, light and carbon dioxide (CO2) promote
plant growth
CO2
Heat
Light
Enriching the greenhouse atmosphere with CO2, keeping the temperature
on a constant level and providing sufficient lighting, plant growth and
harvest yield can be increased significantly.
66
14.02.2011
CO2-Fertilization in Greenhouses
451°C
~50°C
90°C
40°C
condensate
70°C
Electr. Output:
526 kW
Recoverable Heat:
700 kW
LT-IC heat:
0 kW
Therm. efficiency: 53,8%
Additional benefits:
CO2 for fertilization:
380 kg/h
Condensation-Heat from the exhaust gas
67
14.02.2011
Driving innovation: The world‘s first
24-cylinder gas engine
The world’s first 4 MW 24-cylinder gas engine is powering one
of the largest commercial tomato greenhouses in the
Netherlands, offering an economic supply of on-site electrical
and thermal power while also employing the engines’ cleaned
exhaust gas as a fertilizer.
68
14.02.2011
Global Service 2010
69
14.02.2011
Where we are…
Jenbacher gas engine
Global Service
Alblasserdam,
Netherlands
Bussolengo,
Italy
Madrid,
Spain
GE Jenbacher,
Denmark
Hubs
Vienna/Veresegyház
(Central Europe)
Mannheim,
Germany
HQ Service, Austria
Houston,
USA
Midrand
(Johannisburg),
South Africa
Singapore
Facts
•
•
450 GEJ service employees world
wide
7 Subsidiaries + 2 Hubs
•
Presence
> 65 countries
•
Field service > 3,000 engineers
(GEJ and service providers)
70
14.02.2011
How we understand Service
Life-cycle management: The right service at the
right time – throughout the lifetime of your engine
Upgrades, Repair and Overhaul
Spare Parts
Commissioning
Contractual Service Agreements
Field Service
Training
Remote Monitoring,
Diagnostics and Servicing
71
14.02.2011
Broad Range of Service Solutions
Spare
Parts
Contractual
Service
•
•
•
•
Prev. & Corr.
Maintenance
agreements
Operating &
maintaining
Material
stream
agreements
Tele Service
•
•
•
Field
Service
Genuine
parts
• Inspection &
•
Overhauling
repair
•
Reprocessing
Reprocess.
parts
• Minor
•
Repairs
Emergency
packages
•Commissioning
•
Upgrades
•
Products:
- Short blocks
- Long blocks
- Gensets
Overhauls
Training
Center
Repair
Shop
•
•
Customer:
- Operators
-O&M
- Overhauling
Staff:
Improve/
Secure skill
levels
Customer
Support
•
Remote
diagnosis
•
Event
planning
•
2nd level
service
•
Helpdesk
•
Knowledge
base
72
14.02.2011
We are close to you
TOTAL Energy Business,
55th Floreasca st., Bucharest 014453
T : +40 21 569 84 45, F: +40 21 456 84 45
email : [email protected]
Headquarter
Manufacturing facility
Subsidiary/ GE office
Distributor/Service Provider
Jenbach, Austria
Main manufacturing site
and business HQ
Veresegyház, Hungary
Container manufacturing
73
14.02.2011

Jenbacher gas engines a variety of efficient applications

Transcription

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