GE Energy SeparatorsheetJenbacher gas engines

UseFECC this - range GTZ of background colors to introduce new sectionsTraining for Design Institutes - Beijing

From Biogas to electricity- CHP-use in operation

Thomas Elsenbruch

1/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GEEnergyInfrastructure Employees: 65,000 • ‘08 revenue: $38.6B • Operating in 140 countries Power&Water EnergyServices Oil&Gas

• Power generation • Contractual agreements • Drilling & completion • Renewables • Smart Grid • Subsea, offshore & • Gas Engines • Field services onshore • Nuclear • Parts & repairs • LNG & Pipelines • • Optimization • Pipeline integrity • Water treatment technologies • Refining • Process chemicals • Plant management • Processing

2/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GE’sJenbachergasengines

Aleadingmanufacturerofgasfueledreciprocatingengines forpowergeneration

1,700employeesworldwide,1,300 in /Austria 9,100+deliveredengines/10,800+MWworldwide Power range from 0.25 MW to 4 MW Fuelflexibility , biogas, flare gas, , steel gas, coal mine gas Advancedsystemsolutions Generator sets, container modules

, trigeneration, CO2-fertilization Environmentalbenefits Low emissions ecomagination solutions Lifetimeservices plus(parts, repair, CSA, upgrades) 2,000 units under CSA

3/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ProductProgram2010: Biogas,SewageGasandLandfillGas

3.500

3.000  Electrical output [kW]  Thermal output (70°/90°C) [kW] 2.500

Natural gas standard 2880

NOx ≤ 500 mg/Nm3 2737 2.000 (dry Exhaust gas; based on 5 % O2) 2403 2190 1.500 1802 1635 1421 1.000 1415 1138 1131 1088 1065 910 854 844 836

500 8 744 703 680 5 625 5 500 330 400 294

0 250 J 208 J 312 J 316 J 412 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 GS-B.L GS-B.L GS-B.L GS-B.L

4/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ThewholeJenbacherbiogasfleet: •Sewage gas: more than 450 installed engines (313 MW ) •Biogas: more than 1500 installed engines (1065 MW ) •Landfill gas: more than 1400 installed engines (1370MW )

400 400

350 350

300 300

250 250

200 200 MWel/a #units/a

150 150

100 100

50 50

0 0 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 5/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Jenbacher Biogasenginesinsome EUand Asian countries Installed in Biogas plants up to 31.12.2009: • Germany 945 engines 527 MW • Italy 161 engines 130 MW • Austria 90 engines 48 MW • Netherlands 69 engines 72 MW • Denmark 46 engines 35 MW • Czech Rep. 40 engines 28 MW • Belgium 32 engines 36 MW • Spain 32 engines 30 MW • UK 11 engines 12 MW • Poland 8 engines 6 MW • Hungary 7 engines 3 MW • Slovakia 6 engines 6 MW

• Thailand 42 engines 51 MW • India 37 engines 32 MW • Indonesia 28 engines 30 MW • China 10 engines 12 MW

6/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Gasenginesplay core role inbiogas plants

(incaseoffoodwaste) biogas-cogeneration units are core part of biogas plant, in combination with enhanced digester-technology

7/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Targetsofdevelopmentoptim. Biogas engine

Target: Optimized efficiency in operation with Biogas

Basicengines Optimized specific output

Frameconditions: •Biogas •Exhaust emissions •ThermodynamicOptimum

8/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Internalefficiency– combustionduration

Ind.Efficiency 0,53 ε =14 0,51 ε =12 0,49

0,47

0,45 ε =10 0,43

0,41 0 10 20 30 40 50 60 70 80 Combustionduration[°crankshaft] Higher compression-ratio helps the efficiency 9/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Comparisonofefficiencyofdifferentconcepts

The optimum of compression ratio and BMEP must be found

10/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GEJspark plugs/ignition system development

J316 Kläranlage Eugene / pme 17bar

34 P2 31 P3.V3

28 P7.4V1S1

25

22

Ignition voltage in [kV] 19 P1 P2 P4 P7 P3

16

13

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 operating hours

11/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 WWTPStraß/AJMS208GS.B.LC

WWTPStrassZillertal/A 1xJMS208GSB.LC

Electrical ouput 330kW Thermaloutput 420kW

Electr.efficiency

η el =39% Therm.efficiency

η th =48%

12/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 OptimizationofcombustionType2/3/4

OptimizedCombustion Acceleration by „heart-shaped“ bowl Minimized crevice volume • 30% lower HC • 30% lower CO increased compression ratio in combination mit „Miller“-timing

Old New

13/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 EfficiencyincreaseinBiogas

El.efficiency Type4B252011 0,44 Type4A25– 2007 0,4 Type3C212002 0,36

0,32 Type3B211997

0,28 Type3B271994

0,24

0,2 0 20 40 60 80 100 120

Load[%] 14/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Importantcriteriaforgasengineselection

15/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Leanburncombustionwithgasengines

•Lean combustion to ensure low NOx emission limits (500 mg/Nm³ and lower) •Reduced combustion temperatures enable higher specific outputs and efficiency

16/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Details:„Gasengineconcept“

Advantages: • “Cross flow” head (external exhaust gas manifolds) • Clear separation of cold mixture inlet and hot exhaust gas • Exactly defined thermal zones in the • Long cylinder head life time • Better accessibility to the exhaust gas manifolds

17/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 LEANOX® Leanburncombustion 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...) 18/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 TheNetworkingConcept

19/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Importantcriteriaforgasengineselection

•Select a specificallydesignedbiogascogenerationunit •Moderngasengineconcept (“Cross-flow” cylinder head, no derived ) •Turbocharged engine for high power density and efficiency •ElectronicNOxemissioncontrol, preferably with sensors outside the combustion chamber and exhaust gas manifolds •Enhancedignitioncontrolsystem (preferably with integrated electronic ignition voltage control) •Knockingcontrol (at least 1 sensor/ cylinder-line) •Enhancedenginecontrolsystem with alarm management (remote monitoring, diagnosis and control recommended) • Interfaces between engine control and system control

20/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Typicaloperationandmaintenancefigures

•Mainmaintenanceintervals: – Every 1,000 (2,000) ophs: and valve re-gapping, lube oil change (according oil analysis) – Btw 5,000 and 10,000 ophs: overhaul of , water pump… – Minor or top-end overhaul btw. 15,000 and 30,000 ophs depending on manufacturer and engine condition (change of cylinder heads, , liners, …) – Major overhaul: btw. 40,000 and 60,000 ophs depending on manufacturer: exchange of core-engine •Specific maintenance cost: – 1.5 – 2 US/kWh for preventive and corrective maintenance – Major overhaul: Appr. 60% of the initial investment for the genset. O&Mcostsofgenset appr.sameasinitialgenset investment

21/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ExampleBiogasGosdorf – OutstandingReliability

y ilit iab rel et fle ) % its 8+ un 9 0+ ge 45 era s ( av ga • Bio at

• Achieved 8,740 out of 8,760 oph/y in´05

• 99.8% Availability with Biogas 22/ GE Jenbacher / Thomas Elsenbruch • average 98+% fleet reliability at Biogas (450+ units) August 13, 2010 Heatrecoveryopportunitieswithgasengines

23/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Cogeneration ofheat andpower(CHP)

CHP systems utilize the waste heat incurred during engine operation to generate overall plant efficiencies of more than 90%.

HE1 Mixture HE2 Oil exchange heater HE3 Engine jacket water heat exchanger HE4 Exhaust gas heat exchanger

24/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Energysavings through CHPtechnology

Primaryenergy savings: roughly40%

25/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Temperaturelevelsofdifferentheatsources

Min. Max. Danger EngineJacketwater 57°C 95°C Overheating Lubeoil 70°C 90°C Viscosity Intercooler 55°C 80°C Condensation Exhaustgas (50°C) 220 (180)°C Acid dewpoint Condensate!

26/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 RecoverableHeatw/Integration70/90°C

27/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Heatutiliziation inBiogasCHP JMS312GSB.L(C225)

Electr.Output: 526kW Recov.Heat: 524kW LTICheat: 23kW

Therm.Efficiency:40,3%

28/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 SteamproductionwithGasengines

Foto: Biogas Kogel – 1 x JMC 420 GS-B.LC

JMS312GSB.L

Electr.Output:526kW

Therm.Output Hotwat.65/85°C:325kW Sat.steam,8bar:345kg/h (=231kW) LTICheat: 19kW

Therm.eficciency:42,7%

Feedwatermustbe conditioned!

29/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Advantagesoftrigeneration systemsover conventional refrigeration technology

• 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

30/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Trigeneration withgasengines

Electr.Output: 526kW RecoverableHeat: 550kW LTICheat: 40kW Coldproduction: ~385kW Therm.efficiency: 42,2%

31/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Drying process withGasengines

90°C

42 kW

Fuel gas 451°C ~130°C (cleaned)

70°C

JMS312GSB.L Electr.Output: 526kW Recoverable heat: 653kW LTICheat: 24kW Therm.efficiency: 50,2%

32/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Brickyard LUNDGAARD Stoholm Denmark 1xJMS212GSN.LC

Electr.Output: 465kW Recoverableheat:699kW Therm.efficiency: 59,0%

33/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Whatistherightpathwithbiogas?

34/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Whatistherightpathwithbiogas?

35/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Summary– BiogasinCHP

•Biogas plants are operated – weather independent – for base load supply •Biogas plants can be seen as stateoftheart technology •Because of low energetic density of source materials, biogas should be used decentralized •Using biogas in CHPmodules generates highest GHGsavings

36/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Importantdesigncriteria

37/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GasRequirements:

•gas pressure • number •gas temperature/relative Humidity

•heating value fluctuation In general these are •contaminations important criteria for Non Natural gases – Sulphur, – Halogens, – Ammonia, – Silica......

38/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Gas– plant:

Emergency flair

gas train

blower main valve standard Interface at gas train 80 – 200mbar

39/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GasRequirements:

• 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 

40/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Relativehumidity:

60

Example a) and b) : follow step 1 -4:

50 Through heating of a gas with a dew point of 24°C to a) 28°C - reduce the rel. humidity from 100 to 80% b) 37°C - reduce the rel. humidity from 100 auf 50% 80% rel. 40 humidity fog zone 100% rel. humidity 30 50% rel. 2 3a 3b humidity 20 Gas heating does not reduce the water content. It increase the offset to the dew point! 10 Water content [ g / operationcubic / gmeter] Watercontent[ 1 4a 4b 0 5 10 15 20 25 30 35 40 45 50 Gas temperature [°C]

41/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Gashumidity/cooling:

42/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GasRequirementsTI1000– 0300:

Condensate in the intercooler

43/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Reducehumidity:

Gas pipe + pre heating  second best Active humidity reduction  best solution solution

biogas Cooling system

3 soil Gas compressor Gas compressor Condensate trap Condensate trap

4Only reduction of rel humidity; works only at a 4 Effective reduction of water content low gas temperature level 4 Reduce risk of having condensate in the 4Water content is not changed gas system 4 Reduce risk of corrosion! 4Avoid condensate drain off in subsequent parts 4Gas cooling because of gas pipe mounted in soil possible but not sure

44/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Activegasdrying/biogasexample:

Schmack 1/Deutschland 1 x JMS 312 GS-B.L 500 KWel

Gas cooling / drying / dehumidification

Electr. chiller

45/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Layout example:

Condensate trap at the deepest point Condensate drain below the blower

46/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GasRequirementsTI1000 0300 Sulfur:

H2S < 700 mg/10 kWh (without catalyst) < 200 mg/10 kWh (with catalyst)  Standard maintenance schedule ΣΣΣ H2S < 1200 mg/10 kWh  „modified“ maintenance schedule  acidification of oil   reduced Oil lubricity 

 SOx + H2O  corrosion   deposits in exhaust gas heat exchanger, when temperature is below dew point 

47/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GasRequirementsTI1000– 0300 Sewage Treatment Plant Sulfate deposits exhaust gas temperature below dew point

48/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Sulfur/ashdepositsinanexhaustgasheat exchanger:

49/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Solution:specialbiogasheatexchanger

• Coolingdownto180°Cor220°C • Exhaustgasheatexchangerwithoutpipesatthebottom no condensatearoundthepipes • Bigcondensatetrap(DN50)+fallingcondensatepipes

50/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 51/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Internationalreferences

52/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Biogas plant Kogel, Germany

No. of units and engine type: 1 x JMC 420 GS-B.L Fuel: Biogas (potato peelings/pig manure) Electrical output: 1,413 kW Thermal output: 751 kW Steam production: 3 bar(g) 1,037 kg or 698 kW steam production Commissioning: Year 2002

53/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 BiogasplantPræstø,Denmark

No. of units and engine type: 1 x JMS 312 GS-B.L Fuel: Biogas from pig manure Electrical output: 625 kW Thermal output: 726 kW Commissioning: June 2002

54/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 BiogasplantDeQingYuan,China

No. of units and engine type: 2 x JMS 320 GS-B.L Fuel: Biogas from Chicken Dung Electrical output: 2126 kW Thermal output: 1234 kW Commissioning: Sept 2008

55/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Cowmanure“methanetoenergy” plantin Ludhiana India

Biomass Input: 235 ton/day cattle manure Electrical output: 1 MW Organic fertilizer: 35 ton/day

No. of units and engine type: 1 x JMC 320 GS-B.L

56/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ADofbiomass– NaturalpalmOil Thailand

Biomass: – POME - palm oil mill effluent Basic conditions: - 12m3/h POME - Temperature of POME fresh from mill 80°C -> cooling-down in open lagoon

1 x JGS 320 GS-B.L.C Power output: 1064 kWel. Commissioning: 2005

57/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ADofbiomass– NaturalpalmOil Thailand Biogas: biogas H2S content up to 2000ppm -> desulphurization is a must! -> done with a „BioGasclean-System“

Heat demand of the “Palm Oil Plant”: -> steam 22.5 to/hr (3.5bar; air water 0.5to/FFB)

Steam production: -> with “Palm Fiber” -> in addition with exhaust gas

58/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ADofbiomass– Kanoria I+II India: Biomass: – Spent wash – 675 m3/d -> effluent removed after fermenting sugar cane molasses (ethanol production)

1 x JMS 320 GS-B.L 1 x JMS 420 GS-N/B.L Power output: 1034 kWel. / 1416 kWel. Thermal output: Water:586 kWth. / 748 kWth. Steam: ~ 1350 kg/h; 10bar Commissioning: 1998 / 2003

59/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 BiogasplantHighmark,Canada

No. of units and engine type: 1 x JMC 320 GS-B/N.LC Fuel: Biogas from cow manure Electrical output: 1,060 kW Thermal output: 1,240 kW Commissioning: March 2004

60/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Thankyouforyourattention!

Further Questions?

61/ GE Jenbacher / Thomas Elsenbruch August 13, 2010