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Presentation 4. CHP Units in Biogas Operation

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Presentation 4. CHP Units in Biogas Operation GE Energy SeparatorsheetJenbacher gas engines UseFECC this - range GTZ of background colors to introduce new sectionsTraining for Biogas 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 Energy Services Oil & Gas • Power generation • Contractual agreements • Drilling & completion • Renewables • Smart Grid • Subsea, offshore & • Gas Engines • Field services onshore • Nuclear • Parts & repairs • LNG & Pipelines • Gasification • Optimization • Pipeline integrity • Water treatment technologies • Refining • Process chemicals • Plant management • Processing 2/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 GE’sJenbacher gasengines A leading manufacturer of gas fueled reciprocating engines for power generation 1,700 employees worldwide, 1,300 in Jenbach/Austria 9,100+ delivered engines / 10,800+ MW worldwide Power range from 0.25 MW to 4 MW Fuelflexibility Natural gas, biogas, flare gas, landfill gas, steel gas, coal mine gas Advanced system solutions Generator sets, container modules cogeneration, trigeneration, CO2-fertilization Environmentalbenefits Low emissions ecomagination solutions Lifetime services plus (parts, repair, CSA, upgrades) 2,000 units under CSA 3/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Product Program2010: Biogas, SewageGasand Landfill Gas 3.500 Electrical output [kW] 3.000 Thermal output (70°/90°C) [kW] 2.500 Natural gas standard 2880 NOx ≤ 500 mg/Nm3 2737 (dry Exhaust gas; based on 5 % O2) 2.000 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 ThewholeJenbacher biogasfleet: •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 EU and 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 Gasengines play core role in biogas plants (in case of food waste) biogas-cogeneration units are core part of biogas plant, in combination with enhanced digester-technology 7/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Targetsofdevelopment optim. Biogas engine Target: Optimized efficiency in operation with Biogas Basic engines Optimized specific output Frame conditions: •Biogas •Exhaust emissions •Thermodynamic Optimum 8/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Internalefficiency– combustion duration Ind. Efficiency 0,53 ε =14 0,51 0,49 ε =12 0,47 0,45 ε =10 0,43 0,41 0 10 20 30 40 50 60 70 80 Combustion duration [°crank shaft] Higher compression-ratio helps the efficiency 9/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Comparisonofefficiencyof differentconcepts 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 31 P2 P3.V3 28 P7.4V1S1 25 22 19 Ignition voltage in [kV] 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 WWTP Straß/A JMS208GS.B.LC WWTP Strass Zillertal/A 1xJMS 208GS B.LC Electrical ouput 330kW Thermal output 420 kW Electr. efficiency η el = 39% Therm. efficiency η th = 48% 12/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Optimization of combustionType2/3/4 OptimizedCombustion Acceleration by „heart-shaped“ piston 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 Efficiencyincreasein Biogas El. efficiency Type 4 B25 2011 0,44 Type 4A25– 2007 0,4 Type 3C21 2002 0,36 0,32 Type 3B211997 0,28 Type 3B271994 0,24 0,2 0 20 40 60 80 100 120 Load [%] 14/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Important criteriafor gasengineselection 15/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Lean-burn combustionwith gas engines •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: „Gasengine concept“ Advantages: • “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 17/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 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...) 18/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 TheNetworkingConcept 19/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Important criteriafor gasengineselection •Select a specifically designed biogas cogeneration unit •Modern gas engine concept (“Cross-flow” cylinder head, no derived Diesel engine) •Turbocharged engine for high power density and efficiency •Electronic NOx-emission control, preferably with sensors outside the combustion chamber and exhaust gas manifolds •Enhanced ignition control system (preferably with integrated electronic ignition voltage control) •Knocking control (at least 1 sensor/ cylinder-line) •Enhanced engine control system with alarm management (remote monitoring, diagnosis and control recommended) • Interfaces between engine control and system control 20/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Typical operationand maintenancefigures •Main maintenance intervals: – Every 1,000 (2,000) ophs: spark plug and valve re-gapping, lube oil change (according oil analysis) – Btw 5,000 and 10,000 ophs: overhaul of turbocharger, water pump… – Minor or top-end overhaul btw. 15,000 and 30,000 ophs depending on manufacturer and engine condition (change of cylinder heads, pistons, 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&M costs ofgenset appr. same as initial genset investment 21/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 ExampleBiogasGosdorf – Outstanding Reliability • average 98+% fleet reliability at Biogas (450+ units) • Achieved 8,740 out of 8,760 oph/y in • 99.8% Availability with Biogas • average 98+% fleet reliability at Biogas (450+ units) 05´ GE Jenbacher / Thomas Elsenbruch August 13, 2010 22/ Heat recoveryopportunitieswith gasengines 23/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 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 24/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Energy savings through CHPtechnology Primary energy savings: roughly 40% 25/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Temperaturelevelsofdifferent heatsources 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! 26/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 RecoverableHeatw/Integration 70/90°C 27/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Heat utiliziation in BiogasCHP JMS312GS-B.L(C225) Electr. Output: 526kW Recov. Heat: 524kW LT-IC heat: 23kW Therm. Efficiency: 40,3% 28/ GE Jenbacher / Thomas Elsenbruch August 13, 2010 Steam productionwithGasengines Foto: Biogas Kogel – 1 x JMC 420 GS-B.LC JMS 312 GS-B.L Electr. Output: 526kW Therm. Output Hot wat. 65/85°C: 325kW Sat. steam, 8 bar:345kg/h (= 231kW) LT-IC heat: 19kW Therm. eficciency:42,7% Feed water must be 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
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