Wärtsilä and ABB Turbo Systems are jointly developing a two-stage turbocharging system for large four-stroke diesel engines that they claim will reduce fuel consumption and CO2 emissions.
Under the system advanced engine technology works alongside an engine with two turbochargers in series. These raise air pressure and airflow into the engine and raise its efficiency to as high as 76 per cent. Engine output and power density also rise by up to ten per cent, the companies say.
One potential application of the system is high-altitude power plants, where engine performance would improve as the system would compensate for the reduced air density.
The system employs intelligent engine control to allow optimum operation of advanced engine designs over the whole load range. This cuts NOx emissions significantly. Further emissions follow with the use of additional engine systems or exhaust gas after-treatment. Detailed selection of systems configurations allows operators precisely to select a combination of fuel consumption and reduction in emissions of CO2 and NOx, the companies say.
Reducing CO2 and NOx levels is high on the agenda of the market, the companies say, which is demanding environmentally sound solutions with competitive lifetime costs. This has been a driving factor in the development work.
The companies say the market for this technology in power plants could be big and that, according to their calculations, in certain power plant applications the payback time for investment in such systems could be less than two years of operation.
“We see this technology as being a key for the next generation of Wärtsilä emissions-friendly engines,” said Mikael Troberg, director of Wärtsilä testing & performance.
Mr Troberg added: “The conceptual design for the new power plant engine began three years ago. Testing of the concept, and verification of the technology, has been successfully carried out using four-stroke Wärtsilä 20 and Wärtsilä 32 engines.”
The companies say they have performed extensive joint testing of the two-stage turbocharging system at Wärtsilä’s test facility in Vaasa, Finland, on an engine from Wärtsilä. That company is focusing on developing the engine technology while ABB Turbo Systems is delivering the turbocharging technology, which will have defined performance in terms of airflow, pressure ratios and efficiency. They plan a major pilot project soon.
Diesel plants to supply Bangladesh quickly – but expensively
High-cost power from diesel plants will help Bangladesh reduce a worsening electricity supply situation by July.
State electricity authority the Power Development Board (PDB) will sign an agreement with UK-based company Aggreko to set up the two 100 MW plants at Khulna, by June 22, and Ghorashal, by July 28, after a government purchase committee approves the unsolicited deal.
Setting up these rental plants will invlove no floating tenders, the idea being to ensure power becomes available quickly. PDB officials had earlier told prime minister Sheikh Hasina that they wanted to buy electricity from the plants for about one year, before peaking power plants are installed in the country. But the PDB appears to have agreed to buy power from the rental plants for three years.
Aggreko already has a 40 MW diesel plant at Khulna, installed by the company in 2008 after it won a bid. It provides electricity at around Tk13.80 per unit ($0.199), a much lower price than the planned rental power stations. PDB and Aggreko have negotiated a price for power from the rental plants but will not say what its value is until the government committee finally approves the deal. However, an estimate puts it at Tk14.35 per unit.
Electricity from rental power plants is usually high as they are set up on a fast track under a contingency plan.
PDB also recently signed agreements with two local companies to buy 160 MW of electricity from two rental diesel plants, one at Bheramara, for Tk12.58 per unit, and one at Thakurgaon, for Tk13.74 per unit.
PDB has decided to 620 MW of rental plants in Bangladesh because they will provide power more quickly than plants set up after tender process. Land-based tendered plants take 18-24 months to be established. PDB is is negotiating with five other companies, apart from Aggreko, from the US, UK and Australia about the installation of the rental power stations. Prime minister Sheikh Hasina endorsed the decision.
At the signing of the memorandum of understanding for the new plants at Khulna and Ghorashal were finance minister Abul Maal Abdul Muhith, who also heads the government purchase committee, the prime minister’s adviser Tawfiq-e-Elahi Chowdhury and state minister for power and energy Enamul Haque.
Turkey launches power ship using MAN dual-fuel engines
Duel fuel engines are to form the heart of seaborne mobile power plants that will be able to provide electricity to an area quickly.
The engine manufacturer says this is their first use in such an application. Karadeniz Powership of Turkey will receive 24 engines from MAN Diesel for four power ships with a total output of 400 MW.
The engines can run on liquid fuels or ecologically friendly gas, which means they can use any infrastructure available. According to MAN, what makes the electricity-supply vessels unique is their conversion from former freighters into floating diesel plants that can bring power quickly to areas of need across the world.
Local power grids will use the ships temporarily to cover demand whenever existing power stations are insufficient or new facilities cannot be built quickly enough. The average stay of a ship in one place is expected to be three to five years. Their mobility makes them ideal for filling gaps for given amounts of time, for example while the construction of a land-based power plant is in progress or when demand for electricity becomes high, for example during the football World Cup in South Africa, which starts on 11 June.
The ships will supply power to Africa, Pakistan, Iraq and the Mediterranean. Karadeniz plans to extend its fleet of power ships to up to ten. MAN says power ships are gaining popularity in the power generation industry.
Shanduka-Aggreko to supply temporary power to 2010 FIFA World Cup in South Africa
Shanduka-Aggreko will supply temporary power to the 2010 FIFA World Cup, which starts on 11 June.
Under a £30m ($46m) energy rental contract the joint venture will provide electricity for broadcasting all 64 games of the tournament worldwide from South Africa’s ten World Cup stadiums. Power from the joint venture will also supply the International Broadcast Centre headquarters, the headquarters of the world football body FIFA and tournament technical services.
In total Shanduka-Aggreko is providing 35 MVA of power generating capacity to support the broadcasting of the 2010 FIFA World Cup. The power equipment for the International Broadcasting Centre (IBC) will be operating 24×7 during the tournament and is already providing essential power during the establishment and testing of the broadcasting facilities.
The power generating sets are a combination of Aggreko 500 kVA and 800 kVA generating sets at the IBC and 800 kVA generating sets at each World Cup stadium.
There are 10 stadiums with 3 x 800 kVA sets for the broadcasting. In addition twin 350 kVA generators are being provided at each venue to provide power for the LED pitch boards which will carry the sponsor’s messages during the matches.
The 11th venue is the FIFA temporary HQ for the tournament which has been established in Sandton, Johannesburg. Standby power is being provided with an ATS.
Julian Ford, Aggreko International’s director for marketing and sales development, said the joint venture will support the development of the company’s business in South Africa and demonstrates its vision for growth in the country. “This sponsorship builds on our previous contract for the supply of temporary power during the 2009 Confederations Cup and further underlines our long-term commitment to the global major events sector,” he said.
In 2009 Aggreko opened its first permanent depot in South Africa, in Midrand. The company generates over 800 MW across more than 20 African countries and employs 450 people on the continent. Shanduka is an African investment holding company.
MWM boosts gas engine’s performance
MWM of Germany has raised the performance of its TCG 2020 K natural gas engine by ten per cent and improved its efficiency.
The new engine is robust and suitable for isolated operation. It has the same output values as ISO conditions require but has increased inlet air temperatures and setup heights. The manufactuers says these features make it especially suitable for deployment in tropical climates, such as in Asia.
The engine comes in V12 and V16 versions with respective electricity outputs of 1125 kW and 1500 kW. Each has an electrical efficiency of 41.0 per cent. Armin Roeseler, MWM’s head of product management, explained how the company has improved the engine: “Among other things, a newly developed turbo charger and an optimized combustion chamber contributed to the increase in performance and efficiency while retaining the load response and isolated operation capabilities of the predecessor model.” Other improvements include optimizaton of the inlet and the spark plugs. The engine supersedes the company’s TCG 2020 OLS model.
Cummins releases compact gensets
Cummins Power Generation has showcased its latest range of compact generator products at the Bauma exhibition in Munich, Germany.
The C22D5 compact generator set powered by the Cummins X2.5 engine delivers more power from a smaller unit and with less environmental impact.
Cummins’s new gensets include those powered by the X1.3 engine, available in 8-11 kVA configurations at 50 Hz, those powered by the X2.5 in 17–28 kVA configurations at 50Hz and 12–20 kW at 60Hz, and the X3.3 powered sets rated 30-38 kVA at 50 Hz and 27-35 kW at 60 Hz.
Additional features include in-built fuel tanks, which provide fuel autonomy for more than 30 hours at a 75 per cent load, and savings on refuelling frequency, associated costs and emissions. Running costs are further reduced through an extended oil change period of 500 hours. Cummins supports the range with comprehensive warranty on services and parts.
GE grows range of Ecomagination engines
GE has added the LM6000-PF aeroderivative gas turbine to its Ecomagination range.
The LM6000-PF comes in 50 Hz and 60 Hz forms and has high efficiency, low fuel gas consumption, fuel flexibility, low emissions and low water usage.
“The LM6000-PF is a game changer in the 35-60 MW range,” said Darryl Wilson, vice president aeroderivative gas turbines for GE Power & Water. “With environmental and operational benefits that allow customers to meet and, in some cases, exceed governmental regulations while providing full generating capacity within ten minutes,” Wilson added.
GE claims the LM6000-PF’s reliability and availability are over 99 per cent and over 97 per cent, respectively, the highest among 35-60 MW aeroderivative turbines. LM6000-PF has versatile operational flexibility and employs GE’s dry low emissions (DLE) combustion technology, which eliminates the need for water injection to meet emissions requirements and guarantees NOx emissions as low as 15 ppm.
When compared with a typical simple-cycle gas turbine in the 35-60 MW range operating at 50 Hz with 35 ppm NOx, GE’s LM6000-PF avoids 15 000 tonnes of CO2, equivalent to the annual emissions of more than 7600 cars on European Union roads. The LM6000-PF can also reduce natural gas consumption by more than 278 000 GJ, equivalent to the natural gas consumed annually by more than 8000 households in Germany. Annually this can save fuel worth €1.9 million ($2.5 million) at €7 per GJ. The LM6000-PF can also reduce NOx emissions by 360,000 kg by operating at 15 ppm NOx instead of 25 ppm. In the case of water use, the DLE technology can avoid consumption of 37 400 m3 and result in more than €70 000 per year in operational savings.
The unit joins the LMS100 in the ecomagination range, to be part of which a product must significantly and measurably improve environmental and operating performance for customers, GE says. To determine whether this is the case the company performs a multi-tiered review process with an independent, third-party audit to ensure accuracy and thorough documentation of a product’s technological performance.
The core engine technology for the gas generator comes from the engines that power today’s wide-body aircraft.
Coal mine gas gensets offer China clean energy potential
Gensets buring coal bed methane (CBM) could be important sources of energy in major coal mining countries such as China, says German manufacturer MWM.
CBM is an ideal fuel for power plants that employ gas engines as prime movers because it has properties similar to natural gas and can provide high operational efficiency. Coal mines around the world have bought power plants that can burn CBM for their own power needs.
Beijing-based global power generation company MWM China is providing a wide range of China’s industries with electric power plant that employs gas engines to burn CBM.
The company has service centres in China and plans to establish more. China will be the first country outside Germany to install the company’s Remote Monitoring System, which allows MWM China to ensure reliability and availability at its customers’ plants.
Production of CBM for domestic and industrial energy needs has grown significantly in the USA. Other major coal producing countries such as China, Australia, Germany, UK, Poland and India have initiated research programmes into its use to generate electric power.
CBM originates in deep coal beds, in coal mine methane (CMM) and in abandoned coal mines. It has in the past caused explosions and deaths in China’s mines. Extracting the methane trapped in fissures in deep coal beds reduces explosion hazards in mines.
CBM is a clean fuel but when released into the atmosphere its global warming potential is about 21 times higher than that of CO2. Over the past few decades emissions of methane from China’s mines has increased significantly because of their increased productivity. Venting the gas from mines is expensive but modern technology and purpose-built extraction systems now allow CBM to be recovered and used to generate electric power.
Yanmar engines meet tougher emissions limits
Yanmar has launched an engine line that complies with the strictest exhaust emission regulations, EPA Tier 4 and EU Stage 3B.
The company recently displayed the range at the Bauma exhibition in Munich, Germany. Part of the range is the 4TNV88-CR unit, which outputs 35.5 kW at 3000 rpm. Another engine in the new line is the 4TNV94HT-CR unit, which extends Yanmar’s engine range for exhaust emission-regulated areas up to 88.4 kW at 2500 rpm.
The range employs technology such as common rail injection, cooled exhaust gas recirculation, diesel oxidation catalysts, diesel particle filters and electronic engine governing. A specific combination of these technologies with a specific output enables the engines to achieve NOx and particulates limits in line with the emission regulations. Yanmar can also provide “useful life” guarantees and service intervals required by the EPA authorities.
The company says the new technology offers lower fuel consumption, lower noise, precise after-treatment control, cleaner exhaust gas, the possibility for electronic diagnosis and a CAN interface.
The engines have the same engine block size and footprint as Yanmar’s previous units and the same power outputs, the Japanese company says.
For the European market the previous engines of outputs below 37 kW can be used under all exhaust emission legislations.