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November - December 2013
HOW NEW ENGINE TECHNOLOGIES COULD ACCELERATE THE ADOPTION OF HYDROGEN-FUELED CHP Q WHY ONE US CITY CHOSE CHP TO REPLACE AN
AGEING COAL-FIRED GENERATING PLANT Q NOVEL WASTE HEAT RECOVERY TECHNOLOGY PROMISES TO MAKE GENSETS GREENER AND MORE EFFICIENT
Q THE CHALLENGES OF MODERNISING A 100-YEAR-OLD INDUSTRIAL CHP PLANT
W
W
W
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C
O
S
P
P
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C
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REO Town:
Clean and efficient
1311COSPP_C1 1 10/29/13 1:38 PM
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1311COSPP_13 13 10/29/13 11:51 AM
News
Cogeneration & OnSite Power Production | November - December 2013 www.cospp.com
14
Fuel Cell CHP Plant Delivered to
German Ministry
Fuel cell power plant provider
FuelCell Energy Solutions
(FCES) has announced
delivery of a combined
heat and power plant to
the German education and
research ministrys Berlin offce
complex, which is currently
under construction.
FCES will install the power
plant inside the offce
complex and commissioning
is expected in mid-2014.
Generating 250 kW, the
plant will supply 40 per cent of
the offce buildings electricity
needs and 20 per cent of its
thermal needs. Heat from the
plant will be used to generate
steam for facility heating and
absorption chilling.
The company says its
technology is fuel-neutral
and can use natural gas,
renewable biogas, directed
biogas and other fuels such
as propane. The Berlin power
plant will be fueled with
natural gas.
Founded in 2012, FCES is
a joint venture of Fraunhofer
IKTS and US-based FuelCell
Energy Inc. It is headquartered
in Dresden and has opened
a manufacturing facility
in Ottobrun.
LATIN AMERICAN BREAKTHROUGH
FOR BIOMASS APPLICATION
The San Juan de Olivos
olive facility in Argentina is
expecting to make signifcant
savings from the installation of
a biomass gen-set.
Dresser-Rand installed the
frst Guascor gen-set for a
biomass application in Latin
America at the San Juan
olive harvesting and olive oil
production facility.
The technology will power
the plants operation as well
as potentially provide surplus
power for the San Juan area
and is forecast to save the frm
up to US$600,000 in electricity
costs every year.
Dresser-Rand worked on the
project with LatAm Bioenergy
Group, a New York-based
engineering, procurement
and construction company,
focused on the sustainable
development of renewable
energy solutions in Latin
American countries.
The green power project
will use a Guascor SFGLD360
containerized CHP unit to
gasify the facilitys biomass to
produce syngas. The syngas
will power San Juan de Olivoss
production facility. The biomass
employed in this project will
be the waste wood collected
by pruning the olive trees,
and the extracted olive mash
and pits discarded during oil
production.
The process is expected
to yield roughly 250-300 kWe
each day covering all of the
facilitys energy demands. San
Juan de Los Olivos is also in the
process of acquiring a license
that will allow the facility to
generate surplus electricity that
can be exported to the Energa
San Juan power grid.
KIEV RESIDENTS FACING CHILL
Half the residents of Kiev,
Ukraine are in danger of being
left without heat as winter
approaches after the citys
electricity operator ordered gas
pressure to be cut to combined
heat and power plants.
Interfax Ukraine reports that
over 7000 Kiev heat consumers
(including houses and social
sphere facilities) could be left
without heating and hot water
supplies in the coming frst
autumn frosts after Kyivtransgaz
cut gas pressure to combined
heat and power plant fve and
combined heat and power
plant six.
The gas pressure is reported
to have been reduced as
Kyivenergo owed US$256m
(UAH 2.1 billion) to Naftogaz
Ukrainy for gas consumed. The
action has been a frequent
occurrence in the winter
months for the city.
At the moment Kyivenergo
supplies heat to only 17.6% of
residential buildings, 93% of
kindergartens, 48% of schools
and 82% of hospitals, as a result
of the action.
FORTUM SELLS
KUUSAMO
PLANT AS PART
OF EFFICIENCY
STRATEGY
Fortum has sold its cogeneration
plant at Kuusamo, Finland
to district heating specialist
Adven Oy for an undisclosed
price, as the company
seeks to drive through its
effciency programme.
The programme, which
began a year ago, sees Fortum
concentrating its combined
heat and power production to
larger centres and units.
The production capacity
of the Kuusamo plant is 6 MW
electricity and 19 MW district
heat. The Kuusamo energy and
water cooperative has been
responsible for operating the
Fortum-owned plant.
ALSTOM WINS
CHP CONTRACTS
Alstom has won US$231 million
worth of contracts to service
power plants in North America,
two of which are cogeneration
power plants.
The two CHP contracts are
located in Ontario and Alberta,
Canada, respectively.
Alstom was chosen to
execute a LTSA contract
with TransAlta Corp. (TAC)
in Canada for their Sarnia
cogeneration power plant
in Ontario and Poplar Creek
Cogeneration power plant
in Alberta.
Both TransAlta plants
operate Alstom built GT11N2
gas turbines.
The parts agreement will
be progressively booked
throughout the execution of
the contract.
1311COSPP_14 14 10/29/13 11:51 AM
News
www.cospp.com Cogeneration & OnSite Power Production | November - December 2013
15
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On-site power delivers a jolt to US utilities
Which companies generate the most
power from on-site renewable resources
in the US? In absolute terms, some very
large entities indeed Wal-Mart Stores,
the US Department of Energy, Apple,
BMW Manufacturing and Coca-Cola
Refreshments take the frst fve places
in a league table drawn up by the US
Environmental Protection Agency from
companies within its Green Power
Partnership. Wal-Mart stores generate
more than 100 GWh per year from biogas,
solar and wind power installations, while
Coca-Cola generates nearly half of
that, from biogas-to-power plants. But
Wal-Marts on-site generation represents
just 1% of its total power needs; Coca-
Cola generates just 6%.
Higher proportions of total power
use are to be found further down the
table. In fourteenth place lies the mainly
agricultural County of Yolo, in Northern
California, which generates 1.5 times
its own electricity requirements from
a series of solar power plants totalling
7 MW of capacity. And, in 19th place, the
Encina Wastewater Authority in Southern
California generates more than two thirds
of its electricity requirements from its own
waste biogases.
The EPA has recently honoured Apple;
the County of Santa Clara in California;
health care provider Kaiser Permanente
and the Chattanooga, Tennessee car
assembly plant operated by Volkswagen
Group of America for their use of
on-site power generation. Apple uses
a combination of large solar PV arrays
and biogas-to-power plants to supply
16% of the electricity requirements of its
US data centres and other facilities. The
County of Santa Clara, Kaiser Permanente
and Volkswagen Chattanooga all rely
on PV to supply towards 10% of their
electricity needs.
The EPA list ignores those public and
private sector organisations that use
gas-fred on-site CHP schemes, preferring
to highlight the role played by on-site
renewables. Put both of these generation
sources together, though, and a picture
emerges of US businesses staring to see the
sense of on-site energy generation as a way
to cut energy costs and insulate against
supply interruptions.
Separate from the EPA Green Power
Partnership, a recent Wall Street Journal
report describes on-site wind and biogas
schemes for a dairy in Pennsylvania and
a food distribution centre in California.
Meanwhile, home furnishings retailer
Ikea plans to incorporate geothermal
technology into the heating and
cooling systems of the store it is building
outside Kansas City. The company says
it either owns or operates more than
130 wind turbines and has installed
more than 30,000 solar panels for its
European operations.
For more information, enter 8 at COSPP.hotims.com
1311COSPP_15 15 10/29/13 11:51 AM
News
Cogeneration & OnSite Power Production | November - December 2013 www.cospp.com
16
English cogen specialist recognised
for industry leadership
ENER-G has been recognised
as a global leader in combined
heat and power technology,
after being shortlisted for the
Manufacturer and Engineer of
the Year Award in the Insider
North West International
Trade Awards, which will be
announced in December.
The nominations,
which recognise business
achievement in the northwest
of England, comes after the
companys success in the
prestigious COGEN Europe
20th anniversary awards for
exceptional contribution to the
European CHP sector.
ENER-G was the only
UK company recognised,
receiving the Market
Development Award for
its international role in
the advancement of
cogeneration.
The company designs,
manufactures, installs, fnances
and maintains cogeneration
systems from small-scale
4 kWe to large industrial
10 MWe modular installations
fuelled by natural gas, biogas,
propane, biodiesel or pure
plant oil (PPO).
A European market leader
in CHP, the company has
30 million hours of
cogeneration operating
experience and 695 MW of
generation capacity, which
has offset 1.5 million tonnes of
CO2 per year.
Major clients include
GlaxoSmithKline and
David Lloyd Leisure and
the company has worked
throughout Europe and most
recently begun implementing
projects in the US.
ENER-G pioneered the
pay-as-you-save Discount
Energy Purchase scheme in
the 1990s. This gives cash-
strapped organisations
access to CHP technology
and associated energy
effcient solutions, without any
up-front investment.
EIB PROMOTES USE OF CHP IN RUSSIA
The Primorye region on the east
coast of Russia is to beneft
from a European Investment
Bank (EIB) loan, which is set to
improve its energy capacity.
EIB is lending US$135 billion
(RUB 4 billion) to support the
modernisation of power and
heat generation technology
in Vladivostok, the regional
capital. It will enable electricity
to be generated to facilitated
50,000 apartments and heat
more than 600 family homes.
The project is part of a
larger programme to bring
natural gas to Russias Far East,
enabling a switch from coal
to natural gas as the primary
energy source and reducing
CO
2
emissions.
The loan the frst ever to be
extended by the EIB in Russian
roubles will fnance the
installation of three new state-
of-the-art combined heat and
power gas turbine units, which
will increase electricity and
heat production and bring
environmental and energy
effciency performance
into line with best practice.
This loan will contribute
to climate change
mitigation, which is a key
priority for the European
Union and therefore also
one of the key operational
priorities of the EIB, said
Wilhelm Molterer, EIB vice
president responsible
for lending operations in
Russia, adding that the
project also contributes
to the implementation of
the EURussia Partnership
for Modernisation.
The operation is being
carried out under the EIBs
Climate Change Mandate for
non-EU countries introduced
in 2011 and is being
co-fnanced with the European
Bank for Reconstruction
and Development.
Each of the three new
units will consist of a 46.5 MW
high-effciency gas turbine
and an associated 40 Gcal/h
heat-recovery hot water
generator. This will help to cover
the heat base-load throughout
the year in Vladivostok and
supply electricity to the region.
The project also includes
the installation of three
heat-only boilers (100 Gcal/h
each) to cover winter/peak
loads and replace the old
heat-only boilers currently
being used.
VASKILUODON VOIMA CHP PLANT IN LINE FOR METSO RETROFIT
Finnish power producer
Vaskiluodon Voima has agreed
with Metso on an extensive
automation retroft for a
combined heat and power
plant in Seinjoki, Finland,
replacing the automation
system the plant has used
since 1989.
Metso will install its DNA
automation system as well as
new automation for the fuel
reception, water plant, auxiliary
boiler and ash handling. It will
also provide an update to the
reporting system, an emission
monitoring application in line
with Europes 2010 Industrial
Emission Directive, and new
combustion control methods.
Metso expects to complete
the work by August 2014.
The Seinjoki power plant
supplies local electricity and
district heat with a boiler
capacity (steam capacity)
of 299 MW, turbine electrical
capacity of 125 MW and district
heat capacity of 100 MW.
The plants primary fuels are
wood chips and peat, with
coal used as a backup fuel.
1311COSPP_16 16 10/29/13 11:51 AM
News
www.cospp.com Cogeneration & OnSite Power Production | November - December 2013
17
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UNIVERSITY OF CALIFORNIA
COGENERATION PLANT GETS ITS
POWER BACK
Power has been restored to
the University of California at
Berkeleys cogeneration plant,
which had been without power
since an explosion damaged
the campuss underground
power lines on 30 September.
The universitys public affairs
offce said an investigation will
be launched into the cause of
the explosion.
The cogeneration plant
uses a natural gas-fred GE
LM2500 turbine generator to
produce 25 MW of electrical
power and 4 MWth of steam,
which is distributed through
underground tunnels to heat
campus buildings. The plant
is operated by GE and has
been online since 1987, with an
upgrade in 1998.
On-site power and heat
are common on the University
of Californias 10 campuses
-- such as UC Irvines 18 MW
cogeneration plant which uses
a combustion turbine and heat
recovery steam generator with
a chiller addition. And UC San
Diegos combined heat and
power facility, which features
two 13.5 MW gas turbine
generators, is part of a campus
smart microgrid system that
incorporates photovoltaic
solar panels and fuel cells and
meets over 90 percent of the
campuss power needs.
E.ON to supply CHP for Russian
industrial parks
E.ON and DEGA Group, a real estate developer in the Russian
Federation, have entered into a long-term partnership agreement
to build and operate on-site power generation facilities for DEGAs
Russian industrial parks.
DEGA already supplies business tenants on its Industrial Park
Noginsk, 48 km east of Moscow, with electricity and heat from
two 15 MW gas turbine combined heat and power units. E.ON
will now acquire a majority of the DEGA subsidiary that owns
and operates these CHP units, and will have exclusive access to
DEGAs pipeline of Russian industrial parks.
E.ON says it is expanding its distributed energy activities in
Russia, with a focus on services and light industries. The DEGA
partnership was signed with E.ON Connecting Energies, a new
international unit of E.ON SE focusing on energy effciency and
on-site generation solutions for businesses and the public sector.
For more information, enter 9 at COSPP.hotims.com
1311COSPP_17 17 10/29/13 11:51 AM
Cogeneration & OnSite Power Production | November - December 2013 www.cospp.com 18
H
ydrogen as a
cogeneration fuel
has yet to develop
the market
acceptance enjoyed by
natural gas and diesel-
fueled applications. But
that may be changing as
new technologies allow
renewable energy resources
to convert their output into
safe hydrogen that can
be stored for use in CHP
applications. Moreover,
new engine technologies
for generating heat and
electricity from hydrogen
could accelerate the
adoption of hydrogen-
fueled CHP.
In the past, hydrogen-fueled
cogeneration has typically
been associated with fuel
cell technology, and the
high cost of these systems
has been a limiting factor for
hydrogens viability as a fuel for
stationary power applications.
But the recent launch of a
dedicated hydrogen-fueled
CHP cogeneration system
from 2G Cenergy could
be a turning point for a
more economical solution,
according to Michael Turwitt,
the companys president and
CEO, based in St. Augustine,
Florida, US.
The idea to utilise fuel cells
for power generation sounds
very attractive for clean and
effcient energy production,
says Turwitt.
However, there are still
issues associated with the
technology such as very
high manufacturing costs,
performance and durability
issues, and high cost of fuel
production, especially if a
reformer is applied, he says.
Also, fuel cells require very
pure fuel, free of contaminants
including sulphur and other
carbon compounds. None
of these contaminants
inhibit combustion in an
internal combustion engine,
and reciprocating engines
do have a much higher
Hydrogen-fueled
CHP now on the horizon
Hydrogen as a fuel for cogeneration has yet to develop the market acceptance enjoyed by natural gas and
diesel-fueled applications, but new engine technologies for generating heat and electricity from hydrogen
could accelerate the adoption of hydrogen-fueled CHP, writes Ed Ritchie.
Cogeneration & OnSite Power Production | November - December 2013 www.cospp.com 18
Innovations promise hydrogen-fueled cogeneration
The installation of 2Gs hydrogen
fueled, engine-based CHP systems
at the new Berlin Brandenburg Willy
Brandt Airport energy station marks
an important milestone
1311COSPP_18 18 10/29/13 11:51 AM
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1311COSPP_19 19 10/29/13 11:51 AM
Cogeneration & OnSite Power Production | November - December 2013 www.cospp.com 20
Innovations promise hydrogen-fueled cogeneration
tolerance level for such
fuel impurities.
According to the National
Fuel Cell Research Center at
the University of California,
fuel cells could become
competitive with traditional
engine technologies in the
stationary power market if
they reach an installed cost
of US$1500 or less per kW.
(Currently, the cost is in the
range of $4000+ per kW.)
Compared to prices of $800
to $1500 for reciprocating
engine-based CHP systems,
Turwitt expects to see a broad
range of applications for
2G Cenergys products. For
example, the frst units found
a home at an energy station
within the Berlin Brandenburg
Willy Brandt airport in Germany.
The CHP installation
uses two hydrogen-fueled
engines powering 2Gs
Agenitor CHP systems, with
an output currently set at
400 kW/unit (units are capable
of 500 kW output). The CHP
plant functions as part of
a larger hydrogen vehicle
fueling project, operated by
a multi-national oil and gas
consortium that includes
Total (oil and gas distributor
and commercial flling
station operator), Enertrag
(renewable energy and wind
turbine project operator) and
The Linde Group (industrial
gas supplier and hydrogen
plant operator).
Given the commercial
partners and the German
governments strong support
for hydrogen as a clean energy
fuel, the timing could not have
been better to introduce a
hydrogen-fueled reciprocating
engine at the Berlin airport,
because the CHP system
expands the existing hydrogen
vehicle fueling station into
a self-contained hydrogen
complex. By incorporating an
Enertrag wind farm plus solar
panels from a Total subsidiary,
the project could achieve
100% renewable electricity to
power the system, supporting
an electrolyzer that produces
about 200 kg of hydrogen per
day (equivalent to about 50
full tanks of fuel cell cars).
Linde is responsible for the
development, installation
and technical operation of
the hydrogen station, which
plays an important role in
the conversion of wind to
hydrogen as a method for
gaining maximum effciency
from wind turbine generation
when there is no demand for
its output.
A portion of the hydrogen
now fuels 2G Cenergys CHP
system, generating green
energy for heat and electricity
at the airport where safe
operations at the plant are
critical to the projects success,
according to Turwitt. Using
hydrogen has always been a
safety question, he says
A lot of people have
said that hydrogen is highly
explosive and needs to be
handled safely, and that
requires certain technologies.
There are car manufacturers
that have hydrogen engines
in their vehicles but its never
been done as a serious
product for prime power
generation and CHP.
I think the biggest
breakthrough is our fuel
injection technology. Our
engineering group has
been working on this for
quite some time and it
helps tremendously for safe
operations. The port injection
enables us to prepare
and mix the fuel before its
injected into the combustion
chamber. That makes it
extremely safe and very
economical.
It is worth noting that
the CHP plants hydrogen
gas storage system
also represents a major
breakthrough for the industry.
Typically, hydrogen fuel
produced by electrolysis can
fuctuate, but this problem
is solved by a technology
for storing hydrogen in solid
form (metal hydrides) at
low pressure. This storage
enables a permanent supply
of hydrogen fuel for the 2G
CHP system.
It is manufactured by McPhy
Energy, based in Grenoble,
France, and uses a magnesium
hydride solid storage
technology. The airport unit
holds up to 100 kg of hydrogen
produced from electrolysis.
Safe storage is a key beneft,
and the technology can store,
at atmospheric pressure, as
much hydrogen as a 500
bar storage within the same
volume.
Utility-scale energy storage
is a high priority in Germanys
clean energy strategy. The city
of Berlin has offered 200 million
($271 million) between 2011
and 2014 for energy storage-
related research.
For the airport project,
the fnancial commitment
is equally impressive. The
funding for the capital and
operating costs (maintenance
and repair) to mid-2016
alone amounts to about
10 million. Among the
commercial partners, Linde
and Total each invested over
3 million. For Enertrag, it is
2 million and for the CHP
system, 2G has committed
1 million.
On the federal side,
the National Innovation
Programme for Hydrogen and
Fuel Cell Technology (NIP)
is providing 50% funding to
the participants to support
the federal governments fuel
strategy. According to Enertrag,
the investment is justifed. The
companys research shows
that Germanys storage
facilities amount to roughly
2Gs IL6 and V12 hydrogen-fueled engines power its agenitor
306 and 312 CHP systems
1311COSPP_20 20 10/29/13 11:51 AM
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Primary Fuel System Upgrade:
NOTE FOR STOP/RATIO VALVE:
Replace SRV (Stop/Ratio Valve) from Primary Lube
Oil supply and connect to Localized Hydraulic
Power Unit (See Hydraulic details below).
Stop/Ratio
Valve
Gas Control Valve (PM-1)
Gas Control Valve (PM-2)
Gas Control Valve (PM-3)
Quantanary
Gas Control Valve
FUEL
SOURCE
3010E 530 Series
3 Valve
3010E 530 Series
3 Valve
3010E 530 Series
3 Valve
3010E 520 Series
2 Valve
DLN 2.0
Replace all Hydraulic Control Valves with
Proven EMA All-Electric Control Valve
Assemblies (pictured at right).
EMA = Electromechanically Actuated
for PM-1; PM-2; PM-3; and Quantenary. DLN 2.6
Connecting the IGV assembly
to a dedicated HPU drastically
reduces potential for varnish
to occur.
Y&F 1270E200 Series
Hydraulic Power Unit
(
ONLY ADDITION
)
Unison
Ring
Existing Dither Resistant IGV
Oil Feed
Oil Return
Control Signal
Feedback
Existing Turbine
Process Fuel
Control System
(
UNCHANGED
)
Independent HPU
replaces turbine
lube oil supply
for controls.
(SRV & IGV ONLY)
Unhook Inlet Guide Vane Actuator and Stop Ratio Valve from Turbine Lube Oil system.
Install a Hydraulic Power Unit (or HPU, such as the Y&F 1270 Series, pictured below)
and initiate Y&F supply for the system.
Link
GO ELECTRIC.
Y&F 8580 Series
Stop Ratio Valve Assembly
Inlet Guide Vane Actuator and
Stop Ratio Valve Localized
Hydraulic Subsystem Upgrade:
Di h R i
Link
How do you reduce varnish impacts on turbine controls?
Control Signal
Feedback
(
ONLY ADDITION
) (
ONLY ADDITION
)
(
UNCHANGED
) (
UNCHANGED
)
Oil Feed
Oil Return
SPECIALTY SOLUTIONS
QUALITY SOLUTIONS
ENGINEERED SOLUTIONS