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SUPERCRITICAL CO2 REFINES COGENERATION n ENHANCING SCADA FOR COGENERATION nEFFICIENCY BREAKTHROUGH IN SOLAR THERMAL CELLS nREFURBISHMENT
DRIVES GROWTH IN RUSSIA n AWARD-WINNING CHP IN THE UKS nMEXICAN INDUSTRY TAPS COGEN POTENTIAL nTHE MAN DRIVING DOUBLE-DIGIT GROWTH AT MWM
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OnSite Power Production
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IMPLICATIONS OF VARYING GAS QUALITY NEW COGEN FACILITYS ROLE IN GERMANYS ENERGIEWENDE NEW LEASE OF LIFE FOR DH IN CEE REGION
CHINAS AMBITIOUS CHP EXPANSION PLAN AN INNOVATIVE OFF-GRID RENEWABLES PROJECT IN INDIA BIOCOAL: A NEW FUEL FOR COGEN?
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gas
air
Because the quotient of
the two densities (kg.m
3
)
is dimensionless, the WI has
the same dimension as the
calorifc value: MJ/m
3
. If the
WI changes, the power output
of the gas application also
changes unless corrective
steps are taken. The same
applies for the air-to-fuel ratio
, because for most systems
that consume gas, the air-to-
fuel ratio varies in inverse
proportion to the WI:
(new) = WI(initial)/WI(new)
(initial)
The air-to-fuel ratio
determines the temperature of
the fame and the combustion
velocity, so the combustion
process will change with the
WI, and thereby affecting fuel
effciency, thermal load and
emissions.
For example, if the WI drops
from 55 MJ/m
3
to 50 MJ/m
3
, the
initial value of 1.9 increases
to 2.1. If the application is
a gas engine with a venturi
carburettor to prepare the
fuel-air mixture, the engine
would most probably misfre
and stop fully.
If for the same initial value
of 1.9, the WI increased from
50 MJ/m
3
to 55 MJ/m
3
, the new
value of would fall to almost
1.7, resulting in substantially
higher NOx emissions and,
most probably, knocking. In
addition, the power output
would increase by 10% and
potentially leading to system
overload
Standards
Less than a decade ago the US
had big plans for importing LNG
because its domestic resources
were declining and it wanted to
ensure security of supply, plus
natural gas produces lower
greenhouse gas emissions
compared to coal.
Terminals for receiving
LNG were built at major ports
along the east and west
coasts. Up to then the US had
enjoyed reasonably stable gas
compositions, but there were
fears over the consequences
of the differing compositions
of the LNG. This led the Federal
Energy Regulating Committee
(FERC) to approach the US
Natural Gas Council and other
interested parties on how to
deal with the anticipated
problems.
A new committee, NGC+,
was established, with
members from equipment
manufacturers, power plant
companies, pipeline operators,
gas distributors, feedstock
companies and LNG suppliers.
Over the course of 19
meetings, the 71 stakeholders
discussed all aspects of
combustion effciency,
emissions, fame stability and
appliance performance. As a
result, a White Paper on natural
gas interchangeability and
non-combustion end use
1
was
issued on 28 February 2005.
Table 1 gives the agreed
values for some gas indices,
while Figure 2 shows how
these values affect the upper
calorifc value and WI.
In the White Paper, the WI is
allowed to vary in the range
4% around the traditional
average value of 53.16 MJ/
m
3
, while the upper calorifc
value can vary by 6% around
41.17 MJ/m
3
. It is important to
note that the upper calorifc
value is specifed here for
a reference temperature
of 25C, while Table 1 uses
reference conditions for a m
3
of 101.25 kPa and 273.15 K.
These reference conditions
often differ depending on the
country or the organization,
and care should be taken to
take this into account when
comparing different gas
quality standards.
In Europe, the EASEEgas
consortium, made up of
primarily members from
the gas sector, has been
working for almost a decade
on specifcations for the
transborder transfer of
natural gas.
Table 2 lists the gas quality
index values set for this.
Based a mandate from the
Table 1. Limits in gas index values in the US
Index Maximum value
WI 55.06 MJ/m
3
Upper calorifc value 43.73 MJ/m
3
C4
+
gases 1.5 mol %
Inert components 4%
Flow over a restriction: the Wobbe Index
p
P = . H
i
(if this is constant, no change in
energy supply
= c p/
gas
Wobbe = H
i
/
gas
/
air
H
i
= lower calorific value (MJ/m
3
)
= density (kg/m
3
)
Figure 1. Schematic of the Wobbe Index
1305COSPP_14 14 5/14/13 2:17 PM
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Cogeneration & OnSite Power Production | May - June 2013 www.cospp.com 16
Gas qualitys impact on DG
Commission, the organization
of gas transmission
operators, ENTSO-G, and the
normalisation committee, CEN,
are now turning this into a
standard.
It appears that in the
EASEEgas proposal, almost any
natural gas available in the
world can be accepted. This is
welcomed by gas traders and
shippers but has signifcnatly
negative consequences for
gas consumers.
A range in the WI between 49
MJ/m
3
and 57 MJ/m
3
means
that a gas-consuming device
can suddenly experience a
decrease of 14% in fuel supply.
In such a case, an initial air-to-
fuel ratio of 2 in a gas engine
or a gas turbine combustor
will instantaneously become
= 2.3, resulting in combustion
instability and misfring. The
gas standards do not exclude
so-called plug fow, which
means that a sudden change
in composition of the gas
supplied can always occur.
A change in the opposite
direction in other words a
sudden jump in the WI from
49 MJ/m
3
to 57 MJ/m
3
will
decrease the air-to-fuel ration
from 2 to 1.7, resulting in
16% more power, a higher
combustion velocity and higher
combustion temperatures.
The power output controller
of a gas engine can normally
handle a rapid change in
output caused by a change
in WI. In engines that feature
a carburettor, the throttle valve
will readjust the amount of
mixture fowing to the engine,
and in gas engines with
electronic gas admission
valves, the readjustment in
power output will be even
faster. However, the air-to-fuel
ratio of carburettor-based
engines takes longer to control
because of the adjustment in
the carburettor setting.
Knock resistance
In gas engines, a gas with
a higher volumetric calorifc
value will generally have a
lower knock resistance the
knock resistance of gaseous
fuels is expressed by the
methane number (MN).
The MN method was
initially developed at the
laboratories of AVL in Graz,
Austria, with a consortium of
German and Austrian engine
manufacturers in the early
1970s. In that programme,
no hydrocarbons higher
than butane were taken into
account. Subsequently, the
initial method was improved to
ft the actual performance of
modern engines. The effects of
higher hydrocarbons, such as
pentane, hexane and heptane
on the methane number are
now included.
Gas engines in stationary
applications for cogeneration
and on-site power production
demonstrate optimum
performance with a MN of 80
or higher. This also applies to
natural-gas-fuelled trucks and
ships. Fuel effciency, power
output and load-step-response
capability are negatively
affected by low MNs.
Some gases within the
EASEEgas range, such as LNG
from Libya, have a MN as low
as 63. Figure 4 shows MNs for
a selection of natural gases
that lie in the EASEEgas range.
Gases with an MN of less
than 60 might even occur if
the specifcations contain
no lower limit for the MN. The
specifcations for gas in the
US guarantee that the MN is
always above 73.
Gas treatment
Shale gas in the US
3
varies
widely in composition from site
to site. To comply with the NGC+
limits, the concentration of
higher hydrocarbons is reduced
by condensing them out (Figure
5) as natural gas liquids (NGLs).
These NGLs help to make shale
gas production proftable.
According to Valerie Wood,
president of EnergySolutions
3
:
NGLs are priced in accordance
with crude oil prices. The
production of high-value NGLs
helps to lower natural gas break-
even prices.
However, gas transmission
operators in Europe refuse
to see removal of higher
hydrocarbons at LNG terminals
as a solution for obtaining
narrower gas specifcations.
Their excuse is that European
and national legislation
prohibits gas transmission
companies from selling NGLs
to refneries. Such an aberration
can easily be rectifed.
Also, rich gases might occur
only occasionally, resulting
in a low utilisation factor
for a treatment installation.
However, that is no excuse.
In electricity supply, peaking
plants necessary to keep the
system stable also have a
limited number of operating
hours per year. Keeping the WI
in a narrow range, even with a
large number of gas sources,
is not a technical problem.
Gasunie in the Netherlands
has maintained the WI of
the L-gas and H-gas within a
range of 2%.
Billing
An important negative aspect
of a wide range of gas
compositions is the variability
in volumetric calorifc value.
As mentioned earlier, the
EASEEgas specifcations
allow an upper calorifc value
of between 36 MJ/m
3
and
48 MJ/m
3
. However,
commercial and domestic
gas consumers use a gas
meter that is based on volume
fow without a correction for
calorifc value.
Gas distribution companies
have a policy of correcting
gas bills for the average
calorifc value over a certain
time span. However, under
the proposed regulations, the
gas composition can change
Figure 3. The range in upper calorifc value and WI proposed by EASEEgas
compared with the much narrower range of the NGC+
36
38
40
42
44
46
48
48 49 50 51 52 53 54 55 56 57
u
p
p
e
r
c
a
l
o
r
i
f
i
c
v
a
l
u
e
(
M
J
/
m
3
)
Wobbe Index (MJ/m3)
Brown = EU EASEEgas Red = USA NGC+
36
38
40
42
44
46
48
49 50 51 52 53 54 55 56 57 U
p
p
e
r
c
a
l
o
r
i
f
i
c
v
a
l
u
e
(
M
J
/
m
3
)
Wobbe Index (MJ/m3)
USA NGC+ limits
Figure 2.The range in upper calorifc value and WI, as per the USA NGC+
Table 2. Gas index specifcations as per EASEEgas
Quality Index Unit Min. Max.
WI MJ/m
3
48.96 56.92
Relative density 0.555 0.700
1305COSPP_16 16 5/14/13 2:17 PM
For more information, enter 9 at COSPP.hotims.com
1305COSPP_17 17 5/14/13 2:17 PM
Cogeneration & OnSite Power Production | May - June 2013 www.cospp.com 18
Gas qualitys impact on DG
instantaneously and frequently.
Proof of this has already been
seen at a cogeneration
installation at a point at where
three gas streams met.
An owner of a local
generating set, such as a
cogeneration plant for a
greenhouse, might use the
installation to sell electricity to
the grid during times of peak
demand. With todays gas
prices, the proftability of such
plants is only marginal. If the
calorifc value at a given time
is only 36 MJ/m
3
and the gas
company charges the CHP
plant for a calorifc value of
40 MJ/m
3
, it appears that the
electrical effciency of the CHP
plant has dropped from 45%
to 40.5%.
Instantaneous monitoring
of plant performance based
on the quotient of electricity
production and gas fow
will be fawed under such
circumstances.
Optimum adjustment for
minimum NOx emissions is
also not possible with a wide
range in WI.
Widespread concern
It is not only the cogeneration
and on-site power sector that
is worried about the proposed
wide range in gas quality.
BDH, the German association
of energy and environmental
industries, and Figawa, the
countrys association of gas
and water companies, have
voiced their concerns in a
letter to stakeholders.
Most existing gas appli-
ances are not able to cope
with a wide range in gas
composition. In the UK, the
allowed WI is restricted to
between 47.2 MJ/m
3
and 51.2
MJ/m
3
, which is about the
same range as that of the USA
NGC+. Research has shown
that expanding this range is
extremely costly because the
required scale of investment is
factors higher than any profts
that come from acquiring
cheaper gas.
A paper from Jackson, Finn
and Tomlinson
4
propose an
effective method for extracting
higher hydrocarbons from
LNG. Ballasting rich gases
with nitrogen is ofter proposed
to reduce the WI and the
calorifc value. This, however,
is of no use for gas engines
because nitrogen in the fuel
gas does not improve the
knock resistance in modern,
high-performance, lean-burn
engines.
Arguments by the gas
sector that engines and
turbines are just a small
segment in the gas market
does not bear any relationship
to the reality and the future.
Better insulated homes
and solar heat collectors will
drastically reduce the use of
gas for heating purposes. In
contrast, gas use in engines with
the ability to rapidly respond to
the intermittency of renewable
energy from wind and sun will
substantially increase. Next to
that, gas-fuelled cogeneration
is still a favoured way of saving
fuel and reducing greenhouse
emissions.
Unfortunately, the gas
industry is also now trying to
convince countries outside
Europe to adopt the gas quality
range as proposed for that
For more information, enter 10 at COSPP.hotims.com
Figure 4.The MN range of a series of gases that ft the initial
EASEEgas specifcations
y = -4.9945x + 289.33
R = 0.79496
60
65
70
75
80
85
90
95
100
105
36 37 38 39 40 41 42 43 44 45 46 47 48
M
e
t
h
a
n
e
N
u
m
b
e
r
Upper calorific value MJ/m3 (25 C, 273.15 K)
MN
Linear (MN)
1305COSPP_18 18 5/14/13 2:17 PM
www.cospp.com Cogeneration & OnSite Power Production | May - June 2013 19
Gas qualitys impact on DG
region. Hopefully, democratic
processes will prohibit the
interests of consumers from
being ignored.
In 1986, a major gas quality
conference
5
was held in the
Netherlands in which experts
from gas companies from all
over the world participated.
The main message was clear:
gas quality should be user-led,
not supplier-led, and care has
to be taken for it not to become
politician-led.
In a nutshell
The proposed wide range in
transboundary gas composition
by the gas industry in Europe
has negative consequences for
fuel effciency, power capacity
and emissions of gas-fuelled
equipment. And the aspirations
of European policy makers on
security of supply and open
markets for natural gas will
ultimately result in higher costs
for most gas users.
The economic benefts for
Europe of accepting all gas
available on the world market
regardless of its quality may
well be lower than the extra
costs incurred by adapting
gas consuming equipment for
effciency loss and for emission
increases.
Solutions for reducing the
large range in gas quality
available on the market are
standard, proven and globally
widespread.
In Europe, gas companies
have so far dominated all
policy making on gas quality
without taking into account
the expertise of equipment
manufacturers and users of
gas-fuelled equipment. The
US, in contrast, has followed a
more democratic path.
Finally, a wide range in
calorifc value will further
deteriorate and obscure the
way gas energy deliveries are
measured with gas meters.
And legislation in Europe
should allow gas transmission
companies to sell NGLs.
References
1. Natural Gas Council, White
Paper on Natural Gas
Interchangeability and
Non-Combustion End Use,
28 February 2005.
2. Leiker M, Cartelliery W,
Christoph K, Pfeifer U &
Rankl M, Evaluation of the
Anti-knocking Property of
gaseous Fuels by means of
the Methane Number and
its Practical Application to
Gas Engines, ASME paper
72-DGP-4, April 1972.
3. Darin L George &
Edgar B Bowles, Shale
Gas Measurement and
Associated Issues, Pipeline
& Gas Journal, pp3841,
July 2011.
4. www.natural-gasliquids.
com/editorimages/
downloads/UK%20Gas%20
Paper%2013-01%20(fnal).
pdf
5. G J van Rossum, editor,
Gas quality, Proceedings
of the Congress of Gas
Quality, Groningen, the
Netherlands, 2225 April
1986, ISBN 0-444-42628-0.
This article is available
on-line. Please visit
www.cospp.com
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1305COSPP_29 29 5/14/13 2:21 PM
Cogeneration & OnSite Power Production | May - June 2013 www.cospp.com 30
Project profle: Cogen supporting Germanys engery transition
(hot water) for local residents
and industrial customers. It
has a lower-carbon footprint
than conventional power
plants and boilers, and will
assist Germanys effort to
reduce greenhouse gas
emissions by 40% by 2020.
The engines fast start-up
aids Stadtwerke Rosenheims
operational fexibility, to
overcome the challenges
of intermittency caused by
adding wind and solar energy
supplies to the electricity grid.
The integrated
cogen facility has
a power capacity
of 36 MW and a
heat capacity of
44 MW
The J920 FleXtra has the
highest electrical effciency
in the 10 MW class of gas
engines, of 48.7%, and about
90% effciency in cogeneration
mode, depending on heat
utilization, says GE. Its two-stage
turbocharging design will also
help Stadtwerke Rosenheim
to meet Germanys goal to
improve its energy productivity
related to prime energy
usage by 2.1% annually.
Our fexible J920
technology offers both high
effciency and reliability levels,
which makes it the ideal large
gas engine distributed power
solution for industrial and grid
stabilisation applications, while
also minimising the customers
carbon footprint, said Karl
Wetzlmayer, general manager
of Gas Engines for Power
Generation, GE Power & Water.
GE applied more than 50
years of power generation
experience to the development
of its newest Jenbacher
engine, and more than half a
million engineering hours were
devoted to its design, analysis,
testing and verifcation.
The arrival of the new
engine at Rosenheim was
important for all involved: GE
and Stadtwerke Rosenheim
have shared almost a decade
of gas engine innovation
and cooperation, making the
utility an ideal associate to
showcase the J920 FleXtra,
Wetzlmayer added.
J920 FleXtra engine
Operating a J920 FleXtra at
48.7% electrical effciency
provides the capacity to
produce more than 76 GWh of
electricity per year, says GE. It
also avoids the consumption
of more than 6.4 million kWh
of natural gas per year (at a
gas price of 0.034 (US$0.044)
per kWh.), and the emission
of approximately 1500 tonnes
of CO
2
per year which is
equivalent to the annual
emissions of about 800 cars on
European roads.
In cogeneration mode,
the J920 FleXtra offers an
overall effciency of up to
90%, compared with the
separate production of heat
and electricity by a natural
gas-fred boiler and delivery of
electricity on the EU grid. Key
performance data are shown
in Table 1.
The gas engine prime mover
for on-site generation
The two main types of prime mover used for
cogeneration schemes are gas turbines and gas
engines, although fuel cells have also entered
the picture in recent years. However, one major
difference between cogeneration and other
energy plants, dictated by their production of
heat as well as power, is that most cogeneration
schemes are custom-designed, even at quite
small plant sizes. So it is not easy to generalise
about plant design they are all slightly different.
Nevertheless, generalising a little, gas turbines
are highly suitable for larger-scale plants the
type that serve industrial sites. They also provide
more exhaust heat, which is useful where a large
amount of industrial process heat is required. For
smaller cogeneration plants, more often used
to serve buildings, the reciprocating engine is
the prime mover of choice. This is because of
its greater fexibility in terms of starts-ups and
cycling, and because it is more thermally effcient.
Gas, diesel and dual fuel reciprocating engines
can all be used in cogeneration plant, but gas
engines are usually preferred because they have
considerably lower exhaust emissions and work
well with CHP applications, utilizing the fuel highly
effciently. Gas engines also produce very little in
the way of particulates.
Reciprocating engines are highly successful in
small-to-medium-sized CHP installations, where
the prime movers might typically be, say, 3-10 MW
machines. More power is obtainable using several
engines, and an array of engines also adds
operational fexibility and valuable redundancy.
Reciprocating engines tend generally not to be
designed expressly for cogeneration application,
which requires lots of heat in the exhaust.
Therefore, a chosen engine (gas, diesel or dual
fuel), will be optimized for the application. This is
comparatively easy to achieve by programming
control parameters or through fuel/air system
changes, so that a little thermal effciency is
sacrifced to obtain more exhaust heat.
The lean-burn gas reciprocating engine is
ideal for making best use of natural gas. Such
engines have been increasingly seen in Europe
and elsewhere as being ideal for distributed
power generation, which requires clean, reliable
power for long sometimes intermittent periods
of operation, at lowest cost. Other applications
include standby power for critical loads and
cogeneration systems.
Table 1. Key performance data
Performance data J920 FleXtra
(50Hz/1000 rpm)
J920 FleXtra
(60Hz/900 rpm)
Electrical output 9500 kW 8550 kW
Electrical effciency 48.7% 48.7%
Heat rate 7392 kJ/kWh 7392 kJ/kWh
Thermal output 8100 kW 7300 kW
Total effciency 90% 90%
1305COSPP_30 30 5/14/13 2:22 PM
Your source for electric fuel controls. rrrrrrrrrrrrrrrrrroooooooooooooooolllllllssssssssss YYYYYYYYYYYYYYYYYYoooooooooooooooooouuuuuuuuuuuuuuuurrrrrrrrrrrrrrrrrrrrrr sssssssssssssssssooooooooooooouuuuuuuuuuuuuuuurrrrrrrrrrrrrrrrrrrcccccccccccceeeeeeeeeeeeeeeee fffffffffffffffffffffffooooooooooooooooooorrrrrrrrrrrrrrrrrrrrrrrr eeeeeeeeeeeeeeeelllllllllllllllllllllllleeeeeeeeeeeeecccccccccccccctttttrrrrrrrrrrrrrrriiiiiiiiiiiiicccccccccccccccccccccc fffffffffffffffffffffffuuuuuuuuuuuuuuueeeeeeeeeeeeeeelllllllllllllllllllllll cccccccccccccccccooooooooooooonnnnnnnnnnnnnnnnttttttttttttttttttttttttttt oooooollllllllllllllllllllllsssssssssssssss YYYYYYYYYYYYYYYYYYYYYYYoooooouuuuuuuuuuuuuurrrrrrrrrrrrrrr ssssssssssssssooooooooooouuuuuuuuuuuuurrrrrrrrrrrrrccccccccccceeeeeeeeeeeeeee ffffffffffffffffoooooorrrrrrrrrrrrrrrrr eeeeeeeeeeellllllllllllllleeeeeeeeeeeeeeeeeeccccccccccccccccccttttttttttttttttttttttttrrrrrrrrrrrriiiiiiiiiiiiiiiiiiiiiiiiiccccccccccccccc ffffffffffffffffuuuuuuuuuuuuueeeeeeeeeeee cccccccccccooooooooooo lllsssssssssssss tttttttttttttttttttttttttrrrrrrrrrrrrr lllllllllllllll lllllllllllll nnnnnnnnnnnnnn ooooo ss ooooo ttttrrrr llllssssss rrrrrrrooo ..... Your source for electric fuel controls.
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