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1. INTRODUCTION
The OMES Project [1] is partly financed through the EU 5th Frame Working
Programme. Participants in the project are Gasum, Finland Vattenfall/SGC and the
microturbine manufactures Turbec from Sweden Statoil, Norway DONG and Energi
E2 from Denmark. DONG is overall Project leader.
The installations, spread over the six countries Finland, Sweden, Norway, Denmark,
Germany and Ireland, are industrial, commercial as well as domestic installations. The
installations covers a number of different applications:
Data on energy efficiency, availability, emission, O/M costs etc. are recorded and reported over the operation period which is from sometime in 2002 where most of the installations were made, through April 2004.
The data obtained will form a basis for possible energy savings and reduced emission
through the use of efficient microturbines in CHP applications.
Country Units
Demo host
Type of installation
Comments
DK
CHP - Cluster
DK
Cph Airport
DK
Statoil, Stavanger
Fjell Borettslag
CHP - Methanol
School at Kvlinge
SF
VTT
CHP - cooling
CHP - heating
EI
Industry Limerick
CHP - steam
EI
CHP - Hospital
EI
CHP - Hotel
TOTAL
18
3. DESCRIPTION OF INSTALLATIONS
3.1 Cluster installations
Torpgrden
The Torpgrden installation is placed in a group heating station supplying
dwelling houses with heat and hot water. There are 176 tenancies with a size between
31 and 108 m2. The heat consumption for the housing is 7.100 GJ/year. With the
existing boilers this heat consumption resulted in a gas consumption of 200.000
Nm3/year. By establishing the micro gas turbine energy system the total gas
consumption will increase to app 375.000 Nm3/year also resulting in a power production
of 1.200.000 kWh /year to the grid.
The new system will consist of:
the 2 existing boilers
2 new mini gas turbines
2 gas compressors for the gas turbines
a 20 m3 heat accumulator situated outside the building
In the new system the micro gas turbines will run 6.200 h/year producing most
of the heat (6.000 GJ/year), but there will still be produced 1.000 GJ/year from the existing boilers running 3.700 h/year.
Installation costs
Turbines: 2*81.500
Installation costs: 180.000 (estimate)
Cluster installation: 22.000 (estimate)
Total installation: 365.000 (estimate)
Maintenance cost is 1,5 cent/kWh up to (but not inclusive) 60.000 hours overhaul.
Monitoring
Registration of electricity used and produced are made by the local power distribution company
The unit is monitored, controlled and regulated by a cluster installation software
developed by Turbec, Vaasa Automation and Energi E2. The cluster installation
enables remote monitoring, control and regulation from the control room in the
central power plant Kyndbyvrket.
Plant
Plant owner
Installed
Fuel
Function
power gross (excl. pressuration of gas) %
power net %
total gross (excl. pressuration of gas) %
total net %
Water temp. out deg. C
Torpgrden
Energi E2
March 2003
Natural gas
Heating of houses and production of hot water
30% - according to preliminary test of microturbine
29% - according to preliminary test of microturbine
76% - according to preliminary test of microturbine
74% - according to preliminary test of microturbine
95
Hastrupvnge
Energi E2
March 2003
Natural gas
Heating of houses and production of hot water
31%
30%
78%
77%
95
47-50
rnesdet
This unit will be placed in a group heating station supplying dwelling houses
with heat and hot water.
The heat consumption for the housing is 7.000 GJ/year. With the existing boilers this heat consumption resulted in a gas consumption of 180.000 Nm3/year. By establishing the micro gas turbine energy system the total gas consumption will increase
to app 290.000 Nm3/year also resulting in a power production of 730.000 kWh /year to
the grid.
The new system consists of:
2 existing boilers from 1991 with a capacity of 541 kW each
a new micro gas turbine
a gas compressor for the gas turbine
a 20 m3 heat accumulator situated under ground outside the building
In the new system the micro gas turbine will run 7.300 h/year producing app half of the
heat (3.700 GJ/year), and there will still be produced 3.300 GJ/year from the existing
boilers running 6.000 h/year.
Installation costs
Turbine: 81.500
Installation costs: 130.000 (estimate)
Cluster installation: 22.000 (estimate)
Total installation: 233.500 (estimate)
Maintenance cost is 1,5 cent/kWh up to (but not inclusive) 60.000 hours overhaul.
Monitoring
Registration of electricity used and produced are made by the local power distribution company
The unit is monitored, controlled and regulated by a cluster installation software
developed by Turbec, Vaasa Automation and Energi E2. The cluster installation
enables remote monitoring, control and regulation from the control room in the
central power plant Kyndbyvrket.
Plant
Plant owner
Installed
Fuel
Function
power gross (excl. pressuration of gas) %
power net %
total gross (excl. pressuration of gas) %
total net %
Water temp. out deg. C
Water temp. in deg C
rnesdet
Energi E2
March 2003
Natural gas
Heating of houses and production of hot water
31% - according to preliminary test of microturbine
30% - according to preliminary test of microturbine
76% - according to preliminary test of microturbine
75% - according to preliminary test of microturbine
95
45
the 2 existing Veismann boilers from 2001 with a total capacity of 1625 kW
a new micro gas turbine
a gas compressor for the gas turbine
a 20 m3 heat accumulator situated outside the building
The micro gas turbine will run 6.000 h/year producing most of the heat (2.400 GJ/year),
but there will still be produced 800 GJ/year from the existing boilers running 4.800
h/year.
Installation costs
Turbine: 81.500
Installation costs: 122.500 (estimate)
Cluster installation: 22.000 (estimate)
Total installation: 226.000 (estimate)
Maintenance cost is 1,5 cent/kWh up to (but not inclusive) 60.000 hours overhaul.
Monitoring
Registration of electricity used and produced are made by the local power distribution company
The unit is monitored, controlled and regulated by a cluster installation software
developed by Turbec, Vaasa Automation and Energi E2. The cluster installation
enables remote monitoring, control and regulation from the control room in the
central power plant Kyndbyvrket.
Plant
Plant owner
Installed
Fuel
Function
power gross (excl. pressuration of gas) %
power net %
total gross (excl. pressuration of gas) %
total net %
Water temp. out deg. C
Water temp. in deg. C
Tigervej
Energi E2
March 2003
Natural gas
Heating of houses and production of hot water
31% - according to preliminary test of microturbine
30% - according to preliminary test of microturbine
76% - according to preliminary test of microturbine
75% - according to preliminary test of microturbine
95
For outdoor temperature 5C: 55-60C
For outdoor temperature 0C: 65-70C
For outdoor temperature -5C: 80C
Costs
The price of the installation not yet available (February 2003).
Maintenance
A maintenance agreement with the Danish Turbec representative/installer
Frichs Kraftvarmeservice A/S has been signed at a price level of approx. 1.5 Euro
cents pr. hour of operation.
Installation
The units are installed in existing buildings containing boilers, pumps and a
transformer station. The microturbine CHP units are floor mounted at a place obtained
by moving two pumps. This placement gives easy access to the heating system as the
heat production of the Turbec units simply goes in the return water for the boilers as
pre-heating. Also electrical connection has been relatively easy as transformers are
placed few meters away.
Fresh air intake has been made through an area in the glass facade in front of
the units. Exhaust is taken vertically up through the roof of the building.
The gas compressors of the Turbec units are placed in separate cabinets floor
few meters away from the CHP units.
Noise
The cabinets of the Turbec Units are the standard casings. This means (for
each unit) that a noise level of some 70 dB(A) can be expected in 1 meter distance from
the cabinet. The noise of the gas compressors are specified in the data sheets as 75
dB(A) at 1 meter distance. Noise is expected measured during hand-over procedure.
As no people are under normal conditions in the building no extraordinary noise
considerations have been taken into account.
Environmental aspect
No problems to fulfill Danish legislation concerning exhaust emission (NOx, CO)
are expected. This is based on manufacturers data sheets (<15 ppm NOX and CO
respectively at 15 % O2).
Budget
On an annual basis the expected production/consumption of the two base load
units will be as follows:
Power production (2 units)
Heat production (2 units)
Gas consumption (2 units)
Annual operation hours
1527
2285
478.544
7650
MWhe/year
MWh/year
Nm3/year
hours/year
Operation strategy
The installation is designed/sized to enable electricity production that comes as
close to (but does not exceed) the airports statutory buy of prioritized power from the
grid. The production of the plant should replace to as large an extent as possible this
more expensive power from grid. This prioritized power represents approx. 35% of the
power bought to the airport.
Optimization in relation hereto has been done using the computer program ENERGY PRO developed by EMB (www.emd.dk). This computer program has been widely
used for planning and sizing Danish decentralized CHP plants. No significant need for a
heat storage facility has shown up during the studies for the Airport Case.
3.3 Lynge M/R station
This unit was installed in April 2000. This was a follow up upon a pilot test of an
80 kW unit installed April 1999.
Function
The function of the Turbec T100 unit is to produce heat for preheating of natural
gas before pressure reduction (from 80 bar to 30 bar). Beside that two hot water boilers
are installed at the M/R station. The produced electricity is sold to the local network .
The mean electricity price in 2002 was 0,32 DKK/kWh (app. 4,3 cent/kWh).
Mean gas price in 2002 was: 0,17 DKK/kWh - app. 2,3 cent/kWh (excl. tax).
Installation costs
Turbine: 80.000
Installation costs: 100.000
Total installation: 180.000
Maintenance cost is 1,5 cent/kWh up to (but not inclusive) 60.000 hours overhaul.
Monitoring
Registration of electricity sold are made by local power distribution company
Heat production is registered by local installed calorimer and manually logged
Gas consumption registered by local counter and manually logged
One precision test has been made by Danish Gas Technology Centre
(www.dgc.dk)
Remarks
The heat transportation media is a water/glycol solution, which reduce the specific heat from 1 to 0.88, and due to that a reduction in heat transfer (and total
efficiency) for the turbine. This is partly counteracted through the presence of
the needed gas pressure of 6 - 8 bar.
Burning chamber changed after 3000 hours due to erosion. Recuperator
changed after 1300 hours due thermal tensions.
Problems with oil filter. Oil consumption >> 5 l/1000 running hours. New type of
filter installed, oil consumption now 1 l/1000 hours.
Leakages between recuperator and compressor at 7400 hours. New sprigs installed at compressor back plate.
Problems with power electronic unit. Problems declining.
Plant
Plant owner
Installed
Running hours by Dec. 31, 2002
Fuel
Function
Power production, kWh
Heat production, kWh
power gross (no need for pressuration of gas)
total gross (no need for pressuration of gas)
Water temp. out deg. C
Water temp. in deg C
Load
O2 (actual)
CO
NO + NO2 (NOx)
NO
UHC
% vol
ppm
ppm
ppm
ppm
30 kW
19,0
1458
36
18
801
60 kW
18,5
543
24
14
156
100 kW
18,0
6
17
16
0
Power load
Gas consumption
Heating Value
Firing ratio
Power production
Power efficiency
Heat production
Heating
efficiency
Total Efficiency
m3n/h
30 kW
12,7
60 kW
19,0
100 kW
29,6
kWh/m3
kW
kW
11,2
142
28,8
11,2
213
61,1
11,2
332
103,1
% - gross
kW
% - gross
20,3
51,9
36,6
28,7
85,4
40,1
31,1
135,4
40,8
% - gross
56,9
68,8
71,9
Plant
Plant owner
Installed
Fuel
Function
power gross (excl. pressuration of gas) %
power net %
total gross (excl. pressuration of gas) %
total net %
Water temp. out deg. C
Water temp. in deg C
Cooling Capacity
Statoil ASA
February 2003
Methanol
Power, heat and cooling for the office complex
not known yet - February 2003
not known yet - February 2003
not known yet - February 2003
not known yet - February 2003
not known yet - February 2003
not known yet - February 2003
Expected 95 kW, still not measured
A T100 prototype was installed late 2001/beginning 2002 at the Mariestad sewage treatment plant. It was designed to run on the raw biogas from the sewage treatment plant. The turbine should produce heat and electricity for internal use at the plant,
replacing and older oil fired boiler.
Function
The turbine room is situated just next to the digestion chamber. Raw biogas is
fed through pipes and dried to a dew point of about 5C (ambient pressure) and then
compressed and fed to the T100. Promised gas production was initially exceeding 800
Nm3/hr but actual production is about 400 Nm3/hr.
Initially, it was decided to go ahead with the 800 Nm3/hr and run the turbine on
part load (50-80%). Unfortunately, the gas production didnt improve after the tuning of
the digestion chamber. It was only possible to run the turbine on 20-25 kWe.
The first problem was moisture in the gas, this was solved with an additional
water separator. The main problem now is the low gas production.
Installation costs
T100: 80.000
Installation costs are still not clear since work is ongoing.
Remarks
Poor functionality, gas production is less than 50 % of what was initially promised. It
is only possible to run the unit at about 20 kW power.
Gas compressor and combustion chamber changed late 2002.
3.7 Klitte Greenhouse
Klitte & Lundh grows cucumbers: Frillestads Gurka. The total area of the greenhouses is 23 000 m2, whereof the T100 supplies CO2 to 10 700 m2. Klitte & Lundh
produces 4 000 000 cucumbers (1 500 000 kg) annually, corresponding to 5% of the total annual Swedish cucumber production. Heat and CO2 is also supplied from natural
gas fired boilers. At full load, the T100 produces 6.3 g CO2/m2. During cultivations season, more than 20 g CO2/m2 is required on sunny days, and additional CO2 will be
supplied from the existing boiler. A hot water accumulator allows the boiler and T100 to
be run continuously and the CO2 production is optimized without having to waste heat.
Function
The unit was installed in an existing boiler room next to a natural gas fired boiler. A
new CO2 distribution system for the flue gases from the turbine was installed. The CO2
distribution system is a standard system for greenhouses made of PVC. As PVC cannot
withstand temperatures higher than 57C, a secondary heat ex-changer was installed
which ensures that the flue gas temperature is kept below 57C.
For next cultivation season, hoses made of polyethylene (PE) will be fitted to the
exhaust from the PVC pipes to further increase the distribution of the flue gases among
the crops. Currently, 16 fans fitted in the roof of the greenhouse increase the circulation
of the air inside the greenhouse.
Installation costs
The total cost for the installed unit (including unit and modification of unit, modification of the electrical system, computerized control system, CO2 distribution system
and all plumbing) was 148 000 Euro, equaling a specific cost of 1 480 Euro/kW. This is
a high specific cost but the unit at Klitte & Lundh is a pilot installation and the future installed cost of a CHP unit including CO2 fertilization is expected to be around 1000
Euro/kW.
Monitoring
The standard data collection is made by Turbec
Gas consumption registered by local counter and manually logged
One precision test has been made by Sycon AB
Remarks
Minor problems with a pilot valve initially, corrected.
Initially minor problems with power electronic unit, corrected.
Minor problems with the interaction between existing boiler and T100.
Electricity grid to the site is weak causing peaks and dips which trips the unit.
The levels of UHC, CO NO, NO2 and CO2 inside the greenhouse are well below
hygienic limits and well below values that could affect the plants in a negative
way.
Load
O2 (actual)
CO
NO + NO2 (NOx)
NO
UHC
50 kW
19,1
1446
22
16
272
% vol
ppm
ppm
ppm
ppm
75 kW
18,7
666
18
13
71
100 kW
18,4
No detected
14
12
No detected
el groos = 31,3%
total gross = 77,6%
The Turbec T100 unit is producing electricity and heat to the building of VTT
Processes at Otaniemi, Espoo. The unit is connected to both electric and district heating
network. Price of the produced electricity will be credited once a year according to the
production.
Costs
Turbine investment: 86 000
Installation: 87 000
The installation costs were dubbled from the budgeted 40 150 .
3.10 Hamburg, Business Centre
This unit was installed in September/October 2002. The Turbec T-100 microturbine is installed in a container in close connection to an office building and delivers heat
and electricity to the customer.
Function
The function of the Turbec T-100 unit in Hamburg is to produce heat and power
for an office building. The office building at Harburg Channel has a boiler room with two
natural gas fired boilers. The heat from the T-100 is connected to the boiler room with
two pipes. One pipe for the heated water and one pipe for water to be heated. There is
a pipe from the natural gas net in the boiler room to the gas compressor in the container.
The container is insulated inside to meet the demand of low noise level. The container
is ventilated and equipped with a high chimney for the exhaust gases.
Installation costs
Turbine: 82.000 including
This includes the Turbec Additional electrical relay protection system.
Installation costs: not summarized yet (February 2003).
Monitoring
No monitoring so far. But system for data collection and communication has
been developed and is ready to be installed. All data will be transferred daily to Vattenfalls office in Sweden for evaluation.
Remarks
Extra cost for building a new chimney. The reason was that the exhaust gases
could condense and the new chimney is equipped with facilities to evaporate
condensed water.
Plant
Plant owner
Installed
Running hours by Dec. 31, 2002
Fuel
Function
power gross (excl. pressuration of gas) %
power net %
total gross (excl. pressuration of gas) %
total net %
Water temp. out deg. C
Water temp. in deg C
Hamburg CHP
HEW Contract (HEWC, a subsidiary to VAB)
October 2002
Only a couple of hours
Natural gas
CHP (Combined Heat and Power)
No data available
No data available
No data available
No data available
No data available
No data available
The question for permits in Hamburg is still discussed with Bauprfamt. The
main problems are dealing with the gas compressor. The compressor must hermetical
sealed to obtain the allowance to have it in a container in close connection to the microturbine.
Permit from neighbour
The container with the microturbine was placed to close to the border of an adjacent house. HEWC arranged a meeting with the neighbors who now has accepted the
location and given a written permit. This was clear November 20.
Silencer
Schwartz & Grantz has installed a silencer on the outside of the container. The
noise from the air inlet system is reduced to less than 45 db.
Safety stop from out side
A new safety stop system has been installed. The microturbine can be stopped
from outside of the container.
3.11 Steam site, Limerick, Ireland
A T100 was installed in February 2003 at an industry in Limerick on Eastern Ireland. The T100 is a part of a steam boiler/T100 system that produces heat and electricity to the industry.
Function
The T100/Boiler system produces steam and electricity to the industry during
daytime when electricity and peak tariffs are high. Expected annual running hours are 45.000 hrs with an approximately 3-400 starts per year.
Installation costs
Turbine: ongoing - February 2003
Installation costs: ongoing - February 2003
Total installation: ongoing - February 2003
Monitoring
Turbec makes the standard data collection.
Additional OMES specific data is logged.
Additional OMES specific testing will be performed.
Monitoring
Turbec makes the standard data collection.
Remarks
The unit will have to be placed on the top of the roof of the existing boiler room,
making it a somewhat tricky installation. A shed will be built to protect the turbine.
4. Conclusion
In the OMES demo project now (February 2003) all demo sites have been decided
upon.10 plants are in operation, and the remaining plants will be in operation by end of
April 2003.
Most important observations that have been made through the starting of this project
are:
Installation costs:
Costs for the T 100 unit from factory stays at original planned level of 80.000
- 86.000 . This indicates that the microturbine will be able to reach its longer-term
goals, which in the OMES project is set at less than 800 per kW.
Observed costs for the installation of the standard T 100 varies considerably. This variation is of course to a large extent dependant on variations in site specifications. For example many installations are not made in a fully commercial way due to a good environment for the testing and measurements that has to be performed. Further to mention
some installations then have to add extra costs for a methanol tank, heating accumulator, steam mode etc.
This will be analyzed more in details when all installation costs are available. However
already now can be observed that large differences exist between the installations due
to rules and regulations. Both on the fuel side and on the electrical side.
Still a price level of 1000 /kW (hardware + installation) seems reachable when installers and advisory engineers are accustomed with this new technology and installation rules are more clear. A reduction in hardware price from the turbine manufacturers
seems possible when high volume production is established.
Maintenance costs
The original goal for the OMES project indicated O/M costs less than 1
cent/kWh.
This goal is hardly met so far. The observed O/M costs varies between 1 and 1,5
cent/kWh.
Availability 90 % and reliability > 95%
For the plants in operation these goals have been meet.
Power Efficiency and overall efficiency
The original goals to be met were 30 % power efficiency during full load operation and overall efficiency 80 % (ref. LCV).
The measuring results show that the goals for power efficiency at full load is met, still
the overall efficiency stays in the range of 72 - 78%. This is due to higher water inlet
temperature than originally planned for, at the plants measured. All results at "net" conditions where the work to raise gas pressure has been accounted for. At part load there
is a considerable drop in efficiency, so operation at part load < 50% of full load seems
not recommendable.
Environment
The original environmental goals for the OMES project were focusing NOx.
Measurements at the plants Lynge and Klitte & Lundh greenhouse shows that the Turbec T 100 at 100% load emits 14- and 17 ppm at 15% of O2. These results are very
close to the OMES goals of 15 ppm NOx at 15% of O2.
APPENDIX C
REFERENCES
1. H.J. Rasmusen, Optimised microturbine energy systems, EC ENERGY Contract
NNE5/20128/1999, 2001.
2. Mini- and micro-gas turbines for combined heat and power. P.A. Palavachi, Applied
Thermal Engineering (2002) p. 2003 - 2014