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Currently two different types of engines are used in air compressor applications:
industrial and automotive-derivative.
Industrial engines are typically designed to operate for longer lifetimes than
automotive-derivative. These engines operate at speeds up to 1,800 RPM. The time
between major overhauls or rebuilds on this type of engine is in excess of 20,000
hours of operation. Industrial engines are designed so that all the parts that
experience wear can be replaced. These major overhauls allow the life of an
industrial engine to be extended "indefinitely." However, industrial engines are more
expensive than automotive-derivative.
Automotive-derivative engines are rated for higher speed (more than 3,000 RPM)
operation and are modified versions of those used in automobiles and other mobile
applications. These engines are less costly than the industrial grade engines, and
therefore can decrease the capital cost of a project. Other benefits of these engines
are that they are somewhat smaller and lighter in weight. The cost and availability of
parts is generally better than industrial engines. However, the life of these engines is
significantly shorter. Automotive-derivative engines are generally replaced at the end
of their useful life, and are not rebuilt like the industrial engines. Therefore, the
reduced installed cost of this type of engine is countered by the increased operating
costs of replacing the engine at regular intervals. Also to be factored in is the
downtime to overhaul an industrial engine (2 weeks) versus replacing an auto-
derivative engine (2 days).
Analysis to assist in deciding between engine types should consider the following:
Life cycle cost comparison (first cost; operating, repair, and maintenance
costs; and replacement cost)
Duty-cycle (operating hours)
Customer reliability requirements
Overview
Gas engine technologies are available for a variety of applications that require a
prime mover. A prime mover simply converts one form of energy (gas or electricity)
to mechanical work (turning a shaft) for use in a process. Thus, a prime mover can
be an electric motor or a gas engine.
Gas engines perform the same function as an electric motor, they provide shaft work
for process applications. Shaft work includes turning a shaft to operate a pump, a
compressor, a grinder, a crusher or a generator. In many applications an electric
motor can be replaced with a gas engine. The primary advantages of using a gas
engine are:
With gas engine applications, customers will be able to achieve a flexibility for
processes that werent an option just a short while ago. They will be able to "shape"
their energy profile, which will allow them to negotiate much more attractive energy
prices than if they were committed to a single technology/energy source.
Gas engines can help customers operate more efficiently, more cost effectively and
they can offer customers fuel diversity for their facilities.
When identifying an opportunity for, and selling a customer on a Natural Gas Engine
application you should be familiar with the technology. This includes knowing not
only the benefits of installing a Natural Gas Engine but being able to inform the
customer of some facts about the technology and about the maintenance
considerations.
A Natural Gas Engine is similar to the engine in your car except that instead of using
liquid gasoline as a fuel source, natural gas is used as the fuel source.
There are two types of Natural Gas Engine technologies available for customers,
spark ignited Natural Gas Engines and compression ignition Natural Gas Engines.
Spark ignited
Compression ignition
Engines that use a rich air-fuel ratio. These are common in Southern California
because their emissions are very easy to control.
Engines that use a lean air-fuel ratio. These engines are not as common as rich burn
engines because they require a more sophisticated emission control system.
Air Quality Natural Gas engines may need to be permitted and may have
emissions limits. It is important to be aware of this when marketing a gas engine
system to customers.
Maintenance Natural Gas Engines do require maintenance, just like a car engine.
However, with a maintenance schedule that is strictly adhered to, a Natural Gas
Engine will give years of reliable service.
Noise Natural Gas Engines are louder than an electric motor and may require
sound attenuation.
Ventilation combustion processes require air to take place. Natural Gas Engines
need an adequate supply of air to operate. If a central plant is being built or
designed, this fact should be considered in the early stages.
A gas engine converts the chemical energy of natural gas to mechanical work. The
rate of energy conversion in a gas engine is as follows:
Shaft Work
31,000 Btus
(approximately)
Radiation losses
6,000 Btus (not
recoverable)
The energy balance above illustrates why heat recovery adds significantly to engine
system efficiency. Usable heat can be recovered from both the jacket water and
exhaust. Heat from the jacket water can be used to make hot water, heat from the
exhaust can be used to make hot water or low pressure steam.
Air/Fuel system:
Schematic of a Turbocharger
Turbochargers usually have a heat exchanger (an intercooler or after cooler) located
after the compressor fan to remove heat from the compressed air. By cooling the
compressed air, the density is increased, so oxygen content for a given volume of air
is increased and more fuel can be burned.
The advantage of a turbocharged engine is that about 35% more work can be done
by a turbocharged engine as compared to a naturally aspirated engine of the same
size.
Gas engines require regular maintenance just like the engine in your automobile. In
fact, the maintenance activities are similar to the maintenance activities you do on
your car. Customers with Natural Gas Engine systems can sign a maintenance
agreement with their vendor at a reasonable cost.
A good rule of thumb for annualized maintenance costs is $.011 (one and one tenth
cent) per horsepower-hour. This amount will vary depending on how the engine is
used but is a very good ball park figure to use to determine annualized maintenance
costs.
Example: If you have a 200 Hp engine that operates for 2500 hours a year the
annualized maintenance costs would be:
Maintenance is scheduled by the run hours on the engine. A good guide for gas
engine maintenance is in the table below:
Daily:
Check fluid levels and bring them to proper level (if needed)
Visually inspect engine for leaks and/or loose belts and hoses
250 hours:
750 hours:
1500 hours:
6000 hours:
Exchange/rebuild water pump and water pump idler pulley assembly
Inspect Turbocharger and aftercooler (do maintenance per Mfr.s
recommendation)
Check cylinder compression (compression should be uniform across cylinders)
Remove cylinder heads and do a valve job and top end inspection at around 11,000
hours (+/-) for both low speed and high speed engines. (Customer should follow
Mfr.'s recommendations!)
Note: as valves are cycled in the combustion process they may not seal properly due
to wear on the valve and seat surfaces. A valve job refinishes the surface of the
valve and the valve seat so that it seals properly when the valve is closed.
Major overhaul:
Top and bottom end rebuilds (valves, cylinder rings, crankshaft and camshaft
bearings, oil seals) (at around 24,000 hours for high speed engines; around 34,000
hours for low speed engines)
Other maintenance
Chemical / physical properties of oil evaluating oil integrity, checking for water or
coolant in the oil and checking for entrained solids. Oil properties can give a very
good idea of how the engine is performing and may alert customer to a problem
before it becomes a major problem. Customer should check with Mfr. about this
service.
For example, the Mfr. recommends changing the water pump at 6000 hours of
operation. If you drove your car for 6000 hours at 50 mph, you would accumulate
approximately 300,000 miles on your odometer! This gives the customer a better
feel for the maintenance requirements of a gas engine.
Natural Gas engines may require Air Quality permitting if they are installed. The
exception to the permitting requirement is for Agricultural customers (farmers) who
use them for Agricultural water pumping for crops or to supply water to livestock.
Most Air Quality Districts have similar emissions limits. For the South Coast Air
Quality Management District the limits are:
Natural Gas engines of 50 Hp or greater require permitting. (customers in
RECLAIM may need to buy emissions offsets to operate an engine)
Emission requirements for gas engines are (per Rule 1110.2)
Emission controls:
Gas engine emissions are very easy to control. For rich burn engines, a non-selective
catalyst with an air-fuel ratio controller can be used to keep the emissions below the
limits. A non-selective catalyst is similar to the catalytic converter on your car.
Lean burn engines require a selective catalytic reduction system, typically ammonia
injection, to clean emissions. Selective catalytic reduction systems are more costly to
buy, operate and maintain.
On the next several links we will review benefits of gas engines for specific
applications.
Conclusion
Natural Gas Engines offer customers many options for their business and also offer
many benefits to customers that choose to make a Gas Engine an integral part of
their process.
More stable energy prices: Gas engines often have better operating economics
than an electric motor. This is particularly true during warm weather when heavy
demand charge penalties kick in.
Gas engines are high-tech: New gas engine packages have advanced
microprocessor controls that continuously monitor engine conditions and alert
operators of any items that may need attention. They can be used in systems that
have centralized controls.
Higher potential total efficiency: Gas engine systems can incorporate heat
recovery into the process that raises the overall efficiency to well over 50%.
Traditional electric plants have an efficiency of 30%. By including heat recovery in a
process savings are achieved on the shaft work and in the recovered heat.
Natural gas has an Octane rating of 130. Octane rating is a measure of the antiknock
property of a fuel, it can be thought of as resistance to detonation. High compression
engines require high-octane fuels to operate properly and natural gas fits the bill.
Natural gas is free from liquid hydrocarbons. Liquid hydrocarbons, such as Gasoline,
Ethanol and Diesel, wash the lubricant from the cylinder walls and dilute engine
lubricants. They also leave gum and varnish deposits. Natural gas does not dilute
lubricants or leave gum and varnish deposits. Some customers have experienced
longer times between oil and filter changes because Natural Gas burns so clean.
Natural gas burns cooler and cleaner than other liquid fuels such as diesel and
propane. There is less contamination of the lubricating oil with carbon and nitrates,
which helps keep the equipment operating at top performance.