Climate Change and the Emerging Strategies of Mitigation. Increasing Gas Generator Set Efficiencies Bio-Fuel developments

Transcription

1 Climate Change and the Emerging Strategies of Mitigation Increasing Gas Generator Set Efficiencies Bio-Fuel developments

2 Outline Cummins Power Generation Overview CHP Overview Cummins CHP Solutions Cummins CHP Experience 2

3 Cummins Overview Cummins Power Generation Cummins, Inc: $13B Sales (2007), 33,000 employees Cummins Power Generation: $2B Sales, over 1m units in service The Power of One : Integrated Design, Sourcing, and Support of engine, alternator, controls, switchgear 3

4 Global Distribution and Support 4 Cummins global distribution covers 160 countries, with 550 distributors and over 5,000 service and parts outlets.

5 CHP Overview Cogeneration, or Combined Heat & Power (CHP), utilizes the full potential of the input energy. CHP can reclaim over half of the otherwise lost fuel energy 5

6 Efficiency Benefit Heat Balance: QSV91G Mechanical Thermal Electrical output 39% HT circuit (85-95 C) 15% LT & Oil circuit (50-60 C) 9% Exhaust ( 120 C) 25% Recovered Energy 88% Generator losses 1% Cooling circuit CAC 2.5% Engine radiation 3.5% Exhaust ( unburned) 5% Losses 12% 6

7 7 CHP Schematic

8 CHP Overview CHP is not a new technology Used in Thomas Edison s first electric generating plant in 1891 Used in industrial, institution, and municipal applications today Governments see the benefit for both fuel savings and emissions US Department of Energy has a goal to double CHP use by 2010 European Commission has set similar targets 8

9 Environmental Benefit Reduce demand on national electric grid Power often produced by high emitting coal-fired plants Reduction in CO2, NOx, and Particulates Higher efficiency means conservation of natural resources 9

10 Typical CHP Applications 10 Hospitals Greenhouses Hotels Industrial/Chemical Plants Manufacturing Facilities Commercial Facilities Government Facilities Colleges and Universities Food Processing Plants Health Clubs Swimming Pools Nursing Homes District Heating Landfills and Sewage Treatment Plants Coal Mining and Oil Fields

11 Emerging Technologies Define the objectives Identify the barriers Identify the technology The development cycle. 11

12 Key ARES Program Goals for 2010: 50% Efficiency at 0.1 g/hp-hr NOx 10% lower operating cost, Increased fuel flexibility Cummins Targets 55% Brake Thermal Efficiency 50% 45% 40% 35% 50% 47% 44% 39% Planned work is split into 3 phases. Each phase ends with a Field test to demonstrate: 1. 44% BTE in % BTE in % BTE in

13 Addressing Customer DG Needs DOE Advanced Reciprocating Engine System (ARES) Program was Launched Targeted gains for Distributed Generation Market are: - 50% Fuel Efficiency at 0.1 g/hp-hr NOx - 10% lower operating cost Brake Thermal Efficiency Cummins Targets Efficiency Targets 55% 50% 50% 47% 45% 44% 40% 39% 35% NOx (g/hp-hr) Cummins Targets Emissions Targets Program Phase I II III

14 Aggressive Gas Cummins Fuel Classification From Fuel Gas Analysis Limits corrected to LHV 36MJ/m 3 Units mg/nm3ch4 Standard operation with low BTU servicing. Standard low BTU Operation with increased servicing Site specific special servicing required Fuel Categ ory TOTAL SULPH UR C D TOTAL GASEOU S SILICON TOTAL HALOG EN E >2000 >40 >200 14

15 Site Betton Abbots 1 x 1370kW Broadpath 2 x 1370kW Burnhills 1 x 1570kW Dunbar 2 x 1750kW **Pluckley 1 x 1370kW Westbury 1 x 1370kW Ardley 1 x 1750kW Whitehead 2 x 1570kW Dunbar 3 1 x 1750 Jaguar 15 Site 6 x 1530kW Engine Hours Fuel Clas s Sulph ur mg/n m3 Silicon mg/nm 3 Halogen mg/nm3 Hours Spark Plugs Hours Oil Drain Hours Cylinder heads 5,700 E ,000* 5000 E ,000 8,500 E ,500 E ,000 C Operational Comments *Predicted head change Predicted Head change. Regap plugs 500hrs Ex Betton Abbots Regap plugs 750hrs 50% load operation 12,000 E **Ex Pluckley 500 C E Estimated Maintenance Installed July 07 Comm Sept High H2S G1 Ex Burnhills 0 E Install Aug 07 55,000 A ,000 Base Engine reference.

16 Strategy for achieving ARES goals: Improve closed cycle efficiency Explore advanced combustion concepts Improve predictive models Improve air handling Reduce friction contribution Improve controls New sensing technology Waste heat recovery Higher efficiency alternator Long life ignition system Explore aftertreatment technologies 16

17 Key technologies being explored High efficiency turbo charging Miller cycle Advanced lean burn concepts Diesel pilot ignition High Pressure Direct Injection (HPDI) Stoichiometric combustion with EGR HCCI Turbo compound Bottoming cycle High efficiency alternator 17

18 ARES Phase I Efficiency Improvements Efficiency Baseline Miller Cycle Increase BMEP Technical Feature High Efficiency Turbo Reduced RPM 18

19 NOx Control Technologies Miller Cycle Engine The Miller cycle engine is an example of reduced NOx emissions due to Charge Air Cooling. As shown in figure below, intake valve remains open for an additional 30 degrees thus reducing the effective engine displacement. Back flow due to late intake valve open is compensated by density of charge. Reduced combustion chamber temperature at TDC results in lower NOx. Reduced engine size also provides substantial reduction in frictional losses, thus increasing fuel efficiency 19

20 NOx Control Technologies Exhaust Gas Recirculation (EGR) Displacing an engine s intake air with inert material can reduce NOx emission. EGR is a form of intake air dilution. Selective Catalytic Reduction (SCR) by Urea: Typically uses nitrogen containing ammonia or urea as reducing agents to achieve high NOx control (up to 90%+). 20

21 Particulate Matter Control Technologies Diesel Oxidation Catalyst (DOC): PM emissions composed of carbonaceous particles, soluble organic fractions (SOF) and sulphates among other things. Oxidation catalyst reduce SOF but have little impact on other components. Typically reduce PM by 20-30%. Diesel Particulate Filter (DPF): Filters, also called traps, filter PM from exhaust stream with subsequent oxidation of captured PM. Ceramic wall-flow monoliths are used as filter material in most cases. Diesel Fuels: Diesel fuel properties impact diesel exhaust emissions. Many after treatment technologies are sensitive to sulphur in the fuel. 21

22 Emission Control Options Exhaust and Emission Control Systems Diesel oxidation catalyst (DOC) Catalyzed Soot Filter PM Active regenerating filter CRT Miller Cycle Controls Reduction % Diesel Oxidation Catalyst (DOC) PM Catalysed Soot Filter PM above 90 CRT PM above 90 EGR NOx up to 50 SCR NOx up to 90 PM NOx RED: Most commonly used EGR Lean NOx Lean NOx + HC Plasma assisted lean NOx NOx adsorber Selective catalytic reduction(scr)

23 Commercialization Cummins releasing Hi efficiency Products 2 MW using light miller cycle & adaptive engine controls 1 MW with lower temperature combustion, higher power density, increased turbo efficiency and adaptive engine controls 23

24 Commercialization-Customer Benefits Improvements Cummins Gensets 1750kw 2000kw 1000kw Emissions (g/hp-hr NOx) Efficiency 38% 40% 43% (ISO elec.) Emissions are reduced 28% Fuel consumption is reduced 5% and 11.5% respectively 24

25 Biodiesel: Environmental Driver Biodiesel offers the environmental benefit of renewable energy Can also help reduce dependency on imported oil Provides overall emissions advantage with reduced PM, HC, CO and CO2 (production/use cycle basis) Cummins is working with industry groups to standardize fuel specifications Cummins supports the responsible production and use of biodiesel We will use biodiesel in our operations where appropriate and produce products that are capable of operating with biodiesel Biodiesel must not harm the availability or economics of the global food supply Rain forests and water are resources that must be sustained 25

26 B20 Approval Cummins Announces Approval of B20 Biodiesel Blends March 21, 2007 (everytime.cummins.com) Approval limited to targeted engines - Additional approvals under evaluation/testing Requirements specified in Cummins Service Bulletin Vehicle/equipment OEM s have their own specific requirements B20 approved engines: On-Highway: ISX, ISM, ISL, ISC and ISB engines certified to EPA '02 and later emissions standards, and ISL, ISC and ISB engines certified to Euro III Off-Highway: QSX, QSM, QSL, QSC, QSB6.7 and QSB4.5 engines certified to Tier 3/Stage IIIA, QSM Marine and QSM G- Drive. All future products will be compatible with biodiesel B20 26

27 BQ-9000 For North American markets, Cummins Inc. requires that the biodiesel fuel blend be purchased from a BQ-9000 Certified Marketer. The B100 biodiesel fuel used in the blend must be sourced from a BQ-9000 Accredited Producer. Certified Marketers and Producers can be found at the following website: For areas outside of North America, the local Cummins representative must be consulted for applicable fuel quality standards. 27

28 Biodiesel Fuel Storage Use biodiesel fuel within six months of its manufacture. Biodiesel has poor oxidation stability, which can result in long term storage problems. For this reason, Cummins Inc. does not recommend using biodiesel for low use applications, such as standby power or seasonal applications. Consult your fuel supplier for oxidation stability additives. The poor oxidation stability qualities of biodiesel can accelerate fuel oxidation in the fuel system, especially at increased ambient temperatures. 28

29 Fuel Water Separation Biodiesel has a natural affinity to water, and water accelerates microbial growth. Storage tanks must be equipped with a fuel water separator to make sure that water is stripped out before entering the vehicle tank. Make sure that the vehicle and storage tanks are kept full to reduce the potential for condensation accumulating in the fuel tank. Due to the solvent nature of biodiesel, and the potential for cleaning of the vehicle fuel tank and lines, new fuel filters must be installed when switching to biodiesel on used engines. Fuel filters will need to be replaced at half the standard interval for the next two fuel filter changes. 29

30 Biodiesel Fuel Storage (cont.) If biodiesel is used for seasonal applications, the engine system must be purged before storage by running the engine on pure diesel fuel for a minimum of 30 minutes. Care must also be taken when storing biodiesel in bulk storage tanks. All storage and handling systems must be properly cleaned and maintained. Steps must be taken to minimize moisture and microbial growth in storage tanks. Consult your fuel supplier for assistance in storing and handling biodiesel. 30

31 Summary Key Requirements Capable engine Approved engines only Quality fuel B100 Accredited Producers Capable Vehicle / Equipment Approved Vehicles / Equipment Quality blend / delivery B20 Certified Marketers, EMA spec Successful Application Application Requirements, i.e. fuel storage, seasonal use, etc. 31

32 All Cummins products are approved for use with B5. Cummins has completed the necessary testing and evaluations and developed guidance to ensure that customers can reliably operate selected engines with confidence using B20 fuel. Only B100 biodiesel that meets ASTM 6751 or EN14214 and the EMA B20 blend test specification can be used. There are no specifications to define blends above B20. Recent national audit shows quality is still a big issue in the industry. Cummins is currently focused on supporting the B20 release and continued validation efforts to approve additional engines. Critical needs are to improve B100 standards, create B20 standards and improve biodiesel quality. 32

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34 William Floyd School District Prime Movers 2 x kv Natural Gas 1 x kv Diesel Heat Recovery Produces High Grade Hot Water From HT Circuits and Exhaust gas for Space Heating and absorption cooling Operation On-Peak Baseload Generation, Parallel with Utility, Island/Standby Capability Diesel Set Used for Summer Curtailable and Maintenance Power 34

35 35 Acushnet Company / Titleist Ball Plant 2

36 Acushnet Company / Titleist Prime Mover 1 x kv Natural Gas Heat Recovery Produces High Grade Hot Water For Manufacturing and Space Heating From HT & LT Circuits 80 PSI Steam Produced By Exhaust Gas for Manufacturing 36 Operation Continuous Baseload Generation, Parallel with Utility, Island/Standby Capability

37 37 Columbus Water Works Columbus, GA

38 Columbus Water Works Prime Mover 2 x kv Dual Fuel Digester Gas / Natural Gas Heat Recovery Produces High Grade Hot Water For Process Heating From HT & Exhaust Gas. Low Grade Hot Water From LT Circuit for Grease Tank Heating. Operation Continuous Baseload Generation, Parallel with Utility, Island/Standby Capability 38

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40 Hazelwood Greenhouse, UK Hazelwood VHP Nursery, Kent, UK Customer: Nedalo UK (CHP packager/ipp) 6 x 1.5 MW Cummins QSV91G Gas Gensets 9.2 MW Electrical Output 11,58 MW(th) hot water Tri-gen : Uses CO2 for plant growth Electrical Efficiency 36.5% Total Efficiency 80.6% Benefits Upgrade for old oil-fired boiler Liquid CO2 plant food replaced with SCR-cleaned exhaust Surplus electricity sold to grid Lower emissions for electricity and eliminate fuel and CO2 delivery vehicles 40