CHP Application Overview

Engine IQ

Distributed Power
August 2016
GE Proprietary Information—Class III (Confidential)
Export Controlled—U.S. Government approval is required
prior to export from the U.S., re-export from a third country,
Imagination at work or release to a foreign national wherever located.
Natural Gas fueled CHP

> 6,900 natural gas fueled units >10,900 MWel worldwide

• Highly efficient generation of power, heat and cooling
• Reduces primary energy use
• Minimizes transmission losses
• Enhanced total efficiency – greater than 95%
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• Reduces fossil fuel use and greenhouse gas emissions
Distributed Power - Jenbacher gas engines
Applications Overview
GE is a global CHP leader
Installed base spanning ~11,100 units and 9 GW

More than 11,100 CHP Over 9 GW total electrical

units worldwide output globally

Type 2 ~900 Units Type 2 ~220 MW

Type 3 ~ 5500 Units Type 3 ~2900 MW

Type 4 ~1650 Units Type 4 ~ 1800 MW

Type 6 ~3050 Units Type 6 ~3800 MW

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Distributed Power - Jenbacher gas engines
Applications Overview
What is CHP?

The combined simultaneous production of

electricity and heat from a single fuel source.
In Engine case, CHP is the recovery of waste
heat during power generation in order to
make hot water or steam or cooling.

The Term “Cogeneration” is used

interchangeably with CHP.
Heating Application

CHP Application may Include:

Electricity
Steam
Hot water
Process Heating
Cooling and Refrigeration
Drying
Mechanical Drives
Cooling Application

LM6000
CHP is not a single technology
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Distributed Power - Jenbacher gas engines
Applications Overview
Why CHP?
Conventional System

Reduced fuel to process

Less purchased Electricity
Very high efficiency
Greenhouse Gas Savings
Back up Power support
Reliability

Cogeneration

2/3 of the fuel we use to produce power is wasted

CHP Saving 40-60% Compared to Energy required for Conventional System
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Distributed Power - Jenbacher gas engines
Applications Overview
Where does CHP Apply?
• High electric demands
• High thermal (steam, hot water, or direct heat; cooling) demands
• High cost of electricity &/or fuel
• Coincident thermal and electric demands
• Extended operating hours (>5000)
• Access to fuels (by products, natural gas)

Primary Applications for CHP

Sub Segments CHP Size Thermal Demand
District Heating & Cooling 10-100+MW • District heating, Domestic hot water, space heating

Residential & Commercial 0.5-2 MW • Domestic hot water, space heating, pools,
building • Laundry
• Steam
• Centralized space heating or Cooling
Industrial 0.5-10+MW • Low Temp process(<100C)- Hot Water , Space heating/
Cooling
• Med/High Temp Process (100-300C)-Process steam, Hot
Oil, Dryer
• Very High Temp (300-700 C)—Dryer in cement factories
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Distributed Power - Jenbacher gas engines
Applications Overview
NG CHP – Cost of Electricity
Segments
1) District Heating Cost of kW
(Utilities, Municipal Utilities) 9,00
8,00
Fuel
7,00
2) Industries 6,00
6,99 Service BoP

€ Cent / kWh
6,30
Service Genset
(Textile, Chemical, 5,00 5,68
Investment BoP
4,00
Food, Beverage,…) 3,00 Investment Genset
2,00 Thermal Savings
1,00
3) Commercial Buildings 0,00
CoE

(Hospitals, Airports, Shopping Malls, District

Heating
Industrial CHP Comm Bldg

Universities, Hotels) Electrical Oph 6500 8000 8000

(oh/y):

Thermal Oph 6500 6000 4000

(oh/y)
Gas tariff: .025 €/kWh

Gas cost/efficiency and heat utilization drive CoE

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Distributed Power - Jenbacher gas engines
Applications Overview
Energy balance of Recip. Engines

Energy input NG100% HEX 1

Intercooler heat
Mechanical Thermal. exchanger
output ~42% output ~58% HEX 1
HEX 2 HEX 2
HEX 3 Oil heat exchanger
HEX 4
HEX 3
Jacket water heat
Losses ~10%

exchanger
Recoverable
Electrical thermal HEX 4
output~40% output~50% Exhaust gas heat
exchanger

Comp. to turbines, only 50% of the heat is in the exhaust

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Distributed Power - Jenbacher gas engines
Applications Overview
 Electrical and thermal efficiency drive CoE

el
1% = €11k/MW
Avoided cost
for heat

th Electricity
Fuel Rate
1% = €5k/MW Or
Feed in Tariff

Net CoE Net CoE

Service

Invest

Need to optimize on customer specific requirements

Specific engine versions and hydraulic integration variants

Gas @3.5€C/kWh (10€/MMBTU), 6000oh/y 9

Examples of Trigeneration plants
Mussafah Industrial City Airport Köln Bonn
Abu Dhabi, United Arab Emirates Cologne, Germany

Fuel: Natural gas Fuel: Natural gas

Engine type: 3 x JMS 616 GS-N.L Engine type: 4 x JMS 616 GS-N.L
Electrical output: 6,018 kW Electrical output: 7,744kW
Commissioning: June 2003 Commissioning: 1999

03-2006 10
GE Energy Jenbacher gas engines
VMP/Schneider,Eberharter
 Part 2
Detail of Application

Imagination at work.
Basic knowledge
Overview of CHP Technologies
(Prime Movers)

PROS CONS
Reciprocating Engines • Low Initial Investment • Slightly Higher Maintenance
250KW – 4MW • Mature technology Cost
• Part Load Efficiency

Gas Turbine • Mature Technology • Gas Compressor Required

500KW – 200MW • Good Steam Generation • Air Permit Required
28-35% eff. capabilities
$1000-1800/KW

Micro Turbine • Medium Investment cost • High Initial Investment

25MW – 150KW • Low Maintenance Cost • Limited Commercially
20-30% eff. • Small Size • Availability
$1500 - $3000/KW

Steam Turbine • Size Flexibility • High Initial Investment

100KW – 100MW • Low Maintenance Cost • Requires HP steam
30-75% eff. • Turndown Limitations
$300-$3000/KW

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Distributed Power - Jenbacher gas engines
Applications Overview
 Comparison of Technology
Investment costs Mechanical efficiency Service and maintenance costs

Gas engine 100% Gas engine 45% Gas engine 100%

Gas turbine 150% Gas turbine 33% Gas turbine 80%

Diesel engine 70% Diesel engine 48% Diesel engine 120%

0% 50% 100% 150% 200% 0% 20% 40% 60% 0% 50% 100% 150%

Life time (major overhaul) Fuel Heat recovery – Cogeneration

• GAS ENGINES can be operated with different fuel
gases (natural gas / non-natural gas) on a low gas • The recoverable heat of gas engines can be used
Gas engine 60.000
pre-pressure. flexible for the production of HOT WATER, COLD,
STEAM and HOT AIR for drying.
• GAS TURBINES require a high gas pressure
(15 - 20 bar) and a very clean gas. • The clean gas engine exhaust gas can be used for
Gas turbine 60.000
CO2-fertilization in greenhouses.
• DIESEL-OIL is in most countries more expensive than
natural gas. • Soot in the exhaust gas of diesel engines make a
Diesel engine 20.000 • The worldwide resources of Natural Gas are bigger heat recovery difficult.
than the resources of oil.

- 20.000 40.000 60.000 80.000 • Natural gas is the fossil energy of the future!

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Distributed Power - Jenbacher gas engines
Applications Overview
Comparison of emissions
CO₂ emissions [g/kWhel ] SO₂ emissions [g/kWhel ]

Gas engine 500

Gas engine 0,0

Gas turbine 700 Gas turbine 0,0

Diesel engine 650 Diesel engine 3,8

- 200 400 600 800 0,0 1,0 2,0 3,0 4,0

Biogas and Landfill Gas are CO2-neutral SO2-Emissions are responsible for “acid rain”

NO x emissions [g/kWhel ] Particle [mg/kWhel ]

Gas engine 0,7 Gas engine 0

Gas turbine 0,3 Gas turbine 0

Diesel engine 7,0 Diesel engine 250

0 100 200 300

0,0 2,0 4,0 6,0 8,0
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Distributed Power - Jenbacher gas engines
Applications Overview
Engine vs turbine

Engine Pro’s
 Better Heat Rate (efficiency)
 Lower Investment Cost
 Less Complexity of Operation
 No Gas Compressor Required
 Low grade Heat Utilization
 Efficient Part Load Operation
 Not effected by High Ambient

Turbine Pro’s
 Lower O&M costs
 Larger Single Unit Output
 Better Steam Generation Capabilities
(higher grade thermal)

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Distributed Power - Jenbacher gas engines
Applications Overview
Scheme of a Cogeneration Plant
Steam System

Hot water

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Distributed Power - Jenbacher gas engines
Applications Overview
Energy balance of Recip Engines
Energy input NG100% HEX 1
mech. output th. output Intercooler heat
~42% ~58% HEX 1 exchanger
HEX 2
HEX 3
HEX 2
Oil heat exchanger
HEX 4

HEX 3
Jacket water heat
losses ~10%

exchanger
recoverable
el. output~40% thermal
HEX 4
output~50%
Exhaust gas heat
exchanger

Comp. to turbines, only 50% of the heat is in the exhaust

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Distributed Power Commercial Team Meeting | 2014 Distributed Power - Jenbacher gas engines
Applications Overview
Hot Water
Heat Exchanger Principle : 1. Q = (M X p X Cp X ΔT)/3600
2. Conservation of Energy: Q Hot = Q Cold
Where Q : Thermal Heat in KW
M : Flow m3/h
P : density in Kgm3
Cp : Specific Heat Capcity Kj/(Kg C)
ΔT : Temperature difference in Celsius Degrees

Application
Thermal Exchange
T Hot out > TCold in

T Hot in
TC old out ΔT = 2.5-5.5 C
T Hot in

T Cold out T Hot out

T Cold in
Pinch point
T Cold in
T Hot out
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Distributed Power - Jenbacher gas engines
Applications Overview
 Hot Water heat exchanger

Heat Exchanger
Design Description
Type

Used to remove heat from liquid by passing the liquid

through tube attached to fin which radiate the heat in to
Air Cross Flow
stream of air. Common used in automotive radiator, air
Heat Exchanger Cond circuits.

Used to remove heat from or add heat to liquid by way of a

second liquid at difference temperature. Individual plates
are brazed or clamped together to form a series of pockets
Plate Heat through which the two liquids pass without touching.
Exchanger
Mostly used for liquid to liquid and steam to liquid heat
transfer.

Used to remove heat from or add heat to liquid by way of a

second liquid at difference temperature. They consist of a
tube bundle through which one fluid passes surrounded by
Tube and Shell
shell where a second fluid flow,
Heat Exchangers
Often used in higher pressure application such as in steam
heating of water.

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Distributed Power - Jenbacher gas engines
Applications Overview
Jenbacher CHP – Temperature levels
Hydraulic integration variant 1

70/90°C
1492kW

Hydraulic integration variant 2

80/99°C
1422kW

03-2006
Steam Boiler/Heat Recovery Steam Generation
Rules of Thumb
1. Q from exhaust = Q to Steam (Less blow-down & radiant loss)
2. Typical Steam pressure are up to 300 psig
3. 1 ton of steam required energy 680 Kwh (feed water temp 80C)
4. Stack temp limited by fuel sulfur content
5. Pinch point -The pinch point is the minimum temperature difference between the flue gas
and the EVAP saturation temperature. The surface are grows exponentially with lower pinch
point temp. Steam Tools use 20 C. (Aggressive 14C )

Engine
Exhaust Temp

Stack Temp

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Distributed Power - Jenbacher gas engines
Applications Overview
Steam Tool Manual Input
If you are using the Steam tool in ESVU, the data should be automatically filled.
Otherwise, the manual input will be according to data provided by the Technical Specification as following:

Stack temp limited by fuel sulfur content. 120 C is typical number for Boiler OEM.

Feed water Temperature- Can be optimized by integrated with Engine hot water
system

Enter 1 or 2, depending on the steam requirements.

Pressure – 1 or Temperature-2

Enter the value required from the steam

Pinch point typical value 20 C

Heat loss & Bow down loss default value 2%

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GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006
Trigeneration with Jenbacher gas engines
Refrigeration Principle
Refrigeration is required for
• Air conditioning (hotels, conference centres, office buildings, …)
• Industrial processes (food, chemical, computer industry, …)

Choice of cooling technology

• Compression-type refrigeration machine
• Absorption-type refrigeration machine
• Total energy supply requires electricity, heat, cold >>> TRIGENERATION

𝑂𝑢𝑡𝑝𝑢𝑡
COP co𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑝𝑒𝑟𝑓𝑜𝑚𝑎𝑛𝑐𝑒 = 𝐼𝑛𝑝𝑢𝑡

The best ecological and economical solution for the specific demand has to be found!
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GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006
Absortion Chiller tool
Input

Typical value for exhaust fire absorption is 1.3

Customer
requirement

Note: Input is the higher temperature of either 1) Chiller ‘s OEM lowest limited or 2)
Hot water inlet temp. Typical OEM is limited at 80 C

Typical value for Hot water absorption is 0.6 - 0.7

Output

Note: To get the correct output information, fill only the input of customer requirements.
(only exhaust gas/only how water/both)

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GE Energy Jenbacher gas engines VMP
03-2006
Compressor type refrigeration

Refrigerants heat
(CFCs; damage the ozone layer and contribute release
to the greenhouse effect)
condenser
Refrigerant is reduced to a liquid state in the
evaporator, absorbing evaporative capacity.
expansion
valve Compressor
COP power
(electricity)
(Coefficient of Performance) ~ 4
‘’The mechanical compressor capacity is vaporizer
approx. 25% of the cooling capacity“
heat pick-
up (cooling)

Cooling is the removal of thermal energy from an area in which it is not wanted!
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GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006
Absorption type refrigeration
Working principle
• A pair of substances (water / Lithium
bromide) is separated through the addition
of heat (Desorption).
• Through the removal of heat they are
combined (Absorption).
• Desorption and Absorption takes place at
different pressures in the vacuum range.
• (Desorption: 80 mbar abs.; Absorption: 10
mbar abs.)
• Cold water can be produced in a range of
6°C to 12°C
• To produce temperatures as low as - 60°C;
Ammonia and Water is used.

A single stage absorber consists of: Ejector, Condenser, Evaporator, Absorber, Pumps
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GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006
Absorption type refrigeration
Condenser tc~45 ~37°C Cooling water outlet
Pressure °C
~80 mbar abs.

Ejector
Heating water inlet
~70°C

Heating water outlet

Pressure ~95°C
~8,2 mbar abs.
to ~4°C
6 °C
Cold water

12 °C
Vaporizer

Absorber ~32,5°C

~27°C Cooling water inlet

ta ~ 35°C
Cold water
Cooling water
~70°C Enriched solvent (LiBr)
Low solvent solution (LiBr)
Heating water
Solvent (water)

~50°C

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GESource:
Energy Jenbacher gas engines VMP/Schneider,Eberharter
YORK International
03-2006
Absorption chiller: function principle

Evaporator Absorber

Ejector Condenser

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Source: THERMAX GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006
Combination of various systems
Energy flow diagram: Gas engine Cogeneration and Absorption Chiller

Benifit: use of waste heat!

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GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006
Absorption chillers - capabilities

Advantages
• Driving power = heat Hot water
• Low operating costs
Hot Water single stage
• Electrical energy required:
COP 0.7 – 0.75
approx. 1% of refrigeration
capacity
• Few moving parts => Low
servicing and maintenance
costs
• Increased annual utilisation
ratio of cogeneration plants
• Very good behaviour under exhaust gas heat
part-load exhaust heat
COP 1.2 – 1.35
• CFC-free refrigerants only separate use of hot water

Disadvantages
• Relatively high capital costs
• Low power density, large
volume of construction
• High recooling capacity

combined exhaust gas + hot water

total heat
COP 1.0 – 1.05

Source: Trane/Thermax
Examples for trigeneration plants
Mussafah Industrial City Airport Köln Bonn
Abu Dhabi, United Arab Emirates Cologne, Germany

Fuel: Natural gas Fuel: Natural gas

Engine type: 3 x JMS 616 GS-N.L Engine type: 4 x JMS 616 GS-N.L
Electrical output: 6,018 kW Electrical output: 7,744kW
Commissioning: June 2003 Commissioning: 1999

33
GE Energy Jenbacher gas engines VMP/Schneider,Eberharter
03-2006