320

GE Energy
Separator sheet
Jenbacher gas engines
Use this range of background

FECC - GTZ
colors to introduce new
Training for Biogas Design
sections
Institutes - Beijing
From Biogas to electricity-

CHP-use in operation
Thomas Elsenbruch
1/
GE Jenbacher / Thomas Elsenbruch
August 13, 2010
GE Energy Infrastructure
Employees: 65,000 • ‘08 revenue: $38.6B • Operating in 140 countries
Power & Water Energy Services Oil & Gas
• Power generation • Contractual agreements • Drilling & completion

• Renewables • Smart Grid • Subsea, offshore &
• Gas Engines • Field services onshore
• Nuclear • Parts & repairs • LNG & Pipelines
• Gasification • Optimization • Pipeline integrity
• Water treatment technologies • Refining
• Process chemicals • Plant management • Processing
2/
August 13, 2010
GE’s Jenbacher gas engines
A leading manufacturer of gas fueled reciprocating engines
for power generation
1,700 employees worldwide, 1,300 in Jenbach/Austria

9,100+ delivered engines / 10,800+ MW worldwide
Power range from 0.25 MW to 4 MW
Fuel flexibility
Natural gas, biogas, flare gas, landfill gas, steel gas,
coal mine gas
Advanced system solutions
Generator sets, container modules
cogeneration, trigeneration, CO2-fertilization
Environmental benefits
Low emissions
ecomagination solutions
Lifetime services plus (parts, repair, CSA, upgrades)
2,000 units under CSA
3/
August 13, 2010
Product Program 2010:
Biogas, Sewage Gas and Landfill Gas
3.500
Electrical output [kW]
3.000 Thermal output (70°/90°C) [kW]
2880
2737
2.500 Natural gas standard
2403
NOx ≤ 500 mg/Nm3
2190
2.000 (dry Exhaust gas; based on 5 % O2)
1802
1635
1.500
1421
1415
1138
1131
1.000
1088
1065
910
854
844
836
744
703
680
625
500
558
500
330
400
294
250
0
J 208 J 312 J 316 J 412 J 320 J 416 J 420 J 612 J 616 J 620
GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L GS-B.L
4/
August 13, 2010
The whole Jenbacher biogas fleet:
•Sewage gas: more than 450 installed engines (313 MW )
•Biogas: more than 1500 installed engines (1065 MW )
•Landfill gas: more than 1400 installed engines (1370MW )
400 400
350 350
300 300
250 250
#units/a
MWel/a
200 200
150 150
100 100
50 50
0 0
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
5/
August 13, 2010
Jenbacher - Biogas engines in some EU and
Asian countries
Installed in Biogas plants up to 31.12.2009:
• Germany 945 engines 527 MW
• Italy 161 engines 130 MW
• Austria 90 engines 48 MW
• Netherlands 69 engines 72 MW
• Denmark 46 engines 35 MW
• Czech Rep. 40 engines 28 MW
• Belgium 32 engines 36 MW
• Spain 32 engines 30 MW
• UK 11 engines 12 MW
• Poland 8 engines 6 MW
• Hungary 7 engines 3 MW
• Slovakia 6 engines 6 MW
• Thailand 42 engines 51 MW
• India 37 engines 32 MW
• Indonesia 28 engines 30 MW
• China 10 engines 12 MW
6/
August 13, 2010
Gas engines play core role in biogas plants
(in case of food waste)

biogas-cogeneration units are core part of biogas plant, in combination
with enhanced digester-technology
7/
August 13, 2010
Targets of development optim. Biogas engine
Target:
Optimized efficiency in
operation with Biogas
Basic engines
Optimized specific output
Frame conditions:
• Biogas
• Exhaust emissions
• Thermodynamic Optimum
8/
August 13, 2010
Internal efficiency – combustion duration
Ind. Efficiency
0,53
0,51
ε = 14
0,49 ε = 12
0,47
0,45
ε = 10
0,43
0,41
0 10 20 30 40 50 60 70 80
Combustion duration [°crank shaft]
Higher compression-ratio helps the efficiency

9/
August 13, 2010
Comparison of efficiency of different concepts
The optimum of compression ratio and BMEP must be found

10/
August 13, 2010
GEJ spark plugs/ ignition system
development
J316 Kläranlage Eugene / pme 17bar
34
31 P2
P3.V3
28
Ignition voltage in [kV]

P7.4V1S1
25
22
19
P1 P2 P4 P7 P3
16
13
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
operating hours
11/
August 13, 2010
WWTP Straß/A JMS 208 GS.B.LC
WWTP Strass Zillertal/A

1 x JMS 208 GS B.LC
Electrical ouput
330 kW
Thermal output
420 kW
Electr. efficiency
η el = 39%
Therm. efficiency
η th = 48%
12/
August 13, 2010
Optimization of combustion Type 2/3/4
Optimized Combustion
Acceleration by „heart-shaped“ piston bowl
Minimized crevice volume
• 30% lower HC
• 30% lower CO
increased compression ratio in combination mit „Miller“-timing
Old New
13/
August 13, 2010
Efficiency increase in Biogas
El. efficiency
Type 4 B25 2011
0,44
Type 4 A25 – 2007
0,4
Type 3 C21 2002
0,36
0,32 Type 3 B21 1997
0,28 Type 3 B27 1994
0,24
0,2
0 20 40 60 80 100 120
Load [%] 14/
August 13, 2010
Important criteria for gas engine selection
15/
August 13, 2010
Lean-burn combustion with gas engines
•Lean combustion to ensure low NOx emission limits (500 mg/Nm³ and lower)
•Reduced combustion temperatures enable higher specific outputs and efficiency
16/
August 13, 2010
Details: „Gas engine concept“
Advantages:
• “Cross flow” cylinder head
(external exhaust gas manifolds)
• Clear separation of cold mixture
inlet and hot exhaust gas
• Exactly defined thermal zones in
the cylinder head
• Long cylinder head life time
• Better accessibility to the exhaust
gas manifolds
17/
August 13, 2010
LEANOX® - Lean-burn combustion control
•Sensors in non critical measurement ranges (pressure, temperature, deposits...)

•Reliable and durable compliance with exhaust emission limit at changing
operational conditions (fuel gas compositions...)
•Controlled combustion and subsequently controlled stress of various
components (valves, cylinder heads, spark plugs...)
18/
August 13, 2010
The Networking Concept
19/
August 13, 2010
Important criteria for gas engine selection
• Select a specifically designed biogas cogeneration unit

• Modern gas engine concept (“Cross-flow” cylinder head, no
derived Diesel engine)
• Turbocharged engine for high power density and efficiency
• Electronic NOx-emission control, preferably with sensors
outside the combustion chamber and exhaust gas manifolds
• Enhanced ignition control system (preferably with integrated
electronic ignition voltage control)
• Knocking control (at least 1 sensor/ cylinder-line)
• Enhanced engine control system with alarm management
(remote monitoring, diagnosis and control recommended)
• Interfaces between engine control and system control
20/
August 13, 2010
Typical operation and maintenance figures
•Main maintenance intervals:
– Every 1,000 (2,000) ophs: spark plug and valve re-gapping, lube oil
change (according oil analysis)
– Btw 5,000 and 10,000 ophs: overhaul of turbocharger, water pump…
– Minor or top-end overhaul btw. 15,000 and 30,000 ophs depending on
manufacturer and engine condition (change of cylinder heads, pistons,
liners, …)
– Major overhaul: btw. 40,000 and 60,000 ophs depending on
manufacturer: exchange of core-engine
•Specific maintenance cost:
– 1.5 – 2 US/kWh for preventive and corrective maintenance
– Major overhaul: Appr. 60% of the initial investment for the genset.
O&M costs of genset appr. same as initial genset investment
21/
August 13, 2010
Example Biogas Gosdorf –
Outstanding Reliability
i lity
liab
t r e
e
fle its)
8 + % un
e 9 0+
r ag ( 45
ve as
• a Biog
at
• Achieved 8,740 out of 8,760 oph/y in´05

• 99.8% Availability with Biogas 22/
• average 98+% fleet reliability at Biogas (450+ units) August 13, 2010
Heat recovery opportunities with gas engines
23/
August 13, 2010
Cogeneration of heat and power (CHP)
CHP systems utilize the waste heat incurred during engine
operation to generate overall plant efficiencies of more than 90%.
HE 1
Mixture intercooler
HE 2
Oil exchange heater
HE 3
Engine jacket water heat
exchanger
HE 4
Exhaust gas heat exchanger
24/
August 13, 2010
Energy savings through CHP technology
Primary energy
savings:
roughly 40%
25/
August 13, 2010
Temperature levels of different heat sources
Min. Max. Danger

Engine Jacket water 57°C 95°C Overheating
Lube oil 70°C 90°C Viscosity
Intercooler 55°C 80°C Condensation
Exhaust gas (50°C) 220 (180)°C Acid dewpoint
Condensate!
26/
August 13, 2010
Recoverable Heat w/ Integration 70/90°C
27/
August 13, 2010
Heat utiliziation in Biogas-CHP
JMS 312 GS-B.L (C225)
Electr. Output: 526 kW

Recov. Heat: 524 kW
LT-IC heat: 23 kW
Therm. Efficiency: 40,3%

28/
August 13, 2010
Steam production with Gas engines
Foto: Biogas Kogel – 1 x JMC 420 GS-B.LC
JMS 312 GS-B.L
Therm. Output
Hot wat. 65/85°C: 325 kW
Sat. steam, 8 bar: 345 kg/h
(= 231 kW)
LT-IC heat: 19 kW
Therm. eficciency: 42,7%
Feed water must be

conditioned!
29/
August 13, 2010
Advantages of trigeneration systems over
conventional refrigeration technology
• Operated with heat, utilizing inexpensive

“excess energy”
• No moving parts in absorption chillers, no
wear and therefore low maintenance
expenses
• Noiseless operation of the absorption
system
• Low operating costs and life-cycle costs
• Water as refrigerant, no use of harmful
substances for the atmosphere
30/
August 13, 2010
Trigeneration with gas engines

Recoverable Heat: 550 kW
LT-IC heat: 40 kW
Cold production: ~385 kW
Therm. efficiency: 42,2%
31/
August 13, 2010
Drying process with Gas engines
90°C
42 kW
Fuel gas 451°C ~130°C

(cleaned)
70°C
JMS 312 GS-B.L

Recoverable heat: 653 kW
LT-IC heat: 24 kW
Therm. efficiency: 50,2%
32/
August 13, 2010
Brickyard LUNDGAARD
Stoholm - Denmark 1 x JMS 212 GS-N.LC

Recoverable heat: 699 kW
Therm. efficiency: 59,0 %
33/
August 13, 2010
What is the right path with biogas?
34/
August 13, 2010
What is the right path with biogas?
35/
August 13, 2010
Summary – Biogas in CHP
•Biogas plants are operated – weather independent –

for base load supply
•Biogas plants can be seen as state-of-the-art
technology
•Because of low energetic density of source materials,
biogas should be used decentralized
•Using biogas in CHP-modules generates highest
GHG-savings
36/
August 13, 2010
Important design criteria
37/
August 13, 2010
Gas Requirements :
•gas pressure
•methane number
•gas temperature/relative Humidity
•heating value fluctuation In general these are
important criteria for
•contaminations Non Natural gases
– Sulphur,
– Halogens,
– Ammonia,
– Silica.......
38/
August 13, 2010
Gas – plant:
Emergency flair
gas train
blower
main valve standard Interface at gas train
80 – 200mbar
39/
August 13, 2010
Gas Requirements :
• Gas temperature < 40°C
mixture temperature
limited by rubber materials of gas train
•relative humidity < 80%

(at every gas temperature)
condensate in gas supply
–filter; pressure regulator; gas train,.....
–condensate in engine/intercooler
40/
August 13, 2010
Relative humidity:
Water content [ g / operation cubic meter] 60
Example a) and b) : follow step 1 -4:

50 Through heating of a gas with a dew point of 24°C to
a) 28°C - reduce the rel. humidity from 100 to 80%
b) 37°C - reduce the rel. humidity from 100 auf 50%
80% rel.
40 humidity
fog zone 100% rel.
humidity
30
50% rel.
2 3a 3b
humidity
20
Gas heating does not reduce the water content.

It increase the offset to the dew point!
10
4a 4b
1
0
5 10 15 20 25 30 35 40 45 50
Gas temperature [°C]
41/
August 13, 2010
Gas humidity / cooling:
42/
August 13, 2010
Gas Requirements TI 1000 – 0300:
Condensate in the intercooler
43/
August 13, 2010
Reduce humidity:
Gas pipe + pre heating second best Active humidity reduction best solution
solution
biogas
Cooling system
3
soil Gas compressor

Gas compressor
Condensate trap Condensate trap
4Only reduction of rel humidity; works only at a 4 Effective reduction of water content
low gas temperature level 4 Reduce risk of having condensate in the
4Water content is not changed gas system
4 Reduce risk of corrosion!
4Avoid condensate drain off in subsequent
parts
4Gas cooling because of gas pipe mounted in
soil possible but not sure
44/
August 13, 2010
Active gas drying / biogas example:
Schmack 1/Deutschland
1 x JMS 312 GS-B.L
500 KWel
Gas cooling / drying /

dehumidification
Electr. chiller
45/
August 13, 2010
Layout example:
Condensate trap at the

deepest point
Condensate drain
below the blower
46/
August 13, 2010
Gas Requirements TI 1000 - 0300
Sulfur:
H2S < 700 mg/10 kWh (without catalyst)
< 200 mg/10 kWh (with catalyst)
Standard maintenance schedule
Σ H2S < 1200 mg/10 kWh

„modified“ maintenance schedule
acidification of oil
reduced Oil lubricity
SOx + H2O corrosion
deposits in exhaust gas heat exchanger, when temperature is
below dew point
47/
August 13, 2010
Gas Requirements TI 1000 – 0300
Sewage Treatment Plant
Sulfate deposits
exhaust gas temperature
below dew point
48/
August 13, 2010
Sulfur/ash-deposits in an exhaust gas heat
exchanger:
49/
August 13, 2010
Solution: special biogas heat exchanger
• Cooling down to 180°C or 220°C

• Exhaust gas heat exchanger without pipes at the bottom no
condensate around the pipes
• Big condensate trap (DN50) + falling condensate pipes
50/
August 13, 2010
51/
August 13, 2010
International references
52/
August 13, 2010
Biogas plant Kogel, Germany
No. of units and engine type: 1 x JMC 420 GS-B.L

Fuel: Biogas (potato peelings/pig manure)
Electrical output: 1,413 kW
Thermal output: 751 kW
Steam production: 3 bar(g) 1,037 kg or 698 kW steam production
Commissioning: Year 2002
53/
August 13, 2010
Biogas plant Præstø, Denmark
No. of units and engine type: 1 x JMS 312 GS-B.L

Fuel: Biogas from pig manure
Electrical output: 625 kW
Commissioning: June 2002
54/
August 13, 2010
Biogas plant DeQingYuan, China
No. of units and engine type: 2 x JMS 320 GS-B.L

Fuel: Biogas from Chicken Dung
Electrical output: 2126 kW
Commissioning: Sept 2008
55/
August 13, 2010
Cow manure “methane-to-energy” plant in
Ludhiana - India
Biomass Input: 235 ton/day cattle manure

Electrical output: 1 MW
Organic fertilizer: 35 ton/day
No. of units and engine type: 1 x JMC 320 GS-B.L
56/
August 13, 2010
AD of biomass – Natural palm Oil - Thailand
Biomass:
– POME - palm oil mill effluent
Basic conditions:
- 12m3/h POME
- Temperature of POME fresh from
mill 80°C -> cooling-down in open
lagoon
1 x JGS 320 GS-B.L.C

Power output:
1064 kWel.
Commissioning:
2005
57/
August 13, 2010
AD of biomass – Natural palm Oil - Thailand
Biogas: biogas
H2S content up to 2000ppm

-> desulphurization is a must!
-> done with a „BioGasclean-System“
Heat demand of the “Palm Oil Plant”:

-> steam 22.5 to/hr (3.5bar; air water
0.5to/FFB)
Steam production:
-> with “Palm Fiber”
-> in addition with exhaust gas
58/
August 13, 2010
AD of biomass – Kanoria I + II - India:
Biomass:
– Spent wash – 675 m3/d
-> effluent removed after
fermenting sugar cane
molasses (ethanol production)
1 x JMS 320 GS-B.L

1 x JMS 420 GS-N/B.L
Power output:
1034 kWel. / 1416 kWel.
Thermal output:
Water:586 kWth. / 748 kWth.
Steam: ~ 1350 kg/h; 10bar
Commissioning: 1998 / 2003
59/
August 13, 2010
Biogas plant Highmark, Canada
No. of units and engine type: 1 x JMC 320 GS-B/N.LC

Fuel: Biogas from cow manure
Electrical output: 1,060 kW
Thermal output: 1,240 kW
Commissioning: March 2004
60/
August 13, 2010
Thank you for your attention!
Further Questions?
61/
August 13, 2010

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GE Energy

Use this range of background

From Biogas to electricity-

Power & Water Energy Services Oil & Gas

• Power generation • Contractual agreements • Drilling & completion

1,700 employees worldwide, 1,300 in Jenbach/Austria

(in case of food waste)

Higher compression-ratio helps the efficiency

The optimum of compression ratio and BMEP must be found

Ignition voltage in [kV]

WWTP Strass Zillertal/A

0,32 Type 3 B21 1997

0,28 Type 3 B27 1994

•Sensors in non critical measurement ranges (pressure, temperature, deposits...)

• Select a specifically designed biogas cogeneration unit

• Achieved 8,740 out of 8,760 oph/y in´05

Min. Max. Danger

Electr. Output: 526 kW

Therm. Efficiency: 40,3%

JMS 312 GS-B.L

Electr. Output: 526 kW

Therm. eficciency: 42,7%

Feed water must be

• Operated with heat, utilizing inexpensive

Electr. Output: 526 kW

Fuel gas 451°C ~130°C

JMS 312 GS-B.L

Electr. Output: 465 kW

•Biogas plants are operated – weather independent –

•relative humidity < 80%

Example a) and b) : follow step 1 -4:

Gas heating does not reduce the water content.

Condensate in the intercooler

soil Gas compressor

Gas cooling / drying /

Condensate trap at the

Σ H2S < 1200 mg/10 kWh

• Cooling down to 180°C or 220°C

No. of units and engine type: 1 x JMC 420 GS-B.L

No. of units and engine type: 1 x JMS 312 GS-B.L

No. of units and engine type: 2 x JMS 320 GS-B.L

Biomass Input: 235 ton/day cattle manure

No. of units and engine type: 1 x JMC 320 GS-B.L

1 x JGS 320 GS-B.L.C

H2S content up to 2000ppm

Heat demand of the “Palm Oil Plant”:

1 x JMS 320 GS-B.L

No. of units and engine type: 1 x JMC 320 GS-B/N.LC

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