Technology

and Economics of modern Biogas Engines

Agenda
Who is MWM/Euroasiatic? What is Biogas? How to use biogas? Feasibility Calculation Conclusions

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Key figures
MWM
approx. 1,150 employees worldwide
Operations in more than 60 countries worldwide

More than 140 years of experience in gas engines

Euroasiatic
More than 425 employees in Indonesia More than 40 years of experience in energy applications

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The long-established company MWM

The MWM can look back at a tradition lasting over 140 years which has always been accompanied by innovations. 1871 Car inventor Carl Benz set the basis with the foundation of his "Mechanical Workshop" in Mannheim. 1922 The company split up. The Motoren-Werke Mannheim AG, formerly Benz, "Stationary Engine Construction evolved.
1985 Klckner-Humboldt-Deutz AG took over MWM. 2005 Deutz AG spun off a division known as DEUTZ Power Systems

2007 Deutz sold it to the investment firm of 3i in the fall of 2007. 2008 Re-Branding to MWM

1871

1908

1922

1945

1985

2005

2008

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MWM group worldwide

MWM built up a network of 10 subsidiaries in all main markets
MWM Benelux B.V.
MWM Canada Inc.

MWM Energy Hungaria Kf t.

MWM GmbH DEUTZ Power Systems (Beijing) Co. Ltd. MWM France SAS

MWM of America, Inc.

MWM AsiaPacif ic Pte. Ltd.

PT. Euroasiatic

MWM Energy Espaa S.A. MWM Austria GmbH

MWM Energy Australia Pty. Ltd.

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Euroasiatic the company

Offices Locations Regions of operation

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Euroasiatic the company

Core competencies

Mono-Generation (Open-Cycle) Systems Co-Generation / Combined Heat & Power (CHP) Systems Tri-Generation / Combined Cooling, Heating & Power (CCHP) Systems Combined-Cycle Systems
Semi-Turn-Key & Full-Turn-Key Services Mains Parallel Operation Island Mode Operation
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Euroasiatic the company

gas engine generating sets:

gas turbine generating sets:

+ 108 installations
+ 33 plants

diesel engine generating sets : waste heat recovery systems : oil & gas fired steam boiler plants : solid fuel & bio-mass fired steam boiler plants : oil & gas fired thermal oil boiler plants : coal -fired steam boiler plants :
coal -fired thermal oil boiler plants :

+ 2,550 sets + 15 installations + 1,425 plants + 55 plants + 375 plants + 325 plants
+ 50 plants

industrial burners & combustion systems : biogas digester plants

+ 2,250 units + 12 plants

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Euroasiatic the company

Natural gas fired ( gas turbine & gas engine) Total installed capacity (2005 2009)

gas engine generating sets & power plants in mono-generation, co-generation & tri-generation systems: + 300 MW

gas turbine generating sets & power plants in co-generation, trigeneration & combined-cycle systems: + 200 MW

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Biogas definition and characteristics

Definition: Biogas typically defines a gas resulting from the anaerobic (i.e. absence of O2) decomposition or fermentation of organic material like:

Municipal waste or leftovers landfill gas

Sewerage waste (WWTP) sewage gas

Liquid manure or dung

Energy crops (corn, wheat, grass)

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Biogas definition and characteristics

Suspension Chopping-up

Hydrolysis step 1 Dissolution of readily biodegradable components saliva paunch

Hydrolysis step 2 Dissolution of persistent components

Methane formation

digested substrate
small/large intestine abomasum

substrate supply

omasum

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Biogas definition and characteristics

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Biogas definition and characteristics

Typical composition of Sewage and Landfill Gas
Component methane (CH 4)
carbon dioxide (CO2)

[Vol%]

min 57
28

typical 65
34

max 72
43

nitrogen (N 2) Methane number

LCV

0 [-] 125
5,7

1 130
6,5

20 135
7,0

[kWh/m3]

methane (CH 4) carbon dioxide (CO2) oxygen (O2)

nitrogen (N 2) Methane number [-]

45 20 0
10 122

50 27 0
23 130

65 45 10
34 135

LCV

[kWh/m3]

4,5

5,0

6,5

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Principle of a gas treatment system

Khleinheit Cooling unit

Entschweflungseinheit Desulfurization unit

Kondensatabscheidung Moisture strainer

TA + Compressor x

Verdichter Nacherwrmung Heating unit

Fermenter
V

Gasmotor Gas engine

Wasser Water Luft Air Abwasser + Schlamm Waste water + sludge Kondensat Condensate

CH4 CO2 O2 H2 S
Gasanalysator Gas analyzer

Biogas plant

Gas drying

CHP-plant

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Example of a gas treatment system for biogas upgrading

Desulphurisation options:

Scrubbing with aqueous agents / solvents / suspensions

Sorption / linkage on solid particles: Activated Carbon, Iron Hydroxide Fe(OH)3 Biological scrubbing with H2S-eating microorganisms

Example: Gas Scrubbing

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Using Biogas
MWM = market leader in Germany
for Sewage / Landfill / Biogas

Containerized Genset Modules from 400 2000 kW or fitted into buildings: > 2 MW Gas Cleaning Desulphurisation Si-Scrubbing etc.

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50 Hz Product range gas engines

TCG 2032

TCG 2020

TCG 2016

Electrical output per genset in KW el

With our gensets we can cover a power range from 300kWel up to 50 Mwel for decentralized power production

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Engine optimization

Gas supply pressure

Using MWMs turbocharged lean burn combustion system means mixing of gas and air at atmospheric pressure before compressing this mixture in the turbocharger. Hence only very low biogas pressure at engine inlet is required, resulting in

Gas mixer regulation system

Reduction of investment costs as no compressors is required Increase overall plant efficiency (no energizing of compressors required)

Biogas air mixing

When using an electronic multi-gas mixer, the system can be set to a pre-defined starting position depending on the actual gas composition, this allows easy and reliable engine start run with alternative fuel (propane) until the biogas process is running on a stable basis and switching over to biogas operation

TEM

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Engine optimization: Benefits of an optimized control system

TEM (Total Electronic Management) controls the genset by the temperature of every individual cylinder and protects it by an anti-knocking control TEM and the multi-gas mixer enables the engine to run with fluctuating gas qualities and different gas types like Natural gas / CBM / CMM Coke oven gas Pyrolysis-, syn- and flare gases Biogas This leads to a longer engine lifetime without additional maintenance costs
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Engine optimization: Benefits of an optimized control system

TEM EVO main functions Easily adjustable to local conditions Convenient remote diagnosis and remote control A modular system to govern all auxiliary functions Simple and secure operational concept Wide range of control and monitoring options Multiple language documentation and handling

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Engine Optimization: Mixture intake

It is essential for proper engine operation to avoid condensation (= corrosion danger) on the way to the cylinders. Measures adopted include Mixture cooler temperature has to be kept as high as possible (>65 C) Mixture cooler resistance shall be increased by using tin coated fins Crankcase breather has to have a very high water separation capability by adequate size

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Engine Optimization: Combustion Process compression ratio

From a thermodynamic point of view,

the efficiency of combustion is proportional to the compression ratio of the engine.
On the other side higher compression ratio means higher risk of knocking and consequently higher operational risk.

Since the MN of biogas is approx. 30% higher than natural gas, biogas has a significantly higher margin against knocking. This can be used accordingly.

Efficiency gain vs. Compression ratio Epsilon (calculated)

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Engine Optimization: Combustion Process compression ratio

MWM biogas engines have higher

compression ratio (= 15) showing significant mech. efficiency increase of approx. 1,2 % up to 1,5 %

It shall also be considered, that higher

efficiency is the result of a better energy conversion in the combustion chamber resulting additionally in less thermal stress to the engine
Mech. efficiency increase TCG 2016 from Epsilon 12 to Epsilon 15 (DPS measurements)

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Engine Optimization: Combustion Process spark plug design

Use of pre-chamber spark plugs are

part of this improvement step. A prechamber spark plug consists of specially designed: Pre-chamber (1) including the spark electrode

Pre-chamber cover (2) with flame propagation bores

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Engine Optimization: Combustion Process spark plug design

Prechamber volume and bore shape energizes the mixture to increase flame propagation

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Engine Optimization: Combustion Process spark plug design

With the pre-chamber spark plug the required ignition voltage is reduced by means of approx. 25 %, resulting in an extended plug lifetime

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Engine Optimization: Bearing design and metallurgy

When looking for more corrosion resistant bearings, engine manufacturers have concentrated on using sputter bearings. This bearings have a very high resistance against corrosion due to its dense surface reached by sputtering of the running surface
Structure grooved bearings (cut view) Structure sputter bearings (cut view)

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Engine Optimization: Lube oil management

Avoiding acidification of the lube oil resulting from condensation of combustion products with gas contaminants is essential for proper operation. Following strategies have been developed: Operation with high lube oil temperature Keeping lube oil hot during engine standstill (proper preheating and hydraulic connection to plant)
Appropriate ratio of oil volume to power output on the set
Oil Lifetime increase vs. Spec. Oil volume

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Example for a 1,200 kW biogas plant:

How much biogas is needed for 1200 kW output?

1200 kWe / 42% (el. eff.) / 5.7 kWh/m (assumed LCV biogas) 502 m/h
What is needed to generate 500 m/h in a digester?

20.000 t / a biomass, eg. cornsilage, loppings, green cuts, menure, etc. Effluent from a 35 t/h Fresh Fruit Bunch processing plant (300 d/y, 20 h/d), i.e. approx. 27 t/h or 162.000 t/a effluent
What operating income can be achieved?
electricity supply to the grid

heat supply (drying process, heating, ) selling of fertilizer

Logistic input, end-substrate (agricultural crop land required)
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Example for a 1,200 kW biogas plant:

Income: electricity: 6000h x 1200 kW x 975 IDR/kWh heat: 8000h x 1000 kW x 0 IDR / kWh fertilizer ( 8% dry matter) 300 IDR/kg = = = 7,020 jt. IDR 0 jt. IDR 3,888 jt. IDR 10,908 jt. IDR

Costs: Invest biogas plant approx Invest genset approx Working costs Maintenance (plant): 2% v. Invest Service & maintenance: 100 IDR/kWh = = = = = 12,700 jt. IDR 6,246 jt IDR 250 jt. IDR 720 jt. IDR 19,916 jt. IDR

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Example for a 1,200 kW biogas plant:

Results:
Amortisation < 2 years

Secured income
Decoupling from the palm oil market

E N E R G Y with F U T U R E F U T U R E with E N E R G Y

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MWM / EA products for the use with biogas

MWM/EA complement its product portfolio with containers, which are ready to be installed

They will be easily to install and afford a fast displace, if necessary

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Service
Maintenance Our concepts( (e.g. Service contracts), our experts and our response time make sure that we meet your demands to our products at anytime. Service
Worldwide 24-hour support Professional consultancy, product supervision, quick guarantee processing

Documentation
Modern software enables us to identify spare parts for all MWM engines in use worldwide, quickly and precisely

Training Center Permanent training allows us to monitor and improve the qualification of our service personnel Training provided locally

Logisticcenter Optimised processes allow extremly short leadtime of the parts.the high ef f ciency and f lexibilityt enables to deliver our customers worldwide directly: just in time. Euroasiatic has Spare-part Stocks in - Singapore - Jakarta

X-Change Center Cost & time savings, we use basic engines and recycled parts

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Conclusions

Biogas is a renewable fuel with a special composition which demands proper addressing in both, plant layout as well as in engine / genset design Biogas has advantages when used in reciprocating engines resulting in improvements on efficiency and power output (and not only for this gas type) State of the art technology is already making use of this advantages This is a solid support from the industry to the efforts of producing more and more heat and electricity with renewable fuels in order to achieve the levels of CO 2 reduction expected by the both producers and customers

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Why should I use MWM products from EA?

Outstanding electrical efficiency Engines especially designed for the use of biogas Product portfolio throughout the whole range of performance (0,4 - 4,3 MWel) Lightweight engines and containers Easily to displace In EA you will find a reliable and experienced local partner for your power generation purposes

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Thank you.

Contact:

Peter Langohr Phone +62 (0) 21 5696 0555 Fax +62 (0) 21 5696 6132 E-Mail peter.langohr@euroasiatic.com