GENSET DEVELOPMENTS

Gut feeling

DEUTZ Power Systems develops and provides complete plants for decentralised energy supply using gas and diesel engine gensets, and specialises in biofuel units among which its TCG 2016 B, introduced in 2006, has become something of a standard for the industry. Recently the electrical efficiency of this product, which was specifically designed for biogas applications, was raised to 41.5%.

This is associated with a substantial reduction in the utilised biomass: for each genset and at the same power generation level, the new TCG 2016 B consumes approximately 200 metric tons less biomass per year. In view of constantly rising raw material prices, this means a tangible reduction in operating costs and improved profitability for the biogas plant.

It was this unit, the TCG 2016 B V12 biogas engine, that the operators of the Pfullendorf biogas plant, in south western Germany, decided to install as an upgrade for its 2016 V12 version, which had been delivered in 2005. The challenge was to reduce the conversion-related plant outage to an absolute minimum. For the engaged plant engineering companies Johann Hochreiter and Seiler, this requirement was an additional reason for making use of the experience of Deutz in this field. Director Eckhard Seiler was impressed by the collaboration and the result: ‘It is hard to believe what the specialists accomplished here. In only two weeks, the project was successfully completed by the service team – and the desired efficiency was achieved.’

With the upgrade in Pfullendorf, the plant operators save approximately 750 metric tons of corn substrate per year – a fine example of the implementation of a custom-tailored solution

Biogas plant Mölme

In 2007, a biogas plant based on a Deutz TCG 2016 B V16 biogas engine genset was established in Mölme, Germany in collaboration with SEVA Energie AG. The operator, Bio Energie Hoheneggelsen, is an association of local farmers.

An adequate quantity of renewable raw materials – mostly corn and liquid manure – is available in the immediate vicinity. With its strong focus on agriculture, the community is an ideal location. The deployed genset generates 716 kW of electricity for the grid and 642 kW of thermal energy.

Most of the generated heat is used at the plant itself in order to keep the temperature in the fermenter at the required level. In this way, the production of biogas by means of the fermentation process is maximised and accelerated.

The farmers spread the fully fermented substrate on their fields as biological fertiliser. Additionally, a small part of the heat energy is used to heat the adjacent farm facilities.

First ‘sustainable’ island in the W Indies

EcoPower Bonaire BV, a consortium of Enercon, MAN Diesel and Evelop (an Econcern company) has signed the contract with the Water and Energy Company of Bonaire (WEB NV) to build a combined wind biodiesel system, comprising 13 wind turbines and a 13 MW biodiesel power plant.

Bonaire will be the first Caribbean island to run entirely on sustainable electricity. The complete system will be able to provide the whole island with electricity by mid-2009. The first wind turbine was completed five months ago and now has come fully into operation. This also marks the start of the rest of the project.

The first wind turbine was built to gain experience with wind energy on Bonaire and to reduce electricity costs in the short term. During the first months the turbine performed beyond expectation. With the new system the cost of electricity production is expected to be lower than the cost of the present fossil fuel based system.

The total project is scheduled to be completed in the 2nd quarter of 2009. The remaining 12 wind turbines will be built on the north-east coast of Bonaire, the windward side. Each turbine can produce 0.8 – 0.9 MW, so ideally the wind farm alone could meet all of Bonaire’s current demands for electricity. The new biodiesel plant will be constructed at the northwest corner of Bonaire. In the beginning it will burn fossil diesel.

The first experiments with biodiesel from algae are being carried out on Bonaire, with the expectation that the plant will start burning bio fuels after two or three years of operation. This project is illustrative of Econcern’s mission: ‘a sustainable energy supply for everyone’.

EcoPower Bonaire is the owner and operator of the wind biodiesel system, employing local staff for management and operation. Evelop will be the majority shareholder of EcoPower Bonaire, while Enercon and MAN will be minority shareholders.

Dual-fuel recip for the Caribbean

Wärtsilä has been awarded a $US77m EPC contract by Trinidad and Tobago Electricity Commission (T&TEC), the monopoly electric utility in the twin-island Republic of Trinidad and Tobago, to supply a dual-fuel power plant running on natural gas and light fuel oil. This baseload plant will be the first natural gas reciprocating engine plant of its kind in the Caribbean and is the second power plant to be built for T&TEC by Wartsila on the island.

Commissioned is scheduled for September 2009. The facility, which will be producing a total of 64 MW, will be located at the Cove Industrial Estate on Tobago and will supply the island, and, via two existing submarine cables, the main island of Trinidad.

Wärtsilä will also operate the Cove plant for an initial period of five years under a full operations and maintenance agreement. ‘Wärtsilä was selected as the contractor for this new gas-fired power plant in Tobago following a rigorous tendering and evaluation process. With clean-burning natural gas as the primary fuel, this new dual-fired, high-efficiency plant will augment the country’s baseload generation capacity and will fully meet Tobago’s demand, presently at 40MW, for at least the next ten years’ said Indarjit Singh, General Manager of Trinidad and Tobago Electricity Commission. ‘As this new facility replaces the importation of power from Trinidad via very long transmission lines and submarine cables, transmission losses are expected to be reduced significantly, while the voltage in Tobago will be much better controlled’ he said.

The facility will be equipped with four Wärtsilä 18V50DF dual-fuel generator sets and a double bus-bar 66 kV substation to interconnect with the T&TEC electrical grid, producing more than 64 MW on natural gas and 67 MW on the light fuel oil used as the back-up.

Genie’s most powerful model is super-quiet

Genie industries has launched a powerful new ‘super quiet’ Terex generator, the T360, its most powerful model to date, designed mainly for the rental market. It combines ease of operation with flexible power output in single or three phase voltages.

It is powered by a heavy-duty 426 hp Cummins diesel engine, and offers Tier 3 compliance, indeed it is designed for reduced emissions generally and is electronically controlled to provide frequency regulation to an accuracy of ± 0.25% with sensitive electronics such as computers in mind.

The T360 offers 360 kVA, or 288 kW, of prime output for temporary power providing during electrical substation maintenance or for typical rental power applications, such as powering large tower cranes and pumps.

Like all Terex ‘super quiet’ generators, the T360 comes equipped as standard with a permanent magnet generator (PMG) that provides a quicker response to changes in load, resulting in better voltage regulation for motor starting and non-linear loads. The fuel tank capacity is sufficient for 24 hours of continuous operation. Controls feature a common user interface for ease of use, including a simple, flexible Murphy Cascade controller and large, easy-to-read analogue gauges to monitor electrical loads and engine performance. Display technology has given way to ease of use – there is no LCD screen with menus.

The distribution panel includes a five-lug distribution board, single-phase convenience sockets and optional cam lock-style connectors. The three-phase voltages on the unit include 208 / 220 / 240 / 440 / 480, and the single-phase voltages are 120 / 240. The various outlets can be used simultaneously whether or not power is being delivered. Automatic start/stop is also standard. All high-voltage electrical interfaces are safety interlocked to prevent injury or damage to the unit’s sensitive components.

The base is designed to provide 110 % containment of all on-board fluids, including fuel, coolant and oil. The cabinet is designed to reduce noise and water ingress, and the angled plenum design increases cooling capacity and reduces the overall weight of the generator. Detachable front panels, large engine bay doors and removable rear louvre panel allow for convenient access to the radiator, muffler, engine and generator for ease of service.

Perkins unveils its new Tier 4 genset

Engine maker Perkins, which recently announced plans to build a new manufacturing facility in China to produce small to medium size diesel engines, has two new flagship models in its 400 series of Tier 4 compliant small-end gensets.

The new 400D Tier 4 range includes 1.1, 1.5 and 2.2 litre 1800 rpm models, which cover the 9.9 kWe to 31.3 kWe standby power range. The two new models are the 404D-22TG capable of producing power outputs of 25.5 kWe prime and 28.3 kWe standby at 1800 rpm, and the 404D-22TAG capable of producing power outputs of 28.4 kWe prime and 31.3 kWe standby, also at 1800 rpm.

The new 400D Tier 4 family builds on the well known 400C series Tier 2 genset range and offers, according to its maker, superior power density with the addition of turbo and turbo after-cooling technologies, low emissions and low operating costs in a small, efficient package.

The 400 Series industrial engines are well established in the market place and noted for their compactness. The ElectropaK range has a newly designed cooling pack and to create optimum power density making installation and transportation easier and cheaper. All ElectropaK specifications are supplied fully fitted with suitable radiators, charge coolers, air cleaners, pipes, hoses and mounting feet to provide a fully engineered turnkey package that can be installed easily.

Perkins has also recently introduced 1104D-E44TAG1 and TAG2 turbocharged ElectropaKs covering the 72 kWe prime to 100 kWe standby (1800 rpm) power range. These have been designed specifically to met the US EPA tier 3 stationary/mobile emissions legislation, whilst also meeting the specialised needs of the electric power market. They are based on compact, 4.4 litre, in-line, 4 cylinder engines with full authority electronic controls.

Perkins has based the design of its new offering on the results of customer studies with both current and potential customers.

The company intends to announce two further new models shortly, the 1104D-44TG1 and 1104D-E44TG1, of the rating that has been required in EPA Tier 3 stationary/mobile legislated areas from 1 January. The 1104D-44TG1 produces a power output of 51.3 kWe prime and 56.6 kWe standby at 1800 rpm while the 1104D-E44TG1 produces 58.7 kWe prime and 64.6 kWe standby also at 1800 rpm

Power Box thrives on heat and dust

The problem of providing electric power in remote locations far from the grid is common enough in the Middle East and Africa and has given rise to a specialised, sometimes stripped down breed of genset more likely to operate reliably in extreme temperatures and harsh environments.

Operations such as gold mines and water pumping facilities in Saudi Arabia and refineries in Africa have had in the past to rely on power generation equipment not designed to operate in hot, dusty and sandy climates. Operating costs are often higher than necessary due to the need for increased maintenance on generator sets to keep them running.

One of the companies that tends to specialise in providing power in these hot and harsh climates is Cummins Power Generation which has introduced a

1.25 MW rental unit designed to meet the challenge and designated C1250 DR2 Power Box 20. It is a fully integrated system that includes generator set and controls and is designed specifically for power projects in the Middle East and Africa. It comes in 50 and 60 Hz variants and is housed in a 20 foot CSC-plated ISO container.

It can operate in 50+ °C (122+ °F) ambient temperatures and icludes a new cooling system that has been developed using a larger low fin density radiator to avoid plugging from dirt and debris. Hinged radiator louvres also provide necessary protection and allow for easy access to radiator cores for cleaning.

Insulated combustion air pipe-work has also been added to the new unit to further protect combustion air from the heat to help keep joints sealed against dust ingress. External roof-mounted silencers improve engine access for routine maintenance.

The units can be standalone or paralleled with the grid. Cummins currently have projects in a wide variety of on-site prime power applications such as powering remote villages, industrial plants, refineries and mining operations.

The photo shows a multi-unit application at a refinery in Zambia.

German plant to run on palm oil

PBB GmbH, an Oldenburg, Germany, based cogeneration IPPC has signed a contract with MAN Diesel A/S’s Polish licensee H. Cegielski - Poznan for the delivery of a combined heat and power plant to a site in the city of Brake, near Bremen.

A 7L35MC-S engine will power the plant, supplying 4.2 MWe to the national grid and 3.6 MWt to a palm-oil refinery situated nearby. The engine is a two-stroke, low-speed, crosshead uniflow diesel. It will be fired by crude palm oil, with a total acid number (TAN) of up to 15 mg/KOH/g, at a heat rate of 7400 kJ/kWh at site ambient conditions, corresponding to an efficiency of 48.6%; plant total efficiency in CHP-mode will exceed 87%.

The plant will be equipped with a selective catalytic reduction system, an oxidation catalyst and an electrostatic precipitator to meet the rigorous TA-Luft air emissions regulations.

New Tier 3 acoustic generator set packages offer significant sound attenuation

Cummins has introduced a new series of 100, 125 and 150 kW Tier 3 generator sets with advanced sound-attenuated enclosure systems. With a sound level of only 67.5 dB(A), the 100 kW unit is one of the quietest generator sets available at that power node from a generator manufacturer. Available in steel or aluminium with two levels of sound attenuation, the generator set and enclosure packages are intended for all-weather outdoor use wherever local regulations or circumstances require sound abatement.

The genset and enclosure packages are based on Cummins’ QSB7 diesel engines and are available in two levels of attenuation. The quieter sound-attenuation package features an enhanced exhaust silencer and steel construction with sound-absorbing material. This limits sound levels to 67.5 dBA for the 100 kW generator set package; 68.6 dBA for the 125 kW and 69.6 dBA for the 150 kW unit, measured at 23 feet with the generator set operating at full rated load. The weather-protective generator set enclosure package includes an industrial exhaust silencer and 14-gauge steel construction without added sound-absorbing features.

These lower levels are achieved by using the inherently quiet QSB7 engine with its larger cooling system and reduced combustion noise, and by reducing cooling air noise. The airflow through the enclosure is inducted behind the alternator and then routed over the engine and radiator so that it exits upwards out of the enclosure, creating a torturous path that reduces high-frequency sound. “Cooling air movement has always been a significant source of generator set noise, and by making it turn 90 degrees twice, we have been able to eliminate some high-frequency components,” says product marketing manager Vivek Malapati.

The design also allows for the enclosed generator packages to run at full standby load in up to 127 °F (53 °C) ambient air temperature, providing a factory solution for customers that need generator sets to operate in high-temperature environments.

In addition to sound-attenuating features, the enclosures are designed with convenient access doors for the engine and alternator service points. Forklift pockets on the skid base and built-in two-point lifting brackets simplify installation at the job site

Kim Hotstart introduces new engine heater

A new coolant pre-heating system is available from Kim Hotstart that is claimed to offer more energy-efficient engine heating for engines from 15 litre to 100 litre. The pump-driven cold start module offers more efficient heating than thermo-siphon tank heaters, delivering uniform heating throughout the entire engine. On larger engines, one CSM should eliminate the need for two thermo-siphon tank heaters, reducing the cost of installation and material. The heater is UL listed to United States and Canadian safety standards with CE compliant models available.

The cold start module is a turnkey system that includes all required controls and a 10 gpm circulating pump. Forced circulation of the coolant extends element life and offers a significant reduction in electrical consumption, mainly because outlet temperatures are greatly reduced, which results in extended hose life and reduced maintenance, and because of the incorporated low watt-density heating element and adjustable thermostat with optional temperature settings. The compact design requires minimal space for mounting and requires less installation time than two tank heaters.

The unit is available in 3 kW, 6 kW, 9 kW and 12 kW sizes with all standard voltage ratings at 50 Hz or 60 Hz. CSM pre-heaters meet requirements for installation on any UL 2200 listed generator set. Kim Hotstart is a specialist in diesel engine block heaters having been was established in 1942 with the original patent for engine coolant heating.

Highest power density in its class

The new Yanmar Minimax Series engine (to be named the MM series in Europe) is designed for small applications including low rating generators. Its strong points are compactness and fuel efficiency. The 3TNM68, the first in the series to be released, is a 0.784 litre 3 cylinder Tier IV compliant engine with Yanmar’s proprietary indirect injection technology designed to achieve low fuel consumption and low emissions. This claimedly ultra compact and high performance engine also employs Yanmar’s ‘latest structural technology’ to achieve low vibration, noise and size.

High rigidity and therefore low noise & vibration is achieved through incorporating a ladder frame structure in the cylinder block. Low fuel consumption and low emissions are achieved by incorporation of the company’s new proprietary MC type fuel injection pump.

The first of the Minimax series will be the 14.7 kW model 3TNM68, to be later followed by the larger 3TNM72.

Specification:

Type: vertical cylinder, 4 stroke indirect fuel injection water-cooled diesel engine;

Rated output: 14.7 kW gross at 3600 rpm (intermittent);

Dimensions: (L x W x H): 431mm x 400mm x 500mm

Dry mass: with bell housing 82 kg.