Improved efficiency of gas generator sets for CMM 2011 U.S.

Coal Mine Methane Conference

Park City, 11-11-01

Agenda
1. About MWM 2. General challenges 3. Challenges and solutions 4. Applications and references

CMM - Park City | MWM GmbH | 20-Oct-11

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1. About MWM

History
The MWM can look back at 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. 2011: European Commission has cleared Caterpillar's acquisition of MWM

CMM - Park City | MWM GmbH | 20-Oct-11

Profile
Development from an genset producer into a solution provider

CMM - Park City | MWM GmbH | 20-Oct-11

2. General challenges For the use of coal mine gas

General challenges
Methane emissions from coal mines Methane content of 4% - 15% in the air generates a combustible mixture Firedamp explosions are dangerous for people working inside of the coal mines and underground fires can effect large parts of the coal mines Methane has a 20 to 25 times higher greenhouse potential then CO2 Therefore it is necessary to destroy and use the CH4 Technologies to avoid methane emissions Depending on the type of coal mine gas different technologies can be used to avoid methane emissions Mine ventilation with thermal oxidizers Boilers and heat recovery systems Flares Co-generation units (gas turbines and gas engines) Conversion into natural gas

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General challenges
High market potential for gas engines running on coal mine gas For the application of co-generation plants the use of different coal mine gases offer a worldwide potential of more than 7GWel. Only a small part of it is used today. Financing Substantive conditions for the economical use of CMM are: Approval of the projects as Clean Development Mechanism or Joint Implementation-projects referred to the Kyoto Protocol or other Carbon credits For projects which generate electrical power a guaranteed connection to the national grid is needed Also a fixed feed in tariff is useful to guarantee an economical feasibility of the project Utilization of coalmine gas can be lawful duty Higher economy of the coal mine due to higher earnings

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3. Technical Challenges & Solutions How to use different types of CMM in gas engines

Different types of coal mine gas

Coal Bed Methane (CBM), from unexplored mines Coal Mine Methane (CMM), from active mines Abandoned Mine Methane (AMM), from closed mines Ventilation Air Methane (VAM), from mine ventilation
Compounds Methane (CH4) in %vol Carbon dioxide (CO2) in %vol Carbon monoxide (CO) in %vol Oxygen (O2) in %vol Nitrogen (N2) in %vol CBM 90 95 24 0 0 18 CMM < 20 80 16 0,1 0,4 7 17 4 - 40 AMM < 20 60 8 20 0 0 5 60

Different gas compositions in different regions! Higher amount of mines with low CH4 content. Especially in China where traditionally gases with less then 20% CH4 are used.

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Challenge: Different CH4 contents

The venturi gas mixer can handle CH4 contents down to 30-35% without any special adoptions. It does not matter, whether the combustion air comes partially with the mine gas or totally from the ambient. Data obtained from actual pits where MWM gen sets have been installed; comparison mine gas vs. natural gas (green column) The CH4 values in the mines gas vary from 72 % down to 28 % (for natural gas 89 %)
Samples CO2 in %vol O2 in %vol N2 in %vol CH4 in %vol C2H6 in %vol Summ in %vol LHV in kWh/m AR in m/m 1 6.34 0.51 20.90 72.00 0.23 99.98 Free of air 6.51 0.00 19.50 73.75 0.24 2 6.39 4.94 47.20 39.20 0.34 Free of air 8.54 0.00 38.60 52.40 0.45 99.99 5.31 5.08 3 8.69 0.99 58.70 31.30 0.22 99.90 Free of air 9.10 0.00 57.80 33.00 0.23 4 16.70 0.38 54.80 28.00 0.14 Free of air 17.00 0.00 54.40 28.50 0.14 5 2.40 11.60 50.50 35.20 0.20 Free of air 5.30 0.00 16.40 77.85 0.45 100.00 7.84 7.50 Natural gas 1.00 0.00 5.00 89.00 5.00 100.00 9.76 9.33

100.00 98.07 7.40 7.08

100.13 100.02 100.04 99.90 3.32 3.17 2.87 2.74

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Solution: Gas mixing before turbocharger

The diagram shows the spec. volume of required air and mine gas per produced kWh of electricity as a function of the air free CH4 in the mine gases As a consequence of MWM mixture formation the mixture flow in m/kWh is constant, although CH4 in the gas changes from 30%Vol to >90%Vol. Alternating gas properties can be totally outbalanced by mixture formation in mixture charging engines

5 4.5 4 3.5
Volume (m/kWhe)

3 2.5 2 1.5 1 0.5 0 29 33 52

0.88 0.76 0.48 3.58 3.70 4.00 4.12 4.12 4.14 4.23

0.34

0.34

0.32

0.26

74

78

79

89

Free of air CH4 (Vol%)

spec. Gas Volume

spec. Air Volume

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Challenge: Use of CMM with less then 30% of CH4

Danger of explosion Methane content of less then 30% can generate a combustible mixture Local regulations have to be observed, e.g. in Germany the limit is 25% Flame arrestors have to be installed in the generator set or in the gas supply. Limits of the gas mixer and gas engine The Venturi-mixer is limited to an air / gas ratio of 2:1 The limit of the gas mixer is theoretically at 20% CH4 in the gas Particularly critical is the starting process of the gas engine Due to the high amount of CO2 the exhaust temperatures rise

Gas Air

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Solution: Automated air throttle valve

Robust and reliable system for CH4 contents <30% Throttle valve is located between air filters and gas mixer The pressure difference between air and gas can be regulated for the optimal mixing ratio Starting of the engines is ensured due to high amount of gas suction during start sequence Regulation via MWM TEMevo (engine & plant steering) independent of load level, gas quality other parameters Approved on site in China and on the test bench in Mannheim Electrical efficiencies up to 43,7% can also be achieved on gases with low calorific value
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or

Air Fuel Ratio in Pre-Chamber Combustion Engines vs. Open Combustion Chamber Engines.
2,5

Pre-chamber combustion engines need a high difference in the air-fuel ration between preand main chamber for proper combustion In the main-chamber (full green line) the gasair ratio remains constant independent of the actual composition of the coal mine gas The composition in the pre-chamber gas (green dotted curve) changes considerably with changing CH4 contents of the coal mine gas This has a negative effect on ignition behavior and certainly limits the engine's capacity to use low methane CMM

main chamber pre-chamber open chamber

air / fuel ratio - lambda

0,65

1,5

1,2

0,5 20 30 40 50 60 70 80 90 100

CH4 in %

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Challenge: Reliable control concept for different situations

Solution: MWM TEMevo system: all in one steering and control system Quick and robust regulation of NOx-emissions and anti-knock control Quick response to varying gas qualities without affecting emissions or engine behavior due to cylinder temperature and knocking sensors On the basis of the measured knocking the ignition time is individually adapted for every cylinder to avoid crucial knocking Multivariable controller for all adjustment elements Combined adjustment of gas mixer, engine throttle and exhaust wastegate Comparison of target values and actual values in TEM In combination, these arrangements lead to a minimum of 7 load steps for the generator sets
Set values

Tcomb Pel pboost neng

neng pboost Pel Tcom b

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Challenge: 24/7 up to 8.760hrs./a. availability for maximum success

Difficult locations of coal mines, often no population nearby If problems occur a fast response is necessary to solve the problems Every minute counts therefore a fast service is needed How you can secures a high availability: Remote access via internet, GSM or analog modem possible for operation and visualization due to the TEM system Communication with higher-level control systems or guidance system possible via BUS-system, all measured values can be read Service partners are available in nearly every region where MWM gensets are in use Fast shipping of spare parts is secured by subsidiaries or partners

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Solutions: Interfaces for remote diagnosis

Remote diagnosis / access
Remote control and visualization via analog network / GSM e.g. parameterization, remote acces, diagnosis, program download, teleservice Operator, Service

User interface
Local operation and visualization Installation directly at the engine at switchgear or control room Parameterization, status info control, diagnosis, analysis Operator, Service, IB

Direct connection
Local operation and visualization via TEM-Evo-PC-packages Direct connection to CPU Parameterization, status info, control, diagnosis, analysis Operator, Service, IB

System interface
Feldbus for higher-level control or guidance system Reading of data, status, start/stop, fault quit Operator

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Challenge: Fast installation and turnkey systems

Fast on site installation with less civil work is required MWM is providing turnkey solutions for the whole product range Containerized solutions from 400kWe up to 4.300kWe Modular plant components for building installations Gas treatment systems for optimal gas conditions

3,000kW to 4,300kW
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400kW to 2,000kW

5. Proved applications Solutions running on coal mine gas

Worldwide references in the use of coal mine gas

MWM up to date has realized CMM projects with more then 330MWel

5MWel

269MWel 61MWel 4MWel

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Trigeneration plant for Polish coal mine Pniowek.

Plant phase 1 installed in 2000: 2 x TBG 632 V16 - Total electric output: 6,4 MW - Total thermal output: 7,2 MW - Total cooling capacity: 5 MW (underground) + 5,7 MW (over ground) Plant phase 2 installed in 2006: 1 x TCG 2032 V16 - Total electric output: 3,9 MW - Total thermal output: 3,8 MW Total output in 2007: 10,2 MWel + 11 MWth

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Trigeneration plant for Polish coal mine Pniowek.

Heating / Cooling Concept - Background: According to polish law, employees can only work a 7,5 h shift if the ambient temperature is < 28C. Between 28C and 33C the maximal permitted shift time is 6 hours - Working in the underground at ambient temperatures > 33C is not permitted at all - In this mine the temperature was: > 27C at 830 m depth, being the rock temperature approx. 36-40C > 29C at 1.000 m depth, being the rock temperature approx. 41-45C - In order to maintain the extraction rate of approx. 15.000 tons / days, cooling is necessary since the coal deposits are always deeper

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Trigeneration Plant for Polish Coal Mine Pniowek.

P & I Pniowek The energy of the 86C hot water from the jacket water circuit as well as the exhaust heat is used via absorption bromine-lithium coolers in two steps to cool down the chilling water from 18C down to 4,5C. In a last step, a compression cooler reduces the chilling water temperature down to 1,5C

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Trigeneration Plant for Polish Coal Mine Pniowek.

Total operational time in Pniowek > 125,000 operation hours Average CH4 content in the gas approx. 55 % Maintenance experience: - Spark plugs: approx. 4,000 o.h. - Cylinder heads: approx. 16,000 o.h. - The step 2 engine has approx. 8,000 o.h. without oil change - General overhaul for the TBG 632 was after 98,000 o.h. (standard 64,000h) - Oil consumption: < 0.3 g/kWh

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Trailer project USA/Canada

Genset/Engine (R 048): 6 x TBG 620 V12, containerized Segment/fuel type: Coal bed methane (CBM) Customer: HD Supply, USA Total output: 5.4 MWel Installation/Commissioning: 2008

HD Supply needed a short-term solution for the energetic use of coal bed methane. The main task was to develop a package of short delivery periods, high efficiencies and mobile equipment within 3 months. The solution was realised in 6 containers constructed on trailers. The electrical power is generated in island operations and supplies the drilling activities.
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Tai Yuan, China

Genset/Engine (R 043): 3 x TCG 2020 V20, containerized 4 x TCG 2020 V20, containerized Segment/fuel type: Coal mine gas Customer: Region Shanxi, China Total output: 12.0 MWel Installation/Commissioning: 2008/2010 This project is located in Tai Yuan city, Shanxi province for a large state-owned coal mine enterprise. The first stage were 3 TCG 2020 V20, while this project runs that successful the customer ordered another 4 TCG 2020 V20. In a sum the engines supply the region with 12 MW of electrical power. Because this project passes the audit of CDM, additional revenues can be earned.
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Lanhua Daning Coal Mine, China

Genset/Engine (R 059): 8 x TCG 2032 V16 Segment/fuel type: coal mine gas Customer: LDCMMPG, Shanxi, China Total output: 31,2 MWel Installation/Commissioning: 2010

The eight installed 4MW power generators and the 3MW steam turbine generator reduce the methane emissions by 53.68 million m. Additional to that an annual net electricity of 221.2GWh is delivered to the grid. Due to earnings from CDM-certificates the project has a very short payback period.

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Thank you.
Contact: Melf Jasper Thomsen T +49 621 384 8691 F +49 621 384 8747 E melfjasper.thomsen@mwm.net