maximize the success of methane to electricity -- biogas & renewable projects · 2019-07-31 ·...

Maximize the Success of Methane to

Electricity -- Biogas & Renewable Projects

Peter Lau, PhD

Region Manager

Electric Power Gas Sales

Asia Pacific, Caterpillar

Agenda

1. Options for Methane to Electricity -- Biogas &

Renewables Projects

2. Engine Technology Consideration & Selection

3. Engine Installation and Project Time Line

4. Engine Maintenance & Operations (M&O) Costs

5. Caterpillar Support of Power Projects

1. Methane to Electricity Projects

Asia Pacific offers many possibilities

& options….

Resource Rich – Biogas & Renewables

• Agriculture Rich

– Palm oil

– Cassava

– Sugarcane

– Coconut

– Rubber

– Rice

– Wheat

– Luciana

– Jathropa

• Gasification- Syngas

– Wood Gas

– Coal / Coke Gas

• Mineral Rich – Coal

– Natural Gas

– Crude

– Shale Oil and Gas

• Live Stock Rich

– Hog

– Poultry

– Cattle

– Seafood

Typical Biogas Plant

Key Components

Waste Collection System

Bioreactor

Gas Pretreatment System

Gas Generator

Gas CCHP Application

Engine Low Temperature

Circuit

Fuel

Exhaust Gas

Exhaust Gas Boiler

Engine

High Temp.

Circuit Cooling

Towers Absorption

Chiller

Electric

Power

Chilled Water

4 – 6 C

Efficiency vs Uptime

2. Engine Technology Consideration

& Selection

Clean Power Options

• Gas Engines and Gas Turbines

– Environmental

• Low emissions, low noise, low vibration

– High Availability

• Power on demand, continuous, reliable

– Viable

• Low cost of ownership, fast payback, high ROI

– Proven

• Mature technology, growing market, bankable

Caterpillar Gas Generator Set Platforms

CG260 CG132 G3500 CG170 G3300

Special Features

• Able to achieve high annual operating hours

• Able to run on low heating value fuels

• Able to handle corrosive gases

Engine Design Trade-Off

High Robustness Engines (Traditional Otto, non-Miller)

• Accept higher siloxane and H2S contamination

• Efficiency below 40%

• Dirty gas forces more oil changes, higher M&O cost

• Excellent for: ‘dirty’ gas, worst-case ambient swings & quicker load response

High Efficiency Engines (Miller Cycle)

• Usually require costly siloxane & H2S removal

• Efficiency above 40%

• Lower M&O costs due to cleaner gas

• Excellent for: ‘clean’ gas, controlled environments, average load demands

OPEX CAPEX OPEX CAPEX

Fuel Specification Guidelines

• All Manufacturers have guidelines for maximum fuel

contamination. Warranty depends on compliance.

• Miller engine users strongly advised to stay within

the limits of the ‘clean biogas’ definition

Non-Miller Engine Miller Engine

Fuel Contaminant

µg/Btu of

Fuel

Approx.

PPM*

µg/Btu of

Fuel

Approx.

PPM*

Halides (as Cl) 20 230 0.55 7

Sulfur (as H2S) 60 730 12.2 155

Siloxanes (as Si) 0.6 9.0 0.11 1.6

Ammonia 2.96 72 0.17 4

*Based on 500 Btu/scf Fuel Sample Recommendation for Optimal Engine Application

Engine Technology Best Practice

• Run two separate economic evaluations of your methane to electricity project: – Scenario A: high efficiency engine (Miller, CCGT)

– Scenario B: high robustness engine (non-Miller, Gas Turbines, Micro GT)

• Include in your evaluation: – CAPEX: cost of contaminants removal equipment

required by high efficiency engine as well as any additional CC equipment

– OPEX: additional M&O for contaminant removal units

– Risk Factors: Reliability & Durability

3. Engine Installation Options

Building v. Pre-fabricated Module

Container Building

Engine Installation Trade-Off

Building Installation

• Ample space for service

personnel, cranes for safe

lifting of heavy parts,

controls & storage rooms

• Economies of scale for

multi-engine buildings

• Easier to manage dust

contamination and air inlet

temperatures

Modular Installation

• Restricted access and work

space, more time & money

on service steps

• Fast deployment, easier to

quickly add or remove units

• Easier to obtain bank loans

• High reliability: complex

systems integrated by

engine manufacturer

4. Better Estimation of M&O Costs

M&O Costing is critical to any

Methane to Electricity Project

Estimating Maintenance & Operation Costs

• Most financial evaluation tools use just one number

for the M&O cost of a generator set

• Comparison of costs may not be appropriate

without knowing the different elements that went

into the M&O number

• Potential customers need to request separate

estimates for different combinations of service

– Window of time used for calculations is critical

– Gas type used for calculations also critical

Cost per kWh, Cost per Running Hour

• L1-L7 are lists of different service alternatives

Need to Break Down O&M Elements

Included in cost?

• Lube oil?

• Major Overhaul?

• Electrical Items?

• Unscheduled

Maintenance?

• System

Auxiliaries?

Customer Service Agreements (CSA)

Inspection contract

Preventive maintenance contract

Maintenance contract

Full-service contract

CAT provides full support for service contract definition

and calculation

Full Value Chain

Facts and figures

Storage space 12,000m²

Office and common space 600m²

Parts numbers / parts in stock Ø 40,000 / 2,000,000

Customer orders Ø 200 / day

Order items Ø 800 / day

Number of parcels Ø 200 / day

Weight shipped Ø 7,500 kg / day

Hours of operation Mo.–Fr. 7:00 am to 8:00 pm

Emergency service 24/7, 365 days / year

Orders placed by 5:00 pm (CET) will leave the logistic center the same day

CAT Service Logistic Center

Distribution Centers

• Morten and Frankfurt

• Singapore

• Shanghai

• Bangalore

• Melbourne

Frankfurt

Caterpillar Asia Pacific Dealer Network

Australia

Energy Power System Australia

David Moore

+61-417-357-406

China (South & West)

China Engineers Ltd

Lu Yi Hong

+86-136-0289-0110

Japan Caterpillar Services Ltd.

Shinya Suzuki

+81-90-3243-6489

Singapore & Maldives

Tractors Singapore Ltd.

Sean Ang

+65-9232-7596

Bangladesh

BanglaCAT Ltd.

Zahid Islam

+880-171-309-0331

China (SW and NW)

ECI-Metro

Nicholas Thew

+86-139-8181-7050

Korea

Hae-In Co.

S.H. Kim

+82-2-3498-4572

Sri Lanka

United Tractors Ltd.

Manjula

+94-773-157-824

Cambodia

Metro Cambodia

Kim Veng Tan

+855-1251-2333

India (North)

Tractors India Ltd.

Rakesh Ananad

+91-971-133-1139

Malaysia & Brunei

Sime Darby Industrial

Chun Hoong Ng

+60-3-8068-8192

Taiwan

Capitol Machinery Ltd

CS Horng

+886-937-957-288

China (North)

Westrac China

Bill Chu

+86-10-5902-1666 ext. 6011

India (South)

Gmmco Ltd

Chandrasekaran

+91-984-096-6123

Myanmar

Myanmar Tractors Ltd.

Yee Yee Htwe

+951-547-304

Thailand & Laos

Metro Machinery Co. Ltd.

Somkiat Chawitcharoenwong

+66-848-743-642

China (Central)

Leishinghong Machinery

Johnson Jiang

+86-186-1677-2856

Indonesia

PT Trakindo Utama

Edwin Sentoro

+62-812-100-7681

Philippines

Monark Equipment Co.

Luis Diaz

+63-906-314-2735

Vietnam

Phuthai

Truong Dong Phuong

+84-903-830-498

www.catelectricpowerinfo.com/gas

Thank You For Your Attention!

Peter Lau, PhD

[email protected]

14 Tractor Road

Caterpillar Asia Pte Ltd

Singapore, Singapore

mailto:[email protected]

mailto:[email protected]

maximize the success of methane to electricity -- biogas & renewable projects · 2019-07-31 ·...

Documents