phulbari coal mine document

8/13/2019 phulbari coal mine document

1/28

driven by ideaspower solutions with Jenbacher gas engines

GEEnergy


2/28


3/28

overview

company 01

gas as energy source 03Natural gas 04

Biogas and special gases 04

products 09Gas engines 10Generator sets 12Cogeneration systems 12Container solutions 12DIA.NEXT Dialog Network 13Activated carbon adsorber 14CL.AIR Clean Air 15

energy supply 17Decentralized energy supply 18

Cogeneration 18Generation of heating water 19Steam production and drying processes 19CO

2fertilization in greenhouses 19

Trigeneration 19

service 21On-site in more than 30 countries 22Contact addresses 23


4/28


5/28

GEs gas engine business is one of the worlds leadingmanufacturers of gas-fueled reciprocating engines,packaged generator sets and cogeneration units forpower generation. It is one of the only companies in theworld focusing exclusively on gas engine technology.

Jenbacher engines range in power from 0.25 to 3 MW andrun on either natural gas or a variety of other gases (e.g.,biogas, landfill gas, coal mine gas, sewage gas, combustibleindustrial waste gases). A broad range of commercial,industrial, and municipal customers use Jenbacher productsfor on-site generation of power, heat, and cooling. Patentedcombustion systems, engine controls, and monitoring enable

our power generation plants to meet all relevantinternational emission standards, while offeringhigh levels of efficiency, durability, and reliability.

The Jenbacher product team has its headquarters,production facilities, and 1,200 of its more than 1,400worldwide employees in Jenbach, Austria.

This brochure provides an overview of the Jenbacherproduct range, including the variety of possible fuels,their significance as a valuable source of energy, andthe advantages of a decentralized energy supply usingJenbacher equipment.

GEs gas engine business: technology, quality and service

company

striving for excellence

1


6/28


7/28

gas as energy source

seeing the potential ofnature and chemistry

3


8/28

natural gasEnergy source of the future

The natural gas segment of GEs gas engine business includes the productionand delivery of plants for decentralized energy supply based on natural gasas fuel.

Natural gas utilization in gas enginesoffering numerous advantages

Lowest emissions of all fossil fuelsThe utilization of natural gas in gas engines is characterized by the lowestCO

2emission levels among fossil fuels, and particularly low emissions of SO

2,

NOxand particulate matter.

Most important fossil energy sourceNatural gas plays a major role in energy supply today and will become themost significant fossil energy medium in the next 50 years.

Well developed natural gas supply systemThe natural gas supply system is well developed and reliable. Gas engines

are therefore an optimal technology for decentralized energy supply.

Flare gas

In addition to classic natural gas, flare gas also forms part of this fuelsegment. Flare gas is an associated gas obtained during crude oilexploration, largely consisting of methane and higher hydrocarbons. Thiscomposition results in a gas with low knocking resistance, which requiresspecially designed engines. The use of flare gas, which is generally availablefree of charge as a waste product, ensures a fuel source for on-site powergeneration and, if required, the engines can also provide a heat supply forsurrounding facilities. Consequently this problem gas, instead of flaring it offwhile causing ecological exposure, can be used economically and practically.

biogas and special gasesAlternative energy sources

The biogas and special gases segment is comprised of plants fueled bygases from landfills, agriculture, coal mining, chemical plants, and otherindustries. The environmentally-appropriate disposal of problem gases isthe primary concern in this segment. The simultaneous energetic utilizationof these gases for generating power ensures the economic viability of thepower plants. The continuous development of its gas engines and the focuson special gas applications have made Jenbacher engines one of the worldleaders in this segment today.

Due to their cost-effectiveness, high output and measurable benefits tothe environment, Jenbacher biogas, landfill gas, and coal mine gas-fueledengines have been certified as GE ecomagination product by an independentagency. Ecomagination is a GE commitment (www.ge.com/ecomagination)to use and develop new technologies to help customers around the worldmeet escalating environmental challenges.

Biogas and special gas utilization in gas enginesoffering numerous advantages

Highly efficient for cogeneration of power and heatSubstitute for conventional fuelsAlternative disposal of problem gasesAvoids venting methane (CH4) into the atmosphereHigh potential for reduction of greenhouse effects

Overview of the most important applications

-----

BiogasSewage gasCoke gasLandfill gasCoal mine gasPyrolysis gas/wood gas

------


numerous advantages

4


9/28

Biogas

For a wide range of organic substances from agriculture, foodstuff, and feedindustries, anaerobic fermentation is a superior alternative to composting.Biogas a mixture of methane and carbon dioxide is formed in the fermen-tation process and serves as a high-energy fuel with a calorific value of 5 to6 kWh/m3Nthat can substitute fossil fuel energy. Thereby an increased utili-zation of fossil fuels is avoided and fossil CO2emissions reduced. Due to theorganic nature of the components of biogas, burning it in a gas engine forpower generation emits the same amount of CO2into the atmosphere aswas originally absorbed during the process of photosynthesis in the naturalCO2cycle. Using biogas in gas engines promotes proper waste disposal, andallows the use of the end products from the fermentation process as fertilizer.

Landfill gas

Landfill gas is created similar to biogas during the decomposition of organicsubstances in the waste and consists of methane (CH4), carbon dioxide (CO2),nitrogen (N

2), and to a minor part of oxygen (O

2). If this gas escapes uncon-

trolled, it hampers the recultivation of the landfill site. To prevent this and toavoid offensive smells, smouldering fires, or the migration of landfill gas intothe water ways, the gas must be continuously extracted under controlledconditions. With a calorific value of about 4 to 5 kWh/m 3

N, landfill gas con-

stitutes a high-value fuel for gas engines and can therefore be economicallyutilized for power generation.

Farm Wolfring, Germany Landfill site Nent, China

5


10/28


Sewage gas

Sewage sludge is created as a waste product in the mechanical/biologicalprocess stages of sewage treatment plants. The sludge is dried, then trans-ferred to a digester where an anaerobic fermentation process takes place.The fermentation produces biogas also called sewage gas consisting of60 to 70% methane and 30 to 40% carbon dioxide. This composition makessewage gas highly suitable for combustion in gas engines. The electricalenergy produced by the gas engine can be utilized for the treatment plantas well as for feeding into the public power grid. The thermal energy can beused for heating the sewage sludge or to offset the treatment plants otherheat requirements.

Coal mine gas

Coal mine gas (firedamp) is a problematic phenomenon associated withpit coal mining, as the gas can form explosive mixtures together withair. The main component of the primary coal seam gas is methane in aconcentration of 90 to 95%. The gas develops during the geochemical con-version of organic substances to coal (carbonization). Coal seam gas ispresent both as liberated gas in fissures, faults and pores and as adsorbedgas on the inner surface of the coal and neighboring rock. For safetyreasons, the methane gas released during coal mining, must be ventilated,generating a mixture of air and methane. In many countries, coal mine gasis still emitted into the atmosphere, causing high levels of greenhouse gasemissions and thereby contributing widely to the global warming process.Combustion of coal mine gas in gas engines is practical as an environmentalproblem is effectively resolved, while an otherwise lost source of energy iseconomically utilized.

Sewage treatment plant Annacis Island, Canada Colliery Tahmoor, Australia

6


11/28

Coke gas

Coke gas is a by-product of coke production from hard coal. Coke gasconsists mainly of hydrogen (50 to 60%), methane (15 to 30%) and carbonmonoxide. Due to the extremely high hydrogen content of coke gas, speciallymodified Jenbacher engines are used to generate power from this fuelsource.

Pyrolysis gas/wood gasgases from gasification processes

The production of special gases through various gasification processes isbecoming increasingly important for the utilization of alternative energysources. Various base materials (e.g., domestic and commercial waste,

light shredder fractions, bulk waste, wood, meat and bone meal, old tires)are subjected to high-temperature gasification processes, such as fixedbed, fluidized bed, or pyrolytic gasification. The efficient combustion of theresultant gases requires a highly sophisticated gas engine, since compositionand partly problematic trace elements in these gases set a new challenge onthe engine design. Depending on the gasification process, the combustiblecomponents mainly consist of hydrogen, carbon monoxide and methane,having a calorific value in the range from 1.5 to 3.5 kWh/m3N. Sophisticatedgas treatment, rapid reaction to changing calorific values, accuratemonitoring of the combustion process in the engine, and effective systemcoordination between the engine and gasifier, are only some of the complexrequirements for gas engines using such fuels.

Coke production Profusa, Spain Biomass power station Guessing, Austria

7


12/28


13/28

products

finding the rightsolutions

9


14/28

gas enginesCore competence

For about 50 years, GEs Austrian-based gas engine business has beenrecognized as a world leader in the development and production of gasengines for the efficient generation of power and heat . Jenbacher productsare highly-developed and tested, and well matched to each customersspecific requirements. Jenbacher engines are designed for stationary,continuous duty operation, and are characterized by particularly highefficiencies, low emissions, and high durability as well as reliability.

The Jenbacher product engineeringteam, with its 100+ employees, isfocused exclusively on gas engines,and is committed to the continuous

evolution and improvement of gasengines, associated equipment, andservices.

Jenbacher gas engine conceptJenbacher engines are characterizedby the uncooled exhaust manifoldlocated outside the V-space and theresulting cross-flow cylinder heads.This revolutionary engine designallows optimal combustion andthereby ensures highest possibleefficiencies and long life of thecylinder heads and spark plugs.

LEANOXlean mixture combustionThe worldwide, patented JenbacherLEANOXlean mixture combustioncontrol ensures the correct air/gasratio under all operating conditionsto minimize exhaust gas emissionswhile maintaining stable engineoperation.

Optimized combustionWith our focus on highestefficiencies and lowest emissionswe continuously enhance thecombustion behavior of our gasengines. Optimization of cylinderhead flow, continuous spark plugdevelopment and steadily increasedspecific output lead to top efficiencyvalues while maintaining a high levelof reliability.

Development of engine componentsEssential components necessary forreliable engine operation (e.g., sparkplugs, gas mixer, engine controls) aredeveloped directly in Jenbach. Thisallows GE to control the developmentand construction, system integration,and testing of the complete units.

Four success factors

products

outstanding technology

10


15/28

Wide performance range in four engine types

To optimally cover the requirements of various customer power needs and applications, GE offers a gas engine product range divided into four types, and tendifferent engine sizes from 0.25 to 3 MW electrical output.

Type 2Electrical output from 250 to330 kWAvailable as in-line 8 cylinderengineWith 1,500 rpm (50 Hz) and 1,800rpm (60 Hz)Packaged in a 20-foot or 40-footISO-container availableMain applications: biogas, sewagegas, cogeneration, small power-generation

-

-

-

-

-

Type 3Electrical output from 500 to1,100 kWAvailable as V12, V16 andV20 cylinder engineWith 1,500 rpm (50 Hz) and1,200 rpm or 1,800 rpm (60 Hz)Packaged in a 40-footISO-container availableMain applications: biogas, flaregas, landfill gas, sewage gas,cogeneration, on-site power-generation

-

-

-

-

-

Type 4Electrical output from 800 to1,500 kWAvailable as V12, V16 andV20 cylinder engineWith 1,500 rpm (50 Hz) and1.200 rpm or 1.800 rpm (60 Hz)Packaged in a 3m-wide 40-footISO-container availableMain applications: biogas, coalmine gas, landfill gas, cogenera-tion, CO2fertilization

-

-

-

-

-

Type 6Electrical output from 1.5 to 3 MWAvailable as V12, V16 andV20 cylinder engineWith 1,500 rpm (50 Hz, 60 Hz withgear-box)Main applications: coal minegas, flare gas, landfill gas,cogeneration, CO2fertilization

--

-

-

Three key competencies across all four engine types

EfficientTop efficienciesHigh performance densityLong service intervalsLow life-cycle costs

----

DurableEstablished, field-tested designsOptimized, robust engine componentsStationary engine concept

---

ReliableMaximum operational safety and availabilitythrough optimized individual componentsHigh degree of maturityProven control and monitoring conceptContinuous and focused further developmentof the products

-

---

Flexible application

All Jenbacher gas engines are suitable for usewith

Natural gas,Biogas, or

Special gasesand ensure minimum emissions over the entirerunning period. In addition, on costumers requestGE offers gas engines running on a fuel mixtureof different gases, ensuring highest operationalflexibility.

--

-

Product ranges at a glance

GE is committed to providing its customers withthe best fit products, and full range of productconfigurations. Our scope of delivery includes:

Generator sets

Cogeneration systemsContainer solutions

-

--

GEs gas engine business has designed thefollowing innovative systems to further enhancethe performance of its engines:

DIA.NEXT Dialog Network, the user-friendlyman-machine interfaceActivated carbon adsorber, for fuel gas cleaning

of sewage gas and landfill gas to provide gasquality almost equal to natural gasCL.AIR Clean Air, the robust and reliableexhaust gas treatment system also forcontaminated gases

-

-

-

11


16/28

generator setsMaximum efficiency in power generation

Generator sets provide on-site power generation on demand. Jenbachergenerator sets are characterized by a compact design and high powerdensity, and therefore require a comparatively small footprint. The engineand generator are mounted on a frame that is vibration-dampened bymeans of durable elastomer elements. In the same manner, the frame isalso insulated from the foundation, preventing any vibration from affectingthe building.

cogeneration systemsCombined generation of power and heat

Cogeneration systems generate power and heat where required, providingmaximum efficiency in the conversion of energy with minimum emissions.Their basic structure corresponds to that of the generator sets with theaddition of heat exchangers for utilizing the waste heat. A wide range ofengine heat sources from engine cooling water, oil and air/fuel gasmixture to exhaust gas is configured to maximize the benefit to eachindividual customer.

The highly compact design and the efficient elastic mounting of Jenbachercogeneration systems require little in terms of space and foundation designso that the peripheral installation costs are minimal.

container solutionsMaximum flexibility

The scope of delivery for Jenbacher engines includes fully containerized plants, requiring only gas and power connections on location for operation. All plantcomponents required for operating the set are integrated in the container and on the container roof. The electrical control and switching system is located ina separated compartment of the container, providing for comfortable operation of the plant. The overall compact design ensures a space-saving installationwith service oriented accessibility.

With this flexible container design our customers requirements can easily be met.

products

advanced solutions

12


17/28

DIA.NEXT Dialog NetworkOptimum control

DIA.NEXT is the latest Jenbacher engine management system, and isdesigned for use with all Jenbacher engines. The system comprises powerfulcentral industrial controls that handle master control and feedback controlfor the engine-plant, as well as visualization. A link, via standardized industrybuses or using direct signal lines, with central process control is provided tomeet the specific requirements of each customer.

The focus of the DIA.NEXT design lies in combining powerful and flexibleopen- and closed-loop control electronics with a user-friendly operatingconcept. The novel hardware design employs the most modern componentsand sets new standards for performance, functionality and operating safety.The visual display uses a color graphics display screen, providing a clear andcomprehensible presentation of information and measured values whileoffering the greatest possible ease of use.

With additional components it is possible to adapt DIA.NEXT individually to meet various customer requirements:

MONICMonitoring Ignition Control:On-line monitoring system ofthe ignition voltage that allowspreventive maintenance of sparkplugs and ignition coils.

HERMESData remote transmission: HERMESoffers the operator remote diagnos-tics and solutions at any t ime viainternet, modem or LAN connection.

HERMES provides the followingtwo applications, which can beused separately or together:

DIA.NEWINDialog Network for WindowsSystems: Delivers full remote opera-tion of Jenbacher engines as well ascomprehensive functions for anal-ysis and trend identification in thefamiliar Windows environment.

DIA.NE RMCDialog Network for RemoteMessage Control: Automated dataand message transmission to aremote data transmission centerand auto-alarm by way of fax,SMS and/or e-mail. All incomingmessages and data are archived formaximum traceability of operations.

13


18/28

activated carbon adsorberLonger service life through fuel gas cleaning

Sewage gas and landfill gas frequently contain gaseous silicon compounds.For cleaning the fuel gas from these substances, we have developed anactivated carbon adsorber system.

The system prevents the formation of silica in the engine, increasing com-ponent service lives and reducing engine wear. Gas cleaning also extends oillife and enables under certain conditions the use of conventional oxidizingcatalytic converters for the reduction of CO and formaldehyde emissions. Asa result, the Jenbacher activated carbon adsorber allows reliable, durable,highly efficient, and low emission operation with sewage gas and landfill gas.

Especially for landfill gas applications and plants with larger output rangein remote areas, we have developed the TSA (Temperature Swing Adsorber),which is a regenerative system. The advantage of this new technology is thatthe activated carbon regenerates itself, which ensures continuous operationover longer periods of time without the need to change the activated carbon.

In detail:

Fuel gas is passed through a vessel filled withactivated carbon where certain gaseous compounds(mainly silicon and halogen) are adsorbed by theactivated carbon. The degree of saturation of theactivated carbon is regularly checked and replacedwhen the prescribed maximum limit has been reached.For landfill gas plants, GE provides the automatic self-regenerating TSA system where the replacement of theactivated carbon is only necessary at very long intervals.

products

fresh air

14


19/28

CL.AIR Clean AirExhaust gas treatment for cleaner air

If fuel gases such as landfill gas or sewage gas are used, the harmful con-taminants in the gas may inhibit quickly the performance of the oxidizingcatalytic converters. With the CL.AIRsystem, we utilize thermal re-com-bustion to maintain minimum CO, HC and formaldehyde limit values. In sodoing, the engine can be operated with both maximum specific power andmaximum efficiency.

In detai :

The exhaust gas flows over a hot ceramic storagemass where the gas is heated to approximately 800C.Uncombusted components of the exhaust gas (e.g.,CO, or HC) are recombusted at this high temperature.The exhaust gases then flow over a second, coolerstorage mass, which is heated in the process. Througha change-over mechanism, alternately passing theexhaust gas over the two storage masses, the energyrequirement is minimized so that system-relatedthermal losses can be largely compensated.

15


20/28


21/28

energy supply

expanding boundaries

17


22/28

energy supply

decentralized energy supplyNumerous advantages with Jenbacher systems

Jenbacher generator sets and cogeneration systems are well

designed to fulfill any decentralized energy supply needs.Some of the key features of our products are:

High electrical efficiencies of up to 43%Overall efficiencies (electrical and thermal) of over 90%Minimum NOx-emissions through the patented LEANOX

lean mixture combustionSpecially designed engines for utilization of alternative,renewable energy sources (e.g., biogas or landfill gas) andspecial gases (e.g., coal mine gas or coke gas)Maximum operational safety and availabilityHigh power density

Through supply of energy directly at the load source, it is alsopossible to reduce or avoid altogether transport and distribu-tion losses.

---

-

--

cogenerationMaximum overall efficiencies

With combined power and heat generation (cogeneration) the waste heatincurred during engine operation is deliberately and economically utilized,resulting in overall efficiencies of more than 90%. This efficient form of energyconversion is able to achieve primary energy savings of about 40% using gasengine cogeneration systems, compared with conventional separate powerand heat generation. In addition, investment costs for gas engines, relative tocompeting technologies, are low.

Power and heat utilization

The power generated is utilized to cover the consumption of the individualfacilities (e.g., hospitals) and/or fed into the public power grid. The thermalenergy can be used for both generating heating water and steam produc-tion, as well as for various types of process heat. Gas engine cogenerationsystems are also used for CO

2fertilization in greenhouses and trigeneration

systems (combined generation of power, heat, and cooling).

Valley Medical Center, USA

18


23/28

Processing of cocoa beans Altinmarka, Turkey Greenhouse Van der Arend Roses, The Netherlands

generation ofheating water

Cogeneration systems captureexcess heat from the engine. Theheat can be used to generate heatingwater, which can then be utilized bylocal or district heating systems tocover their basic heat requirements.Peak heat demand can be coveredthrough the combined use of a bufferand a peak boiler. Due to varyingheat demands during the year, multi-engine-installations are the preferredsolution for district heating systems.

steam productionand dryingprocessesRoughly 50% of the thermal energygenerated in a gas engine consistsof exhaust gas heat with a temper-ature of approximately 400 to 500Cand can be utilized for the productionof steam. The remaining waste heatcontained in the engine coolingwater, oil, or air/fuel gas mixture,can be utilized for feeding waterpreheating. Applications includeprocessed steam for industrialoperations, hospitals to meet theirrequirement for sterilization steam,and foodstuff processing operations.The exhaust gas from the gasengines can also be utilized directlyor indirectly for drying processes

(e.g., in brick works, the ceramicindustry, animal feed drying). Overallefficiencies of more than 98% can beachieved through the recovery of theheat discharged from the cogenera-tion plant by way of heat exchangersand the exhaust and radiation heat.

CO2fertilization in

greenhouses

Heat, light and CO2promote the

growth of plants in greenhouses.With artificial lighting, plants absorbeven more CO2. If the greenhouseatmosphere is enriched with CO

2,

plant growth and consequently theharvest yield can be increased byup to 40%. This process also calledCO

2fertilization is able to make use

of the CO2contained in the exhaustgas of a gas engine through catalyticconverter purification. As a result,greenhouses utilizing gas enginecogeneration systems can cover thepower and heat requirement for theartificial lighting and heating in aneconomical manner, while effectively

utilizing CO2of the engine exhaust gas.

trigeneration

The combination of gas engines

with absorption chillers is an optimalsolution for generating air condi-tioning and/or refrigeration. Thewaste heat from the mixture inter-cooler, the engine oil, the enginecooling water, and the exhaust gasserves as drive energy for the chillers.Combining a cogeneration plantunit with an absorption refrigerationsystem allows utilization of seasonalexcess heat for cooling. Using tri-generation, it is possible to achieveoverall efficiencies (power and airconditioning and/or refrigeration) ofup to 75%, increasing both annualcapacity and overall plant efficiency.

19


24/28


25/28

On the way to the top you better have a strong partner.

service

for your reliability

21


26/28

service

on-site in more than 30 countriesThe Jenbacher product teams commitment to the customergoes beyond designing the best available technology. Oursuccess is measured by our customers long term satisfactionwith the performance of our equipment. The main concern

in this regard is to offer customers the full range of servicesneeded to ensure a reliable and efficient energy supply andspecial gas disposal from one source.

Service agreements

With customized service agreements GE ensures the best possible fulfillmentof individual customer requirements.

Worldwide service organization

Jenbacher service technicians and authorized external service providers arelocated in more than 30 countries. This service network secures the optimumcare and support of our customers.

Remote diagnosis and remote servicing

The in-house Jenbacher competence center makes use of remote diagnosisand remote servicing by means of HERMES, the data remote transfer systemdeveloped in-house, and networked worldwide by satellite. The competencecenter is run by a team of experienced and highly-qualified commissioningservice engineers in Jenbach and ensures timely and accurate technicalsupport.

Training center

The Jenbacher training center, located in Jenbach, offers specific participant-oriented training courses for customers, operators, and sales and serviceproviders. Hands-on training programs are offered either at the customersite or at the training center.

Gas engine manufacturing building at the Austrian headquarters

22


27/28

Austria (Headquarters)Achenseestrae 1-3

A-6200 JenbachT +43 5244 600-0F +43 5244 [email protected]

Bulgaria36, Dragan Tsankov Blvd.1040 SofiaT +359 2 971 4390F +359 2 971 [email protected]

China8 Floor, The Lee Gardens

33 Hysan Avenue Causeway BayHong KongT +852 2100 6976F +852 2100 [email protected]

DenmarkIndustrivej 19DK-8881 ThorsT +45 86966788F +45 [email protected]

GermanyAmselstrae 28

D-68307 MannheimT +49 621 77094-0F +49 621 [email protected]

HungaryKisret t 1H-2112 VeresegyhzT +36 2858 7376F +36 2858 [email protected]

ItalyVia Crocioni, 46/HI-37012 Bussolengo (VR)

T +39 045 6760211F +39 045 [email protected]

North America5244 North Sam Houston Pkwy E.Houston, TX 77032T +1 832 2955600F +1 281 [email protected]

RussiaTaganskaya Street, 17-23

Business Center Mosenka 4109147 Moscow, RussiaT +7 495 7755885 1015F +7 495 77558 [email protected]

Spain and PortugalAvda. del Camino de lo Cortao, 34 Nave 8E-28700 San Sebastin de los Reyes (Madrid)T +34 916586800F +34 [email protected]

The NetherlandsStationspark 750

NL-3364 DA SliedrechtT +31 184 495222F +31 184 [email protected]

United Arab EmiratesCity Tower II, Sheikh Zayed RoadP.O. Box 11549, DubaiT +971 4 3131486F +971 4 [email protected]

for more information on Jenbacher gas engines


28/28

2

006GEJenbacherGmbH&CoOHG.A

llrightsreserved.

GEA-14068A-R1

phulbari coal mine document

Documents