ENERGY SOLUTIONS USING NATURAL GAS

transcript

ENERGY SOLUTIONS

NATURAL GAS

Combined Heat & Power (CHP)

CHP or Co-generation is a simultaneous

production of electricity and usable thermal

energy from a single fuel source.

What is CHP ?

CHP Plant consists of four basis elements:-

1.A Prime Mover (Engine).

2.An Electricity Generator.

3.A Heat Recovery System.

4.A Control System.

Natural Gas

Generator

Heat Recovery

System

Turbine Electricity

25～40%

Steam/Hot Water/Hot

Air/Chilled Water 40～50%

Engine

Prime Mover

What is CHP ?

Why CHP ?

1.Operating Cost Savings.

• Generate own electricity.

• Recover useful heat.

2.Savings from reliability improvement.

3.Savings from capital cost offsets.

• Offset equipment upgrade.

• Offset electrical service upgrade.

4. Improve Environmental Quality.

5.Possibility of step-by-step capacity increase.

Water Heater

80% Efficient

Generator

33% Efficient

Electricity

Hot Water

75kW Fuel

Traditional

57% Total Efficiency

75kW Fuel

Electricity

Heat Exchanger

Hot Water

85% Total Efficiency

Why CHP ?Competitiveness in Operating Costs

Why CHP ?

Total Energy Efficiency

70 to 80%

Total Energy Efficiency

Customer

City Gate

Power Generation 25 - 40%

Waste Heat Utilization 40 - 50%Loss 20 to 30%

Customer

Transmission Loss 2%Unutilized Waste Heat 55%

Power Plant

CHP System

Conventional Power

Supply System

1. Increase Energy Efficiency 2. Reduced CO2 Emissions 3. Improved Air Quality

CHP Technology

Gas Turbines Absorption Chillers

Gas EnginesMicro Gas Turbines

CHP TechnologyAvailable and Innovative Technologies

STEAM TURBINESGAS TURBINES

GAS ENGINE ABSORPTION CHILLER

MICROTURBINES

CHP ApplicationsPotential Industry/Sectors :-

• Ceramic

• Rubber Products

• Chemical/Oleochemical

• Glass

• Paper Products

• Steel Products

• Food, Beverage & Tobacco

• Automotive/Parts Manufacturing

• Hotels

• Commercial Complex

CHP Applications

MAJOR APPLICATIONS :

✓ Direct Exhaust (Hot Air)

✓ Hot Water

✓ Steam

✓ Chilled Water

ELECTRICITY +

CHP Technology – Gas Turbine

Gas Turbine

Parameter Value

NG Consumption 335 Sm3/hr/ MW

Potential Recovery Steam*1 - 4 ton/hr/MW

Hot Air*2 – 3 x 106 kcal/MW

Average system

efficiency

82 % (Steam)

90 % (Hot Air)

Range per unit 1 – 60 MW

Note :

*1 – Steam at 10 bar.g saturated.

*2 – Exhaust Temperature at 450 - 500°C

Gas Turbine

• Suitable for steam / hot air recovery.

• Electrical efficiency of approx. 25 - 32%.

• Influenced by ambient temperature and elevation.

• Inlet pressure for fuel requirement ~ 14 to 21 bar.

• Capital investment about RM 3,000 / kW.

Gas Turbine With Steam Recovery

Application in the manufacturing process for Pulp &

PaperINFORMATION

Capacity : 9.60 MW.

Model : 2 x SOLAR Taurus 60 Gas Turbine

with supplementary firing.

Gas Consumption : 4,025 Sm3/ hour.

Steam Generation : 43 t/hr at 10 bar.g,

saturated.

Application : To provide electricity and steam

for paper making machine.

NATURAL GAS

GAS TURBINE

GENERATOR SET

11 kV, 50hZ

INTAKE AIR

HEADER

HEAT RECOVERY STEAM

GENERATOR (HRSG)

CHP – Steam Application

EXISTING BOILER

SUB-STATION

TNB SUPPLYPLANT

POWER DEMAND

STEAM DEMAND

Economic Analysis

Gas Turbine

Utility Generation Usage Rate Avoided Cost

(RM/hr)

Operation

(RM/hr)

Electricity 9,490 kW - 1,765 -

Steam 43 t/hr - 1,673 -

Gas - 4,025 Sm3/hr - 1,957

O & M - RM0.03/kWhr - 285

Stand-by

- RM8.70/kW/m

Saving RM 9,832,320/year

Average Electricity Tariff = RM0.186/kWh (E2S) Operation hours = 8,640 hr/yr

Boiler : NG Consumption = 3,440 Sm 3/hr Steam Conditions = 10 bar, Saturated

Natural Gas Tariff = RM0.4863/Sm3 Electricity Stand-by (Based on one unit GT capacity) = 4,745 kW

(Non-Firm)

Configuration Gas Turbine

Average Ambient Temp. (˚C) 30

Electricity Produced (kW) 9,490

Steam Produced at 10 bar (ton /hr) 43

Gas Price (RM/mmBtu) 12.79

Savings (RM/year) 9,838,062

Capital Expenditure (RM) 30,000,000

Simple Payback Period (Years) 3.1

Economic Analysis

Gas Turbine with Steam

Recovery – Simple Payback

Gas Turbine With Direct Exhaust Heat

Application in the manufacturing process for

ceramic products

INFORMATION

Capacity : 4.2 MW.

Model: SOLAR Taurus 60 Gas Turbine.

Gas Consumption : 1,073 Sm3/ hour.

Hot Air Generation : 79,284 kg/hour at 450 ˚C.

Application : To provide electricity and hot air

for Spray Dryer.

Electricity

Intake Air

(Natural Gas)

Gas Turbine Generator

Exhaust Outlet, 135°C

Filter

Housing

Diverter

Damper

CHP – Hot Air Application

375 - 510°C

Gas Turbine and Absorption Chiller

Application in the commercial building

for power and chilled water

INFORMATION

Capacity : 1.2 MW and 1,000 RT.

Model: KAWASAKI gas turbine and

SIGMACHILL steam driven absorption

chiller.

Gas Consumption : 433 Sm3/ hour.

Application : To provide electricity and chilled water

supply for commercial building.

4.14 t/h

(8.5 kg/cm2G)

NATURAL GAS

GAS TURBINE GENERATOR SET

1,250 kW, 11 kV, 50hZ

INTAKE

400 RT

HEADER

4.3 t/h

8.5 kg/cm2G,176 °C

CHILLER

(STEAM ABSORPTION

COOLING TOWER

37.6 °C 32 °C

400 + 600 m3/h

600 RT

CHP – Chilled Water Application

CHP Technology –Micro Gas Turbine

Micro Gas Turbine

Parameter Value

NG Consumption 0.38 Sm3/hr/ kW

Potential Recovery Hot Water*1 - 35 litre/hr/kW

Chilled Water*2 – 0.63RT/kW

Average system

efficiency

82 % (Hot Water)

70 % (Chilled Water)

Range per unit 30 – 200 kW

Note :

*1 – Hot Water at 80°C.

*2 – Chilled Water through Direct Exhaust Absorption Chiller

with 7/12°C system.

Micro Gas Turbine

• Suitable for hot water / chilled water / hot air recovery.

• Electrical efficiency of approx ~ 25 - 27%.

• Influenced by ambient temperature and elevation.

• Inlet pressure for fuel requirement ~ 4 to 6 bar.

Micro Turbine

Application in the manufacturing process

for rubber products

INFORMATION

Capacity : 80 kWelectrical and 150 kWthermal

Model: BOWMAN TG80 CG Micro turbine.

Hot Water Production : 3,000 litres/ hour at 80 °C.

Application : To provide electricity and constant hot

water supply for leaching process.

Exchanger

Storage

Drain Pipe

Water Supply

Gas Supply

Hot Water

@ 80 °C

Electricity

CHP – Hot Water Application

Hot Air

Performance Unit Capacity

Fuel Consumption kW 310

Gross Electrical Output kWe 80

Hot Water Recovery @ 80°C kW 174

Total Usable Energy kW 254

Generating Efficiency % 26

Thermal Efficiency % 56

Overall Efficiency % 82

Max. Hot Water Output at 80°C litre/hr 3,000

MGT – Data Sheet

MGT – Economic Analysis

Utility Generation Usage Rate

Avoided Cost

(RM/hr)

Operation

(RM/hr)

Electricity 80 kW - 20.64

Hot Water 3,000 l/hr - 13.72

Gas - 28 Sm3/hr - 13.72

O & M - RM0.04/kWh - 3.20

Total 34.36 16.92

Saving RM139,520/year

Electricity Tariff = RM0.258/kWh (Tariff D)

Hot Water Equivalent Replacement Input = 28 Sm3/hr (NG)

Operation Hours = 8,000 hrs/year

Natural Gas Tariff = RM0.49/Sm3

Configuration

Average Ambient Temp. (˚C) 35

Electricity Produced (kW) 80

Hot Water Produced at 80 ˚C (litre /hr) [max] 3000

Gas Price (RM/Sm3) 0.49

Savings (RM/year) 139,520

Capital Expenditure (RM) 440,444

Simple Payback Period (Years) 3.2

Economic Analysis

MGT with Hot Water

Recovery

CHP Technology – Gas Engine

Gas Engine

Parameter Value

NG Consumption 260 Sm3/hr/ MW

Potential Recovery Hot Water*1 – 20.8 m3/hr/MW

Chilled Water*2 – 215 RT/MW

Average system

efficiency

80 – 85 %

Range per unit 0.3 – 3 MWNote :

*1 – Hot Water at 80°C.

*2 – Chilled Water through Hot Water Absorption Chiller

with 10/15°C system.

Gas Engine

• Uses low pressure fuel ~ < 1 bar.

• Producing lower grade recovery heat

(< 90°C) suitable for hot water/steam.

• Electrical efficiency of 35 - 40%.

• Performance is not significantly influenced by

elevation and temperature.

Gas Engine - CCHP

Application in the industry

for power, chilled water & hot water

INFORMATION

Capacity : 1.2 MW and 262 RT / 28.2 m³/hr.

Model: Air Cogen -Deutz V – 16 Gas Engine and

LG hot water driven absorption chiller.

Application : To provide electricity, chilled water

and hot water for process

requirement.

CCHP – Combined Cooling, Heat & Power Application

Hot Water

Absorption

Chiller

Jacket Water System

Exhaust System

Gas Supply

Hot Water

Buffer Tank @ 80°C

Electricity

ΔT = 5°C

Heat Exchanger

Gas Engine - CHP

Application in the industry for power & steam

INFORMATION

Capacity : 2.13 MW and 1.5 t/hr steam @10 bar.g.

Model: 2 x 1065 kW – V 20 GE Jenbacher Gas

Engine with steam recovery.

Application : To provide electricity and steam for

process requirement.

Absorption Chiller

Absorption Chillers – Technology

Absorbent:

Lithium Bromide

Refrigerant:

Absorption Chillers – Technology

Absorption Chiller

Parameter Value

NG Consumption 0.28 Sm3/hr/ RT*

Turndown ratio 10 - 100 %

Range per unit 5 – 2500 RT

Note :

* RT = Refrigeration Ton

1 RT = 3024 kcal/hr

1 RT = 1.2 hp

Absorption Chiller

• Suitable for industry, hotels and commercial complex.

• Operates on low pressure fuel ~ < 1 psig.

• Weighs about 40 kg / RT (heavy) but minimal vibration.

• Operates using low pressure steam/hot water/gas-fired/hot air (exhaust).

• Use minimal electricity.

• Capital is about RM 1100 per Refrigerant Ton (RT).

Absorption Chillers

for pharmaceutical products

INFORMATION

Gas Consumption : 222.1 Sm3/ hour

Electrical Consumption : 12 kW/ hour

Application : To provide chilled water supply for

manufacturing process

Absorption Chillers

Application in the space cooling

for hotel

INFORMATION

Capacity : 3 x 500 RT

Model: Double Effect Gas Direct Fired

Gas Consumption : 165 Sm3/ hour / 500 RT

Electrical Consumption : 12 kWhr/ 500 RT

Application : To provide chilled water supply for

space cooling

Absorption Chillers

for rubber products

INFORMATION

Location: PGA, Jeram, Klang.

Gas Consumption : 15.2 Sm3/ hour.

Electrical Consumption : 4.3 kW/ hour.

Application : To provide chilled water supply

for latex cooling.

Economic Analysis

Gas Absorption Chiller

Utility Generation

Operational Cost

(RM/year)

Investment

Direct Fired

Absorption Chiller

1,000 936,837 1,100,000

Centrifugal Chiller 1,000 1,162,480 900,000

Net Investment 200,000

Saving - 225,643

Payback Period - 0.89

Gas Heat Pump (GHP)

Gas Heat Pump

Application in the small scale commercial building

for air-conditioning & hot water

INFORMATION

Capacity : 11 x 20 hp

Location: GMSB HQ, Shah Alam

Gas Consumption : 47.52 Sm3/ hour (Max)

Electrical Consumption: 20.46 kW/ hour (Max)

Application : To provide space cooling &

domestic hot water at 35°C

Gas Heat Pump (GHP)

Parameter Value

NG Consumption 0.2 Sm3/hr/hp

Potential Recovery

(Hot water @ 20oC rise)

22 liters/hr/hp

Range per unit 5 – 20 hp

Gas Heat Pump (GHP)

• Suitable for restaurants, commercial complex and

manufacturing.

• Operational from 5 – 100 % loading.

• Operates on low pressure fuel ~ 300 mmH2O.

• Electricity power through single-phase current

(240 V).

• Capital investment about RM 5,200 per hp.

Merits of GHP• Speedy and powerful cooling

- Inverter-like effect

The GHP maintains the temperature at the set temperature. The secret of this is the inverter-like effect of the gas engine.

A gas engine is used to drive the compressor. The speed of the engine is controlled efficiently by a microcomputer according to the room temperature, so that there is no temperature loss.

Engine

Compressor

Exhaust H

Exchanger

Heat E

r refrig

Water Heater

Storage

Cold Water

Ｔ＜５５℃

Engine Warming up

55℃＜Ｔ＜62℃

Reuse of waste heat

Ｔ＞６２℃

Heat radiation

When the hot water temperature is 80℃ or more

40 % ~ 50%

of wasted

heat can be

collected.

GHP – Heat Recovery System

Demand / Deliverables for

220 HP

Type of Air-Conditioning

EHP GHP

Gas consumed (kWhr) - 527

*Energy required (kWhr) 80** 0

Elec. consumption (kWhr) 767*** 48***

Total energy (kWhr) 847 575

Annual energy (kWhr) 3,557,400 2,415,000

Savings (kWhr/year) 1,142,400 ( 32 % )

* EHP has separate system for hot water with 90% efficiency.

*** Reference for electricity taken from the point of power plant (Average efficiency : 43%)

Maximum existing EHP electrical consumption : 1 hpthermal = 1.5 kWelectrical

Maximum GHP electrical consumption : 20 hp = 1.86 kW

Maximum GHP gas consumption = 4.32 Sm³/hr per unit

Operational hours taken at 4,200 hrs per year

GHP - Energy Analysis

GHP – Gas Engine

GHP – Compressor

Water Heater Technology

Cold water in

Gas inWater outHot Water out

Burner

Solenoid Valve

Heat Exchanger

Combustion fan

Outgoing water

thermistor

Exhaust Duct

IMPIANA HOTEL

CONVENTION

CENTRE

Instantaneous Hot Water System

Infinity Project

Infinity – V Series

Utilizes the latest in water heating technology

• Incorporate a high efficiency forced combustion system.

(Thermal efficiency, η > 80 %)

• Computer based electronic ignition and control system

– System includes both feed forward and feedback

control loops which provide accurate of outlet water

temperature

• The system only heats water while it is flowing

– Economical for low and high demand application

• Space saving, Compact size

COMPARISON ENERGY COST

NG LPG ELEC

Infinity – Energy Cost

Approx 70% saving

Manifold Units with digital controller

Infinity – Manifold System

Gas inletHot water

outlet

Cold water inlet

Flow water

Commercial

Digital Controller

Kuala Lumpur Convention Centre

Location : Concourse Level , KLCC

Ring Line : 600 m

Return Pump : Grundfos UPS

Hotel Impiana, KL

Infinity – Manifold & Storage Tank

Location : Impiana KLCC Hotel

Capacity : System B – 12,000 ltr/hr @ 60 deg C

- serve 1st to 10th floor

System A - 6,000 ltr/hr @ 60 deg C

- serve 11th to 14th floor

System C – 5,000 ltr/hr @ 85 deg C

- serve restaurant and cafe

System : System B

- 2 sets of Manifold pack of 6 Infinity 26

- 2 units of 1,000 liter storage tank

System A

- Manifold pack of 6 Infinity 26

- 1 unit of 1,000 storage tank

System C

- Manifold pack of 8 Infinity 26

Hotel Impiana, KL

Infinity – Hot Water Supply System

High Zone

Low Zone

Kitchen

Flow water

Cold water inlet

Manifold units with Storage Tank and building flow & return pipework

Gas inletHot water

outlet

65 deg C

Storage

no burner

or element

Thermostat

set point 65 deg C

Unit preset at 75 deg CFlow Return

Primary pump

Flow & Return

Commercial

IMPIANA HOTEL

(GAS TRAIN & STORAGE TANK SYSTEM )

Bi-Fuel Systems for

Heavy-Duty Diesel Engines

What is Bi-Fuel?

• Bi-Fuel is a “co-firing” of standard diesel fuel and natural gas (methane)

• It is designed for use conventional, heavy-duty diesel engines

• No engine modifications are required

• The Bi-Fuel Systems can be installed in the field or accomplished as an OEM up-fit

• Natural gas typically substitutes between 50-80% of the diesel fuel required to maintain a given speed and load

Primary Applications• Prime power

• Peak shaving

• Distributed power

generation

• Transportation

• Marine

• Compressors

Characteristics of the

Bi-Fuel System

• High efficiency

• Compression ignition

• Low gas supply pressure

• Sophisticated engine protection system

• Auto-switching of fuel modes

• Non-intrusive, simple installation

• Easy to operate

Bi-Fuel System

Air-Gas Mixer• Low air restriction

• Fixed venturi –

no throttle

• No moving parts

• CNC-machined from T6 aluminum

• Anodized finish for corrosion

resistance

Bi-Fuel System Operation

Bi-Fuel System

Gas Train

• State-of-the-art design

• Carries all major approvals

• DC-powered

• Valve proving system

• 50 micron gas filtration

MINIMUM

VOLUME

(Sm3/Month)

UNIT CHARGE

(RM/Sm3)

APPLICABLE RANGE

(Sm3/year)

( mmBtu/year)

Domestic Tariff (A) - RM 0.75 /Sm3 n/a

Minimum monthly charge - RM 5.00

Small Business Tariff (B) 210 RM 0.58 / Sm3 0 - 15,793

(0 - 600 mmBtu)

Small Commercial &

Industrial Tariff (C)

980 RM 0.51 / Sm3 15,794 -131,513

(601 - 5,000 mmBtu)

Small Commercial &

Industrial Tariff (D)

1,600 RM 0.50 / Sm3 131,514 - 1,315,013

(5,001 - 50,000 mmBtu)

Large Commercial &

Industrial Tariff (E)

25,000 RM 0.49 / Sm3 1,315,014 - 5,260,013

(50,001 - 200,000 mmBtu)

Large Commercial &

Industrial Tariff (F)

25,000 RM 0.49 / Sm3 5,260,014 - 19,725,000

(200,001 - 750,000 mmBtu)

Natural Gas - Tariff

1. Import duty and sales tax exemption for equipment used in energy

conservation, which are not produced locally. Equipment purchased

from local manufacturers is given sales tax exemption.

2. Investment Tax Allowance of 100% on the qualifying capital expenditure

incurred within a period of 5 years with the allowance to be set-off

against 100% of statutory income for each year of assessment.

3. Effective for applications received by Malaysian Industrial Development

Authority (MIDA) from 8 September 2007 until 31 December 2010.

Government Incentives

Companies which incur capital expenditure for conserving

energy for own consumption:

1. Import duty and sales tax exemption for equipment used in energy conservation, which are not produced locally. Equipment purchased from local manufacturers is given sales tax exemption.

2. Investment Tax Allowance of 100% on the qualifying capital expenditure incurred within a period of 5 years with the allowance to be set-off against 100% of statutory income for each year of assessment or;

Pioneer status with tax exemption of 100% of statutory income for 10 years.

3. The ESCO’s company required to implement the project within one year from the date of approval and the incentive has been extended until 31 December 2010.

Government IncentivesCompanies Providing Energy Conservation Services:

THANK YOU

Mohd Rozi Othman

Gas Malaysia Sdn Bhd

Tel : 603-51923000 ext 3434

h/p : 019-2626102

E-mail : rozi@gasmalaysia.com

ENERGY SOLUTIONS USING NATURAL GAS

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