Climate Change and the
Emerging Strategies of
Mitigation
Increasing Gas Generator Set Efficiencies
Bio-Fuel developments
2
Outline
Cummins Power Generation Overview
CHP Overview
Cummins CHP Solutions
Cummins CHP Experience
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Cummins OverviewCummins Power Generation� Cummins, Inc: $13B Sales (2007), 33,000 employees
� Cummins Power Generation: $2B Sales, over 1m units in service
� The “Power of One”: Integrated Design, Sourcing, and Support of engine, alternator, controls, switchgear
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Global Distribution and Support
Cummins global distribution covers 160 Cummins global distribution covers 160
countries, with 550 distributors and over 5,000 countries, with 550 distributors and over 5,000
service and parts outlets.service and parts outlets.
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CHP Overview
Cogeneration, or Combined Heat & Power (CHP), utilizes the full potential of the input energy.
CHP can reclaim over half of the otherwise lost fuel energy
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Mechanical
Thermal
Electrical output 39%
HT circuit (85- 95°C) 15%LT & Oil circuit (50- 60°C) 9%
Exhaust (120°→35° + unburned) 5%
Generator losses
1%Cooling circuit CAC 2.5%
Exhaust (→ 120°C) 25%
Engine radiation 3.5%
Recovered
Energy
88%
Losses
12%
Efficiency Benefit
Heat Balance: QSV91G
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CHP Schematic
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CHP Overview
CHP is not a new technology
�Used in Thomas Edison’s first electric generating plant in 1891
�Used in industrial, institution, and municipal applications today
Governments see the benefit for both fuel savings and emissions
�US Department of Energy has a goal to double CHP use by 2010
�European Commission has set similar targets
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Environmental Benefit
Reduce demand on national electric grid
�Power often produced by high emitting coal-fired plants
�Reduction in CO2, NOx, and Particulates
Higher efficiency means conservation of natural resources
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Hospitals
Greenhouses
Hotels
Industrial/Chemical Plants
Manufacturing Facilities
Commercial Facilities
Government Facilities
Colleges and Universities
Food Processing Plants
Health Clubs
Swimming Pools
Nursing Homes
District Heating
Landfills and Sewage Treatment Plants
Coal Mining and Oil Fields
Typical CHP Applications
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Emerging Technologies
Define the objectives
Identify the barriers
Identify the technology
The development cycle.
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Key ARES Program Goals for 2010:50% Efficiency at 0.1 g/hp-hr NOx
10% lower operating cost, Increased fuel flexibility
Cummins Targets
39%
44%
47%
50%
35%
40%
45%
50%
55%
2001 2005 2007 2010
Bra
ke T
herm
al E
ffic
ien
cy
Planned work is split into 3 phases.
Each phase ends with a Field test to demonstrate:
1. 44% BTE in 20052. 47% BTE in 20073. 50% BTE in 2010
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Cummins Targets
1
0.10.05 0.02
0
0.2
0.4
0.6
0.8
1
1.2
2001 2005 2007 2010
NO
x (
g/h
p-h
r)
Cummins Targets
39%
44%
47%
50%
35%
40%
45%
50%
55%
2001 2005 2007 2010
Bra
ke
Th
erm
al E
ffic
ien
cy
Efficiency Targets Emissions Targets
Addressing Customer DG Needs• DOE Advanced Reciprocating Engine System
(ARES) Program was Launched• Targeted gains for Distributed Generation
Market are:- 50% Fuel Efficiency at 0.1 g/hp-hr NOx- 10% lower operating cost
Program Phase I II III
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Aggressive Gas
Cummins Fuel Classification
From Fuel Gas Analysis
Limits corrected to LHV 36MJ/m3
Units mg/Nm3CH4
FuelCateg
ory
TOTAL SULPH
UR
TOTAL GASEOU
S SILICON
TOTAL HALOG
EN
Standard operation with low BTU servicing.
C 100-1000
1-20 1-100
Standard low BTU Operation with increased servicing
D 1001-2000
21-40 101-200
Site specific special servicing required
E >2000 >40 >200
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SiteEngineHours
Fuel Clas
s
Sulphur
mg/nm3
Silicon mg/nm
3
Halogen mg/nm3
HoursSpark Plugs
HoursOil
Drain
HoursCylinder heads
Operational Comments
Betton Abbots1 x 1370kW
5,700 E 4 29 203 1500 1500 10,000**Predicted head change
Broadpath2 x 1370kW
5000 E 22 98 61 1000 500 7,000Predicted Head change.
Burnhills1 x 1570kW
8,500 E 22 30 214 1000 1500 7000
Regap plugs 500hrsEx Betton Abbots
Dunbar2 x 1750kW
18,500 E 17 50 223 1500 1500 7500Regap plugs 750hrs
**Pluckley1 x 1370kW
11,000 C 2 11 46 3000 3000 700050% load operation
Westbury1 x 1370kW
12,000 E 23 41 131 1000 1000 7000 **Ex Pluckley
Ardley
1 x 1750kW500 C 0 8 54 1500 1500 10000
EstimatedMaintenance
Whitehead
2 x 1570kW0 E 62 88 93 1000 500 7000
Installed July 07Comm SeptHigh H2SG1 Ex Burnhills
Dunbar 3
1 x 17500 E 17 50 223 1500 1500 7500 Install Aug 07
Jaguar Site6 x 1530kW
55,000 A 0 0 0 2000 4000 30,000Base Engine reference.
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Strategy for achieving ARES goals:
Improve closed cycle efficiency
Explore advanced combustion concepts
Improve predictive models
Improve air handling
Reduce friction contribution
Improve controls
New sensing technology
Waste heat recovery
Higher efficiency alternator
Long life ignition system
Explore aftertreatment technologies
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Key technologies being explored
High efficiency turbo charging
Miller cycle
Advanced lean burn concepts
Diesel pilot ignition
High Pressure Direct Injection (HPDI)
Stoichiometric combustion with EGR
HCCI
Turbo compound
Bottoming cycle
High efficiency alternator
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ARES Phase I Efficiency
Improvements
Eff
icie
ncy
Baseline Miller Cycle Increase
BMEP
High
Efficiency
Turbo
Reduced
RPM
Technical Feature
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NOx Control Technologies
Miller Cycle Engine� The Miller cycle engine is an example of reduced NOx emissions
due to Charge Air Cooling.
� As shown in figure below, intake valve remains open for an additional 30 degrees thus reducing the effective engine displacement.
� ‘Back flow’ due to late intake valve open is compensated by density of charge.
� Reduced combustion chamber temperature at TDC results in lower NOx.
� Reduced engine size also provides substantial reduction in frictional losses, thus increasing fuel efficiency
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Exhaust Gas Recirculation (EGR)� Displacing an engine’s intake air with inert material can
reduce NOx emission.
• EGR is a form of intake air dilution.
Selective Catalytic Reduction (SCR) by Urea:• Typically uses nitrogen containing ammonia or urea as
reducing agents to achieve high NOx control (up to 90%+).
NOx Control Technologies
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Particulate Matter Control Technologies
Diesel Oxidation Catalyst (DOC):• PM emissions composed of carbonaceous particles, soluble organic
fractions (SOF) and sulphates among other things.• Oxidation catalyst reduce SOF but have little impact on other components.• Typically reduce PM by 20-30%.
Diesel Particulate Filter (DPF):• Filters, also called traps, filter PM from exhaust stream with
subsequent oxidation of captured PM.• Ceramic wall-flow monoliths are used as filter material in most cases.
Diesel Fuels:• Diesel fuel properties impact diesel exhaust emissions.• Many after treatment technologies are sensitive to sulphur in the fuel.
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Emission Control OptionsEmission Control Options
Diesel oxidation catalyst (DOC)
Catalyzed Soot Filter
Active regenerating filter
CRT
Miller Cycle
EGR
Lean NOx
Lean NOx + HC
Plasma assisted lean NOx
NOx adsorber
Selective catalytic
reduction(SCR)
NOx
Exhaust and Emission Control Systems
PM
RED: Most commonly used
Controls Reduction %
Diesel Oxidation Catalyst (DOC) PM 20 - 40
Catalysed Soot Filter PM above 90
CRT PM above 90
EGR NOx up to 50
SCR NOx up to 90
PM 20 - 40
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Commercialization
Cummins releasing Hi efficiency Products
2 MW using light miller cycle & adaptive engine controls
1 MW with lower temperature combustion, higher power density, increased turbo efficiency and adaptive engine controls
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Commercialization-Customer
BenefitsCummins Gensets
1750kw 2000kw 1000kw
Improvements
Emissions 0.7 0.5 0.5
(g/HP-hr NOx)
Efficiency 38% 40% 43%
(ISO elec.)
Emissions are reduced 28%
Fuel consumption is reduced 5% and 11.5% respectively
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Biodiesel offers the environmental benefit of renewable energy
Can also help reduce dependency on imported oil
Provides overall emissions advantage with reduced PM, HC, CO and CO2 (production/use cycle basis)
Cummins is working with industry groups to standardize fuel specifications
Cummins supports the responsible production and use of biodiesel
We will use biodiesel in our operations where appropriate and produce products that are capable of operating with biodiesel
Biodiesel must not harm the availability or economics of the global food supply
Rain forests and water are resources that must be sustained
Biodiesel: Environmental Driver
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B20 Approval
Cummins Announces Approval of B20 Biodiesel Blends – March 21, 2007 (everytime.cummins.com)
Approval limited to targeted engines - Additional approvals under evaluation/testing
Requirements specified in Cummins Service Bulletin 3379001Vehicle/equipment OEM’s have their own specific requirements
B20 approved engines:
� On-Highway: ISX, ISM, ISL, ISC and ISB engines certified to EPA '02 and later emissions standards, and ISL, ISC and ISB engines certified to Euro III
� Off-Highway: QSX, QSM, QSL, QSC, QSB6.7 and QSB4.5 engines certified to Tier 3/Stage IIIA, QSM Marine and QSM G-Drive.
� All future products will be compatible with biodiesel B20
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BQ-9000
For North American markets, Cummins Inc. requires that the biodiesel fuel blend be purchased from a BQ-9000 Certified Marketer.
The B100 biodiesel fuel used in the blend must be sourced from a BQ-9000 Accredited Producer.
Certified Marketers and Producers can be found at the following website: http://www.bq-9000.org.
For areas outside of North America, the local Cummins representative must be consulted for applicable fuel quality standards.
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Biodiesel Fuel Storage
Use biodiesel fuel within six months of its manufacture. Biodiesel has poor oxidation stability, which can result in long term storage problems. For this reason, Cummins Inc. does not recommend using biodiesel for low use applications, such as standby power or seasonal applications. Consult your fuel supplier for oxidation stability additives.
The poor oxidation stability qualities of biodiesel can accelerate fuel oxidation in the fuel system, especially at increased ambient temperatures.
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Fuel Water Separation
Biodiesel has a natural affinity to water, and water acceleratesmicrobial growth. Storage tanks must be equipped with a fuel water separator to make sure that water is stripped out before entering the vehicle tank.
Make sure that the vehicle and storage tanks are kept full to reduce the potential for condensation accumulating in the fuel tank.
Due to the solvent nature of biodiesel, and the potential for “cleaning” of the vehicle fuel tank and lines, new fuel filters must be installed when switching to biodiesel on used engines. Fuel filters will need to be replaced at half the standard interval for the next two fuel filter changes.
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Biodiesel Fuel Storage (cont.)
If biodiesel is used for seasonal applications, the engine system must be purged before storage by running the engine on pure diesel fuel for a minimum of 30 minutes.
Care must also be taken when storing biodiesel in bulk storage tanks. All storage and handling systems must
be properly cleaned and maintained. Steps must be taken to minimize moisture and microbial growth in storage tanks. Consult your fuel supplier for assistance in storing and handling biodiesel.
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Capable engine
Quality fuel
Capable Vehicle/ Equipment
Quality blend/ delivery
Successful
Application
B100 Accredited Producers
B20 Certified Marketers, EMA spec
Approved engines onlyApproved Vehicles/ Equipment
Application Requirements,i.e. fuel storage,seasonal use, etc.
Summary – Key Requirements
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All Cummins products are approved for use with B5.
Cummins has completed the necessary testing and evaluations and developed guidance to ensure that customers can reliably operate selected engines with confidence using B20 fuel.
Only B100 biodiesel that meets ASTM 6751 or EN14214 and the EMA B20 blend test specification can be used. There are no specifications to define blends above B20. Recent national audit shows quality is still a big issue in the industry.
Cummins is currently focused on supporting the B20 release and continued validation efforts to approve additional engines.
Critical needs are to improve B100 standards, create B20 standards and improve biodiesel quality.
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William Floyd School District
Prime Movers
2 x 1250 kW @ 13.2 kVNatural Gas1 x 1500 kW @ 13.2 kVDiesel
Heat Recovery
Produces High Grade Hot Water From HT Circuits and Exhaust gas for Space Heating and absorption cooling
Operation
On-Peak Baseload Generation, Parallel with Utility, Island/Standby Capability Diesel Set Used for Summer Curtailable and Maintenance Power
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Acushnet Company / Titleist Ball Plant 2
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Acushnet Company / Titleist
Prime Mover
1 x 2000 kW @ 13.2 kVNatural Gas
Heat Recovery
Produces High Grade Hot Water For Manufacturing and Space Heating From HT & LT Circuits
80 PSI Steam Produced By Exhaust Gas for Manufacturing
Operation
Continuous Baseload Generation, Parallel with Utility, Island/Standby Capability
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Columbus Water Works – Columbus, GA
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Columbus Water Works
Prime Mover
2 x 1750 kW @ 12.47 kV
Dual FuelDigester Gas / Natural Gas
Heat Recovery
Produces High Grade Hot Water For Process Heating From HT & Exhaust Gas.
Low Grade Hot WaterFrom LT Circuit for Grease Tank Heating.
Operation
Continuous Baseload Generation, Parallel with Utility, Island/Standby Capability
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Hazelwood VHP Nursery, Kent, UK� Customer: Nedalo UK (CHP packager/IPP)� 6 x 1.5 MW Cummins QSV91G Gas Gensets� 9.2 MW Electrical Output� 11,58 MW(th) hot water � “Tri-gen”: Uses CO2 for plant growth
� Electrical Efficiency 36.5%� Total Efficiency 80.6%
Benefits� Upgrade for old oil-fired boiler� Liquid CO2 plant food replaced
with SCR-cleaned exhaust� Surplus electricity sold to grid� Lower emissions for electricity
and eliminate fuel and CO2delivery vehicles
Hazelwood Greenhouse, UK