76
ENERGY SOLUTIONS USING NATURAL GAS
ENERGY SOLUTIONS
USING
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 ?
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
Heat
＋
＋
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
25kW
Electricity
60kW
Hot Water
50kW
Waste
15kW
Waste
75kW Fuel
Traditional
57% Total Efficiency
75kW Fuel
25kW
Electricity
Heat Exchanger
60kW
Hot Water
15kW
Waste
CHP
85% Total Efficiency
100kW
Fuel
Why CHP ?Competitiveness in Operating Costs
Why CHP ?
Total Energy Efficiency
70 to 80%
Total Energy Efficiency
43%
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
80%
43%
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.
FUEL
NATURAL GAS
GAS TURBINE
GENERATOR SET
11 kV, 50hZ
C T
INTAKE AIR
STEAM
HEADER
HEAT RECOVERY STEAM
GENERATOR (HRSG)
CHP – Steam Application
C
EXISTING BOILER
SUB-STATION
TNB SUPPLYPLANT
POWER DEMAND
STEAM DEMAND
Economic Analysis
Gas Turbine
Utility Generation Usage Rate Avoided Cost
(RM/hr)
Operation
Cost
(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
TNB
Stand-by
- RM8.70/kW/m
onth
- 58
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
Fuel
(Natural Gas)
Gas Turbine Generator
Exhaust Outlet, 135°C
Filter
Housing
Diverter
Damper
CHP – Hot Air Application
Dryer
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)
FUEL
NATURAL GAS
GAS TURBINE GENERATOR SET
1,250 kW, 11 kV, 50hZ
C T
INTAKE
AIR
400 RT
STEAM
HEADER
HRSG
4.3 t/h
8.5 kg/cm2G,176 °C
CHILLER
(STEAM ABSORPTION
TYPE)
COOLING TOWER
37.6 °C 32 °C
400 + 600 m3/h
C
600 RT
CHP – Chilled Water Application
7°C
12°C
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.
• Capital investment about RM 5,000 / kW.
Micro Turbine
Application in the manufacturing process
for rubber products
INFORMATION
Capacity : 80 kWelectrical and 150 kWthermal
Model: BOWMAN TG80 CG Micro turbine.
Gas Consumption : 26 Sm3/ hour.
Hot Water Production : 3,000 litres/ hour at 80 °C.
Application : To provide electricity and constant hot
water supply for leaching process.
M
Heat
Exchanger
HOT
COLD
Storage
Tank
Drain Pipe
Water Supply
Gas Supply
Hot Water
@ 80 °C
M
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
Cost
(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.
• Capital investment about RM 3,800 / kW.
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.
Gas Consumption : 306 Sm3/ hour.
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.
Gas Consumption : 480 Sm3/ hour.
Application : To provide electricity and steam for
process requirement.
Absorption Chiller
Absorption Chillers – Technology
Absorbent:
Lithium Bromide
Refrigerant:
Water
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
Application in the manufacturing process
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
Application in the manufacturing process
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
(RT)
Operational Cost
(RM/year)
Investment
(RM)
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.
Gas
Engine
A/C
Compressor
Ra
dia
tor
Exhaust H
eat
Exchanger
Heat E
xch
an
ger
Fo
r refrig
era
nt
Wate
r Pu
mp
220V
Water Heater
Storage
Tank
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
PCB
Solenoid Valve
Heat Exchanger
Combustion fan
Outgoing water
thermistor
Exhaust Duct
IMPIANA HOTEL
KLCC
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
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
NG LPG ELEC
RM/HR
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
Infinity – Manifold System
Kuala Lumpur Convention Centre
Infinity – Manifold System
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
A B
C
High Zone
Low Zone
Kitchen
Flow water
Cold water inlet
Manifold units with Storage Tank and building flow & return pipework
Infinity – Manifold & Storage Tank
Gas inletHot water
outlet
65 deg C
Storage
Tank
no burner
or element
Thermostat
set point 65 deg C
Unit preset at 75 deg CFlow Return
Primary pump
Flow & Return
pump
Commercial
Infinity – Manifold & Storage Tank
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;
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 : [email protected]
