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■ Technology and Economics of modern Biogas Engines
■ Technology
and Economics of
modern Biogas
Engines
2 / PL
Who is MWM/Euroasiatic?
What is Biogas?
How to use biogas?
Feasibility Calculation
Conclusions
Agenda
MWM
approx. 1,150 employees worldwide
Operations in more than 60 countries worldwide
More than 140 years of experience in gas
engines
Euroasiatic
More than 425 employees in Indonesia
More than 40 years of experience in energy
applications
Key figures
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1871 1908 1922 1945 1985 2005 2008
The MWM can look back at a tradition lasting over 140 years which has always been accompanied by innovations.
1871 Car inventor Carl Benz set the basis with the foundation of
his "Mechanical Workshop" in Mannheim.
1922 The company split up. The Motoren-Werke Mannheim AG,
formerly Benz, "Stationary Engine Construction” evolved.
1985 Klöckner-Humboldt-Deutz AG took over MWM.
2005 Deutz AG spun off a division known as DEUTZ Power Systems
2007 Deutz sold it to the investment firm of 3i in the fall of 2007.
2008 Re-Branding to MWM
The long-established company MWM
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MWM built up a network of 10 subsidiaries in all main markets
MWM Canada Inc.
MWM of America, Inc.
MWM Energy
España S.A.
MWM France SAS
MWM Benelux B.V.
MWM GmbH
MWM Energy
Hungaria Kf t.
MWM Austria GmbH
DEUTZ Power Systems
(Beijing) Co. Ltd.
MWM Asia-
Pacif ic Pte. Ltd.
MWM Energy
Australia Pty. Ltd.
PT. Euroasiatic
MWM group worldwide
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Euroasiatic – the company
■ Offices Locations
■ Regions of operation
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Core competencies
■ Mono-Generation (Open-Cycle) Systems
■ Co-Generation / Combined Heat & Power (CHP) Systems
■ Tri-Generation / Combined Cooling, Heating & Power (CCHP)
Systems
■ Combined-Cycle Systems
■ Semi-Turn-Key & Full-Turn-Key Services
■ Mains Parallel Operation
■ Island Mode Operation
Euroasiatic – the company
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■ gas engine generating sets: + 108 installations
■ gas turbine generating sets: + 33 plants
■ diesel engine generating sets : + 2,550 sets
■ waste heat recovery systems : + 15 installations
■ oil & gas fired steam boiler plants : + 1,425 plants
■ solid fuel & bio-mass fired steam boiler plants : + 55 plants
■ oil & gas fired thermal oil boiler plants : + 375 plants
■ coal -fired steam boiler plants : + 325 plants
■ coal -fired thermal oil boiler plants : + 50 plants
■ industrial burners & combustion systems : + 2,250 units
■ biogas digester plants + 12 plants
Euroasiatic – the company
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Natural gas fired ( gas turbine & gas engine)
Total installed capacity (2005 – 2009)
■ gas engine generating sets & power plants in mono-generation,
co-generation & tri-generation systems: + 300 MW
■ gas turbine generating sets & power plants in co-generation, tri-
generation & combined-cycle systems: + 200 MW
Euroasiatic – the company
10/PL
Definition: Biogas typically defines a gas resulting from the anaerobic (i.e. absence of O2)
decomposition or fermentation of organic material like:
Sewerage waste (WWTP) sewage gasMunicipal waste or leftovers landfill gas
Liquid manure or dung Energy crops (corn, wheat, grass)
Biogas definition and characteristics
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Hydrolysis step 1
Dissolution of readily biodegradable components
Hydrolysis step 2
Dissolution of persistent
components
Suspension
Chopping-up Methane formation
substrate
supply
saliva
paunch
omasum
abomasum
small/large intestine
digested
substrate
Biogas definition and characteristics
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Biogas definition and characteristics
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Typical composition of Sewage and Landfill Gas
Component [Vol%] min typical max
methane (CH4) 57 65 72
carbon dioxide (CO2) 28 34 43
nitrogen (N2) 0 1 20
Methane number [-] 125 130 135
LCV [kWh/m3] 5,7 6,5 7,0
methane (CH4) 45 50 65
carbon dioxide (CO2) 20 27 45
oxygen (O2) 0 0 10
nitrogen (N2) 10 23 34
Methane number [-] 122 130 135
LCV [kWh/m3] 4,5 5,0 6,5
Biogas definition and characteristics
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CH4
O2
H2S
CO2
Entschweflungseinheit
Desulfurization unit
V
M
TA+
x
Gasanalysator
Gas analyzer
Fermenter
Kühleinheit
Cooling unit
Kondensat-
abscheidung
Moisture strainer
Verdichter
CompressorNacherwärmung
Heating unit
Gasmotor
Gas engine
Kondensat
Condensate
Abwasser + Schlamm
Waste water + sludge
Wasser
Water
Luft
Air
Biogas plant Gas drying CHP-plant
Principle of a gas treatment system
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Desulphurisation options:
■ Scrubbing with aqueous agents /
solvents / suspensions
■ Sorption / linkage on solid particles:
Activated Carbon, Iron Hydroxide
Fe(OH)3
■ Biological scrubbing with
H2S-eating microorganisms
Example: Gas Scrubbing
Example of a gas treatment system for biogas upgrading
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MWM = market leader in Germany
for Sewage / Landfill / Biogas
■ Containerized Genset Modules
from 400 – 2000 kW
or fitted into buildings: > 2 MW
■ Gas Cleaning
• Desulphurisation
• Si-Scrubbing
• etc.
Using Biogas
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With our gensets we can cover a power range from 300kWel up to 50 Mwel for decentralized power production
Electrical output
per genset in KWel
TCG 2032
TCG 2020
TCG 2016
50 Hz Product range gas engines
18 / PL
Gas supply pressureUsing MWM’s turbocharged lean burn combustion system means mixing of gas and air at atmospheric
pressure before compressing this mixture in the turbocharger. Hence only very low biogas pressure at
engine inlet is required, resulting in
• Reduction of investment costs as no compressors is required
• Increase overall plant efficiency (no energizing of compressors required)
Biogas – air mixingWhen using an electronic multi-gas mixer, the system
can be set to a pre-defined starting position depending on the actual gas composition, this allows
• easy and reliable engine start
• run with alternative fuel (propane) until the
biogas process is running on a stable basis and
switching over to biogas operation
Gas mixer regulation system
TEM
Engine optimization
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TEM (Total Electronic Management)
controls the genset by the temperature
of every individual cylinder and protects
it by an anti-knocking control
TEM and the multi-gas mixer enables the
engine to run with fluctuating gas qualities and different gas types like
• Natural gas / CBM / CMM
• Coke oven gas
• Pyrolysis-, syn- and flare gases
• Biogas
This leads to a longer engine lifetime without
additional maintenance costs
Engine optimization: Benefits of an optimized control system
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TEM EVO – main functions
Easily adjustable to local conditions
Convenient remote diagnosis and
remote control
A modular system to govern all auxiliary
functions
Simple and secure operational concept
Wide range of control and monitoring
options
Multiple language documentation and handling
Engine optimization: Benefits of an optimized control system
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It is essential for proper engine
operation to avoid condensation
(= corrosion danger) on the way to
the cylinders.
Measures adopted include
• Mixture cooler temperature has tobe kept as high as possible (>65 C)
• Mixture cooler resistance shall be increased by using tin coated fins
• Crankcase breather has to have a very high water separation capability by adequate size
Engine Optimization: Mixture intake
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Efficiency gain vs. Compression ratio Epsilon (calculated)
Engine Optimization: Combustion Process – compression ratio
From a thermodynamic point of view,
the efficiency of combustion is propor-
tional to the compression ratio of the
engine.
On the other side higher compression
ratio means higher risk of knocking
and consequently higher operational risk.
Since the MN of biogas is approx. 30% higher than natural gas, biogas has a
significantly higher margin against
knocking. This can be used accordingly.
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MWM biogas engines have higher
compression ratio (ε= 15) showing
significant mech. efficiency increase
of approx. 1,2 % up to 1,5 %
It shall also be considered, that higher
efficiency is the result of a better
energy conversion in the combustion
chamber resulting additionally in less
thermal stress to the engine Mech. efficiency increase TCG 2016 from Epsilon 12 to Epsilon 15 (DPS measurements)
Engine Optimization: Combustion Process – compression ratio
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Use of pre-chamber spark plugs arepart of this improvement step. A pre-chamber spark plug consists of specially designed:
• Pre-chamber (1) including the
spark electrode
• Pre-chamber cover (2) with
flame propagation bores
Engine Optimization: Combustion Process – spark plug design
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■ Prechamber volume and bore shape
energizes the mixture to increase flame
propagation
Engine Optimization: Combustion Process – spark plug design
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Engine Optimization: Combustion Process – spark plug design
With the pre-chamber spark plug the required ignition voltage is reduced
by means of approx. 25 %, resulting in an extended plug lifetime
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Engine Optimization: Bearing design and metallurgy
When looking for more corrosion resistant bearings, engine manufacturers have concentrated on using sputter bearings.
This bearings have a very high resistance against corrosion due to its dense surface reached by sputtering of the running surface
Structure grooved bearings (cut view) Structure sputter bearings (cut view)
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Avoiding acidification of the lube oil
resulting from condensation of
combustion products with gas
contaminants is essential for proper
operation. Following strategies have
been developed:
• Operation with high lube oil
temperature
• Keeping lube oil hot during
engine standstill (proper pre-
heating and hydraulic
connection to plant)
• Appropriate ratio of oil volume
to power output on the setOil Lifetime increase vs. Spec. Oil volume
Engine Optimization: Lube oil management
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How much biogas is needed for 1200 kW output?
■ 1200 kWe / 42% (el. eff.) / 5.7 kWh/m³ (assumed LCV biogas) ≈ 502 m³/h
What is needed to generate 500 m³/h in a digester?
■ 20.000 t / a biomass, eg. cornsilage, loppings, green cuts, menure, etc.
■ Effluent from a 35 t/h Fresh Fruit Bunch processing plant (300 d/y, 20 h/d),i.e. approx. 27 t/h or 162.000 t/a effluent
What operating income can be achieved?
■ electricity supply to the grid
■ heat supply (drying process, heating, …)
■ selling of fertilizer
Logistic input, end-substrate (agricultural crop land required)
Example for a 1,200 kW biogas plant:
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Income:
electricity: 6000h x 1200 kW x 975 IDR/kWh = 7,020 jt. IDR
heat: 8000h x 1000 kW x 0 IDR / kWh = 0 jt. IDR
fertilizer (≈ 8% dry matter) 300 IDR/kg = 3,888 jt. IDRΣ 10,908 jt. IDR
Costs:
Invest biogas plant approx = 12,700 jt. IDR
Invest genset approx = 6,246 jt IDR
Working costs =Maintenance (plant): ≈ 2% v. Invest = 250 jt. IDR
Service & maintenance: ≈ 100 IDR/kWh = 720 jt. IDR
Σ 19,916 jt. IDR
Example for a 1,200 kW biogas plant:
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Example for a 1,200 kW biogas plant:
Results:
E N E R G Y with F U T U R E
F U T U R E with E N E R G Y
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Amortisation < 2 years
Secured income
Decoupling from the palm oil market
■ MWM/EA complement its product
portfolio with containers, which are
ready to be installed
■ They will be easily to install and
afford a fast displace, if necessary
MWM / EA products for the use with biogas
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Maintenance
Our concepts( (e.g. Service
contracts), our experts and our
response time make sure that
we meet your demands to our
products at anytime.
Documentation
Modern software enables us to identify spare parts for all MWM engines in use
worldwide, quickly and precisely
Logisticcenter
Optimised processes allow extremly
short leadtime of the parts.the high
ef fciency and f lexibilityt enables to
deliver our customers worldwide
directly: just in time.
Euroasiatic has Spare-part Stocks in
- Singapore
- Jakarta
X-Change Center
Cost & time savings,
we use basic engines and
recycled parts
Service
Worldwide 24-hour support Professional consultancy,
product supervision, quick
guarantee processing
Training Center
Permanent training allows us to monitor and
improve the qualification of our service personnel
Training provided locally
Service
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Conclusions
■ Biogas is a renewable fuel with a special composition which demands proper addressing
in both, plant layout as well as in engine / genset design
■ Biogas has advantages when used in reciprocating engines resulting in improvements
on efficiency and power output (and not only for this gas type)
■ State of the art technology is already making use of this advantages
■ This is a solid support from the industry to the efforts of producing more and more heat
and electricity with renewable fuels in order to achieve the levels of CO2 reduction
expected by the both producers and customers
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Why should I use MWM products from EA?
■ Outstanding electrical efficiency
■ Engines especially designed for the use
of biogas
■ Product portfolio throughout the whole
range of performance (0,4 - 4,3 MWel)
■ Lightweight engines and containers
■ Easily to displace
■ In EA you will find a reliable and experiencedlocal partner for your power generation purposes
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Thank you.
■ Contact:
Peter Langohr
Phone +62 (0) 21 5696 0555
Fax +62 (0) 21 5696 6132E-Mail [email protected]
