coge - ge power | general electric high-efficiency power plant powered by four jenbacher gas engines...

GE Energy gas engines

cogen

Functional Applications as Diverse as Mother NatureCHP technology helps North America achieve its energy and environmental goals

Raising the Bar for Unconventional Gas Applications GE introduces the Waukesha 275GL+ gas engine

Financial Benefits from Federal IncentivesGovernment incentives reward waste heat and renewable utilization

REGION SPECIAL USA

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Dear Customer,

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North America Special cogen

This issue of cogen coincides with the launch of

the Waukesha 275GL+ natural gas engine as an

ecomagination qualified product. On launch day,

September 20, 2011, we are at the Waukesha,

Wisconsin, factory for a comprehensive presentation

on the 275GL+ – including a hands-on view of the lat-

est 12- and 16-cylinder models – to demonstrate their

effectiveness for our oil and gas industry customers.

The high-performance, cleaner-burning 275GL+ is one

of the Waukesha compression technologies that have

enhanced our newly integrated gas engines portfolio,

which includes Jenbacher gas engines, Waukesha gas

engines, and Heat Recovery Solutions. Our business is

focused on providing innovative and reliable solutions

in power generation, gas compression and waste heat

to power to our diverse customers throughout North

America, from small towns like Auburn, New York, to

major metropolitan cities like San Diego, California.

These solutions operate on a broad range of fuel

gases, including low-quality waste gases, and in many

applications, from natural gas processing stations to

dairy farms. In North America, and elsewhere, the

fuel-flexible, highly efficient Jenbacher gas engines

product line’s synergies with the low emissions and

reliability features of the Waukesha gas engines

line create more solutions for the petrochemical,

mining and manufacturing sectors. Our Heat Recovery

Solutions portfolio meets the needs of our gas engines

customers involved in renewable energy who are

converting waste heat to power in smaller-scale

output applications.

Due to the regulatory push at the state and

national levels in the U.S. for more efficient tech-

nologies that have minimal environmental impact,

North America is in an excellent position to take ad-

vantage of the gas engines portfolio that GE offers.

Federal policy, in particular, is providing financial

incentives for innovations like the Clean CycleTM

system that recover waste heat from natural

gas and biogas applications. Additionally, many

regions are offering incentives for customers to

install cogeneration applications. Gas engines

and waste heat recovery are a critical part of

our strategy at GE to lead the global trend of

maximizing energy production while minimizing

greenhouse gas emissions. I am excited to be a

part of it and look forward to working with you

to build the next generation of energy-efficient

products.

Yours sincerely,

Rafael Santana,

president and CEO Gas Engines, GE Energy

North America Special

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Functional Applications as

Diverse as Mother Nature

–> SAN FrANciSco, cAliF., U.S

04


High efficiency, dependability, and the capability to operate on

a wide variety of fuels including natural gas, biogas, landfill gas,

and a host of other fuel sources, are just some of the advantages

offered by GE Energy‘s Gas Engines business‘ combined heat and

power (cHP) plants. Vast resources of natural gas, biogas, and

landfill gas are some of North America‘s greatest advantages,

yet today they remain largely untapped sources of energy.

TAkiNG AdVANTAGE oF THE FAST cHANGiNG World.

GE’s gas engines CHP technology helps North America meet its

ever-increasing demand for electricity from coast to coast by

using the continent’s abundant natural gas resources to generate

power in a wide range of applications – from dairy farms to office

buildings; from small towns to metropolitan cities; from Auburn,

New York, to San Diego, California.

GE’s gas engines CHP technology helps North America meet its ever-increasing

demand for electricity from dairy farms to office buildings;

from small towns to metropolitan cities; from Auburn, New York, to San Diego, California.

MEETiNG PoWEr dEMANdS…ANd ENViroNMENTAl

rEqUirEMENTS. GE’s gas engines CHP plants are supplying

onsite heat and power to more than 450 facilities across North

America, including hospitals, universities, farms, and green-

houses. And because CHP (also known as cogeneration) plants

are inherently more energy efficient than using separate systems

to create heat and power, the plants generate power while using

less fuel and reducing environmental effects in the process. GE’s

CHP plants meet power demand while also meeting increasingly

stringent environmental standards and Environmental Protection

Agency (EPA) regulations, helping North America toward its long-

term goals of reducing emissions from power production.

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North America Special

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rEAl World rESUlTS – TrANSForMiNG lANdFill GAS iNTo

ENErGy. Using GE’s advanced gas engines CHP technology, a

Missouri correctional facility is transforming waste gas from a

nearby landfill into 3.2 MW of power to provide electricity and

heat for site operations. Generating power from this previously

unused fuel source produces enough energy annually to power

1,900 homes and heat water for 1,400 homes while reducing CO2

emissions equivalent to removing nearly 3,800 automobiles from

American roads. Missouri Governor Jay Nixon stated, “This project

creates a cleaner, reliable, and consistent source of energy from

a naturally occurring by-product of our landfills. I commend this

innovative partnership for the benefits it will bring our economy,

environment, and communities.” 1

A GrEENHoUSE USES cHP To MAkE GrEENEr ENErGy.

A high-efficiency power plant powered by four Jenbacher gas

engines cogeneration modules is providing onsite power and

heat, along with a ready supply of CO2 to fertilize the facility’s

tomato crop, to a 55-acre tomato greenhouse complex operated

by Great Northern Hydroponics, a division of Detroit-based Soave

Enterprises, in Ontario, Canada. In addition to generating power

and heat for greenhouse operations, the plant also treats the gas

engines’ exhaust, enabling CO2 from the exhaust to be recycled

and used as fertilizer to enhance greenhouse crop production.

Surplus power from the greenhouse power plant is being sold to

the local grid under a contract with the Ontario Power

Authority, and the plant supplies enough electricity to power

12,000 – 15,000 Canadian homes annually.

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The tomato greenhouse complex in Ontario, Canada, also treats the gas engines’

exhaust, enabling CO2 from the exhaust to be recycled and used as fertilizer to enhance greenhouse crop production.

The 12 MW plant operates at greater than 90 percent

overall efficiency, and is one of seven Ontario Power Authority

projects intended to demonstrate how advanced cogeneration

technologies can lead to energy independence and improved

grid reliability, and can support Canada’s clean energy goals.

“Our first-ever greenhouse cogeneration project was made

possible because of Ontario’s commitment to energy efficiency

and national initiatives to add significant amounts of energy from

cogeneration to the provincial power grid,” said Guido van het

Hof, president of Great Northern Hydroponics.

06


facts and figures:

• High electrical efficiencies up to 48.7 percent

• overall efficiency (electrical and thermal) up to 90 percent

• Wide range of power and heat outputs

• reduced co2 emissions

• compact design, small footprint

• Gas engines operate on alternative energy sources

• Enhanced operational safety and availability

• low investment costs

regional sales leader

for GE’s Gas Engines

business in North America

roGEr GEorGE

THE FiGUrES SPEAk For THEMSElVES.

“With overall efficiencies up to 90 percent and the ability to

convert fuel into cleaner energy in a variety of applications, GE’s

gas engines CHP plants have proven to be tailor-made for helping

North America achieve its energy and environmental goals,” said

Roger George, regional sales leader for GE’s Gas Engines business

in North America. “The figures speak for themselves.”

“GE’s gas engines CHP plants have proven to be tailor-made for helping North America achieve its energy and environmental goals,”

said Roger George, regional sales leader for GE’s Gas Engines

business in North America.

–> GE’S GAS ENGiNES cHP PlANTS rANGE FroM 0.25 MW To 9.5 MW

source:

1 http://www.republicservices.com/pr-32.html

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North America Specialcogen

Raising the Bar for Unconventional Gas ApplicationsGE introduces the Waukesha 275Gl+ gas engine, demonstrating expertise in compression, oilfield power generation

and mechanical drive applications, and strengthening the competitive position of GE’s Gas Engines business in the

emerging unconventional gas space.

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THE 275Gl+ AddS To THE TrAdiTioN. Sometimes it takes a

new technology to meet unconventional needs, and the 275GL+

is just that. The 275GL+ represents the combination of outstand-

ing engine design with over 80 years of Waukesha experience in

manufacturing engines for the oil and gas industry.

The 275GL+ boasts the most horsepower, the best fuel efficiency

and flexibility, and the lowest emission levels in its class. The

combination of reduced environmental emissions and high

performance qualify the 275GL+ as an ecomagination product –

the first product from the Waukesha gas engines line to achieve

such status.

The 275GL+ boasts the most horsepower, the best fuel efficiency and flexibility,

and the lowest emission levels in its class.

rEliAblE EVEN iN UNForGiViNG ENViroNMENTS. The

high performance 275GL+ is designed to drive natural gas

compressors and generators in harsh environments. The

275GL+ can operate on raw, untreated gas extracted at produc-

tion sites, which reduces customers’ operating costs by limiting

(or eliminating) the need for the transportation, storage and

treatment of fuel. In addition to running on fuels of varying

quality, gas compression site operators also require powerful,

reliable and fuel-efficient engines that operate around the clock

in challenging conditions with low emissions and long main-

tenance intervals. Designing all of these performance require-

ments into a single solution is certainly a technical challenge,

but the 275GL+ addresses these sometimes competing priorities

while delivering increased revenues for owner and operators. The

275GL+ meets these demands with no trade-offs, as it delivers

all-around performance, including improved fuel tolerance and

efficiency, more horsepower in a wider range of conditions, and

lower emissions. With its low NOx capability, the 275GL+ meets

the current 0.5 g/bhp-hr NOx requirement for non-attainment

areas and the EPA’s 2010 Spark-Ignited New Source Performance

Standard requirements of 0.5 g/bhp-hr NOx and 1.8 g/bhp-hr CO.

UNcoNVENTioNAl GAS – A kEy FUEl SoUrcE For TodAy, ANd

ToMorroW. The technology behind the 275GL+ illustrates

GE Energy’s unwavering global commitment to provide advanced,

innovative solutions to meet our customers’ most pressing opera-

tional and environmental challenges.

“The advanced technology behind the 275GL+ demonstrates the expertise and innovation of the Waukesha product line in compression, oilfield power generation and

mechanical drive applications for the oil and gas industry.”

– Brian White, president of Waukesha gas engines

Brian White, president of Waukesha gas engines, explains,

“Unconventional gas is one of the key sources of gas in North

America and successful engine performance at these sites is all

about application flexibility.

08



09

–> UNcoNVENTioNAl GAS iS A kEy PoWEr SoUrcE iN NorTH AMEricA

10


President

of Waukesha gas engines

briAN WHiTE

It’s about being able to maximize power output on a wide range

of fuel quality and composition, from 750 Btu/ft3 in the Canadian

Horn River area to over 1200 Btu/ft3 in the Marcellus and Eagle

Ford shale plays in the United States. It’s about meeting ever-

tighter emission requirements as gas compression sites move

closer to larger population centers.”

“The 275GL+ allows our customers to maximize their revenues and positions

them to successfully meet the growing demand for energy

and the production, transportation and storage of unconventional gas.”

– Brian White, president of Waukesha gas engines

As an example of how 275GL+ technology is being applied in

unconventional gas projects, GE recently sold three 12-cylinder

12V 275GL+ models into a coal seam methane application at the

Kenya production site near Queensland, Australia. This project

represents the first time Waukesha and Jenbacher gas engines

are being jointly deployed as a groundbreaking integrated

solution to provide compression and onsite power generation

in the same project. The Kenya project will be strategically

crucial to positioning the Australian site as a global supplier

of liquefied natural gas.

facts and figures:

• 16-cylinder16V275GL+,4,835hpat1,000rpm

• 12-cylinder12V275GL+,3,625hpat1,000rpm

• 2percenthorsepoweradvantageincreases

gasthroughputby920millionscfperyear,

creatingadditionalannualrevenueof

$3.6millionatawellheadpriceof

$3.90/1,000ft3

• 1.2percentfuelefficiencyadvantageand

lowerCO2emissionsreducecarbonfootprint

by9percent.Greenhousegasemissions

advantageisequivalenttoremoving380cars

fromU.S.roadsannually

• 1.2percentgreaterfuelefficiencysaves

3.3millionscfofnaturalgasperyear,enough

topower46averageU.S.homesannually

11

AdAPTiNG orc TEcHNoloGy To SMAllEr-ScAlE

APPlicATioNS. The Clean Cycle system is an adaptation of the

Organic Rankine Cycle (ORC), a process that operates like a steam

power plant, but with a working fluid that has a much lower

boiling point than water. This allows the Clean Cycle system to

generate electricity from waste heat as cool as 250°F (121°C).

The working principle is basic: An evaporator captures waste heat

that converts the high pressure working fluid from liquid to vapor.

This high pressure vapor is expanded over a turbine coupled to

a generator, which produces electricity. Then the vapor is cooled

back into liquid form to be used again in the process. For decades,

ORCs have been applied to very large industrial projects, but the

vast majority of wasted heat – worth billions of dollars – has been

emitted from smaller sites by machines such as reciprocating

engines, gas turbines and biomass boilers. Now, the Clean Cycle

waste heat-to-power generation system makes it possible to har-

vest the low temperature heat from these applications and turn it

into 125 kW of power that can be used onsite or sold back to the

grid. In many applications, the solution can pay for itself within

18-to-36 months, and since it requires no fuel, the Clean Cycle

system generates energy with no additional emissions or fuel.

For decades the vast majority of wasted heat – estimated to be worth billions of

dollars – has been emitted from smaller sites by machines such as reciprocating engines,

gas turbines and biomass boilers.

The charter product in GE’s Heat recovery Solutions portfolio, the clean cycle™ system provides innovative

technology for capturing waste heat from small-scale applications and converting it into electricity providing

a significant source of additional revenue.


U.S. Customers Can Reap SignificantFinancial Benefits from Federal Incentives

biG FEdErAl iNcENTiVES For WASTE HEAT rEcoVEry.

Aside from the technology’s distinct operational advantages,

Clean Cycle customers in the U.S. can reap significant financial

benefits from federal incentives that reward waste heat and

renewable utilization. These include 100 percent depreciation

of the capital costs in the first year for a 2011 installation – or

50 percent depreciation if the project is installed in 2012;

an investment grant covering 30 percent of capital costs for

renewable energy projects that generate more than 150 kW

(if some of the construction occurs in 2011); and a $0.022/kWh

production incentive for qualified renewable energy projects –

including biomass facilities – that generate electricity

before 2016.

12


–> GoVErNMENT iNcENTiVES rEWArd bioMASS FAciliTiES To ENcoUrAGE WASTE HEAT UTilizATioN

1513

Clean Cycle customers in the U.S. can reap significant financial

benefits from government incentives that reward waste heat

and renewable utilization.

Many states in the U.S. also have their own

grants and other incentives to encourage waste

heat recovery. 33 states now have renewable

portfolio standards that compel operators to

generate set percentages of electricity from

renewables, and 13 states qualify waste heat

as cleaner energy.

AlTErATioNS iMProVE orc FUNcTioNAliTy.

The Heat Recovery Solutions segment has im-

proved upon the standard Rankine Cycle process

so that it can be applied to smaller-footprint

plants and applications such as reciprocating

engines, gas turbines and biomass boilers, and

still generate up to 125 kW per unit. This involves

three major changes.

• An Integrated Power Module (IPM) housing

the high-speed turbine and generator

contains highly-efficient magnetic bearings

that allow the shaft to spin in a magnetic field

instead of riding on a mechanical bearing.

President

Heat recovery Solutions

brAd GArNEr


This reduces friction losses – and the need

for expensive-to-maintain lubrication systems

– and signifcantly improves reliability.

• Once the IPM generates raw power,

sophisticated power electronics convert

it into usable electricity with the same

frequency and voltage as the connected

grid – without the gearboxes or mechanical

step-down techniques that can produce

parasitic losses and operating issues. A

constant power factor of 1 makes costly

capacitors unnecessary.

• While most ORC working fluids are hazard-

ous, the Clean Cycle system uses a hydro-

fluorocarbon that is not flamable and

minimizes the environmental effects.

SyNErGiES crEATE NEW bUSiNESS oPPor-

TUNiTiES. “Since Clean Cycle is such an ideal

complement to GE’s gas engines technology

portfolio, it will be a catalyst for innovative

integrated solutions that drive business growth,”

proclaims Brad Garner, president of Heat

Recovery Solutions. Indeed, the flagship offering

of Heat Recovery Solutions segment can grow

GE’s global renewable energy footprint precisely

because of its synergies with the highly efficient

power generation capabilities of Jenbacher and

Waukesha gas engines.

“Clean Cycle …is a catalyst for innovative integrated

product solutions that drive business growth.”

– Brad Garner, president of Heat Recovery Solutions

A textbook example of that is GE’s newly

announced collaboration with the Italian-based

cogeneration systems provider AB Group. Over

the next three years, GE will provide a large

number of Clean Cycle units to combine with

AB Group’s existing Jenbacher J416 gas engines

in a packaged solution that will generate 10

percent more electricity, improve plant electrical

efficiency to 45 percent total output, decrease

biomass usage in combined heat and power

applications by 10 percent, and lower nitrogen

oxide (NOx) and carbon monoxide (CO) emissions.

–> AN AGricUlTUrAl ENTErPriSE iN THE STATE oF MicHiGAN, U.S.

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MASTHEAd

Publisher: GE Jenbacher GmbH & Co OHG, Achenseestr. 1-3, 6200 Jenbach, AustriaEditorial team: Nancy Deptolla, Robert L. DiCocco, Sheila Gailloreto, John Lerch, Shonodeep Modak,Debra Murphy, Anja Pegger, Ray Pelosi, Susanne Reicheltdesign and layout: Zimmermann Pupp WerbeagenturPrinter: Welch Printing, Louisville, Ky., U.SPicture credits: GE Energy

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