Gasmotoren, Trends und Möglichkeiten

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1 Gasmotoren, Trends und Möglichkeiten Stefan Reuß Senior Program Manager Gas engines June 6 th 2014 Imagination at work.

2 Agenda GE - - Product Portfolio Trends - Age of Gas - Drive for efficiency - Big Data Gas Engine Technology - Efficiency development - Areas of improvement - Outlook & trade offs Intuition - Case study 2

3 GE s portfolio structured for growth 8 businesses operating in more than 100 countries 125+ years >300,000 employees worldwide 2012 revenue $147.4B Power & Water $28.3B Oil & Gas $14.9B Energy Management $7.5B 2012 Revenue Aviation $19.7B Healthcare $18.3B Transportation $5.6B Home & Business Solutions $7.9B GE Capital $45.2B PG Products PG Services Renewables Water Aeroderivatives Jenbacher Waukesha Nuclear Drilling & Surface Digital Energy Global Services Power Measurement Conversion & Control Industrial PII Pipeline Systems Solutions Subsea Systems Turbomachinery Commercial Military Service Avionics/ Systems Healthcare Systems Life Sciences Healthcare IT Molecular Diagnostics Locomotives Services Propulsion Systems Appliances Lighting Intelligent Platforms Commercial Consumer Real Estate GECAS EFS 3

4 Headquarters in Cincinnati, Ohio, USA: ~ 4,500 employees 35,000 engines Power Generation Jenbacher, Waukesha Gas Comp/Mech Drive Waukesha Power/Mech Drive Aeroderivatives Electrical output: 120 9,500 kw Electrical efficiency up to 48.7%, overall efficiency up to 95% 20,500+ engines delivered, 21,800 MW power globally Natural gas and CHP, excellence in special gas applications (biogas, landfill gas, coal mine gas, blast furnace gas), oilfield power Output: 160 bop 4,835 bhp (119 kw 3,605 kw) 12,000+ compression engines delivered, over 13.2 million bhp power globally (9,850 MW) Wellhead, gathering, storage/transmission 18MW 100MW turbines and packages 2,350+ units installed, more than 93 million operating hours Compression, Power Gen, Mechanical Drive, Cogen, CHP Rental power: rapid deployment. Gas turbine solutions Global services covering all offerings 4

5 product range MW 5-25MW 25-50MW 50MW 100MW Power Gen Type kW Type 3 500kW 1MW Type 4 800kW-1.6MW Type MW J920 FleXtra 9.5 MW LM MW LM MW LMS MW VGF kW VHP 270kW-1.5MW APG MW 275GL MW Mech drive / O&G / Mining / Marine VGF kW VHP 270kW-1.5MW 275GL MW LM MW LM MW Mobile/ Emergency Power J320 Gas engine generator set 1MW 12V228 Diesel engine generator set 2MW TM2500 Gas turbine generator set 22-31MW 5

6 Innovative gas engine technology st gas engine st cogeneration module st LEANOX gas engine st 20 cylinder gas engine J World s smallest 20 cylinder gas engine in the 3 MW power range J Presentation of High Efficiency Concept J World s 1 st 24-cylinder 4 MW engine J World s 1st 2-Stage- Turbocharged gas engine and 1st gas engine with ORC Introduction of Jenbacher J920 FleXtra 2011 Launch of Clean Cycle* 125 kw utilizing waste heat for energy production 2013 Building one Distributed Power business together with Waukesha gas engines and Aeroderivative gas turbines product lines 6

7 Jenbacher product portfolio 12,000+ engines delivered Operating in 100+ countries Jenbacher Type 2 Electrical output: kw (50 Hz), 335 kw (60 Hz) V8 cylinder 1,500 rpm (50Hz) 1,800 rpm (60Hz) Delivered engines: ~ 990 Since 1976 in the product program Jenbacher Jenbacher Type Electrical output: 526-1,063 kw (50 Hz), 633-1,059 kw (60 Hz) V12, V16 and V20 cylinder 1,500 rpm (50 Hz) 1,800 rpm (60 Hz) Delivered engines: ~ 6,530 Since 1988 in the product program Jenbacher Type Electrical output: 844-1,562 kw (50 Hz), 852-1,421 kw (60 Hz) V12, V16 and V20 cylinder 1,500 rpm (50 Hz) 1,800 rpm (60 Hz) Delivered engines: ~1,340 Since 2002 in the product program Type Electrical output: 1,639-4,491 kw (50 Hz) 1,622-4,335 kw (60 Hz) V12, V16, V20 and V24 cylinder 1,500 rpm (50 Hz, 60 Hz with gear-box) Delivered engines: ~3,000 Since 1989 in the product program Jenbacher Type Electrical output: 9,500 kw (50 Hz), 8,550 kw (60 Hz) V20 cylinder Electrical efficiency: 48.7% Total efficiency: 90% 1,000 rpm (50 Hz), 900 rpm (60 Hz) 9 7

8 Trends Age of gas Drive for efficiency Big Data or the industrial internet 8

9 Natural Gas outlook U.S dry natural gas production by source, (trillion cubic feet) Shares of primary energy Natural gas production will increase by 85% over the outlook periode. - Inter-regional pipelines grow by 3.0% p.a. - Shale gas production up by 7.0% p.a. - LNG distribution grows by 4.3% p.a. 30% of gas production will be used for power generation. Global Electricity demand will grow by 85% over the Outlook periode 150% in Non-OECD countries 2x of Gas Power Generation by

10 Big Data Cost of sensor dropped Cost of computing dropped Smart grid Smart power generation Predictive analytics Robust cyber security Raise of predictivity and the industrial internet 10

11 Level of integration From Solution Optimize How can I reach my system s fullest potential? Optimize enterprise throughput Predict How can I create a predictable operation? Connect people, processes, and equipment for optimization Analyze How should I maintain my assets? Eliminate Unplanned Downtime Monitor How are my assets behaving? Monitor Asset Health and Uptime To Intuition Reactive predictive fully integrated smart power generation 11

12 TSO requirements ( e.g. BDEW ENTSOE ) Static grid support: Defined voltage and frequency range. Must stay on grid Dynamic grid support: fault ride through capability 30% / 150ms Reactive current supply Certifications: Genset certificate from supplier Power plant certificate from customer Challenge for manufacturer: country / TSO specific requirements 12

13 Gas engine contributes to grid stability Transmission system requirements Active Power Stability Voltage Stability Positive reserve Negative reserve Primary and secondary reserve Reactive Power Control - Cosphi Interface to transmission system operator is challenge 13

14 Efficiency The Intergovernmental Panel on Climate Change (IPCC) has recognized the key role played by combined heat and power (CHP) in reducing greenhouse gas emissions from energy supply When doe we hit 50% electrical efficiency can we reach >90% total? 14

15 CHP installed capacity and share Installed CHP capacity (GWe) CHP share of total national power World 10% 310 GWe for 40 countries Very limited data for Africa, LATAM where CHP non significant USA: 85GW, EEU: 67GW, Russia 65GW World share: 10% ( US share) Denmark and Finland, world leaders (40-50%) Russia both in top 3 for generation and share Source: IEA data and analysis;

16 Gas engine technology 16

17 Customer demands & related challenges OPEX Fuel cost Maintenance cost Uptime Availability Reliability CAPEX Investment gas engine Efficiency Knock suppression Thermal stress Lower service cost Parts life time RM&D Lower specific costs Power density Mechanical stress 17

18 CoE impact 3cts/kWh cost from investment: gas cost IPP 3 cts/kwh service CoE impact 1,5cts/kWh cost from investment: gas cost IPP 1,5cts/kWh service Gas cost drives cost of electricity +1%ppt el. Eff 50k savings in gas cost per year* 18

19 Wirkungsgrad des vollkommenen Motors v [%] Efficiency - basics Ottomotoren ,6 1,4 1,2 Gleichraum, Saugmotor 100% 50% 45% heat 10% losses Real combustion Heat transfer Mecanical Gas exchange 45 0, ,8 45% electrical Verdichtungsverhältnis [-] 1. Increase compression ratio challenge knocking 2. Increase lambda challenge ignition 3. Reduce losses challenge friction & scavenging 19

20 Specific engine output Miss firing The knock & ignition-challenges Miller Ignition BMEP power density Knocking knocking GE Jenbacher Operating Point Power density drives efficiency Air fuel ratio drives Nox Technologies required 1) Knock supression 2) Ignition technology Air / fuel ratio =1 = Stoichiometric Stoichiom. ~1,8-~2,3 Air/Fuel Ratio Direct ignition Lean burn engines 20

21 Combining technologies Increase TC efficiency Increased boost pressure Enhanced Miller timing (cooling) Increase knocking margins Output and efficiency increase Steel piston / spark plug / Increased part life time Pre chamber ignition concept Accelerated ignition 21

22 Or increased flexibility 500m altitude + 40 C Ambient temperature 40 C Mixture cooling CHP 22

23 Intuition Title or Job Number XX Month 201X GE Business Unit Name 23

24 BHKW Stapelfeld J920 + Wärmepumpe BHKW*) BHKW + WP*) Pth [kwth] WP_Pel ~ -105 [kwel] Pel_net [kwel] eta_el 48% 47,3% [%] eta_th 45,5% 49,0% [%] eta_ge 93,5% 96,3% 60/105 C Besonderheiten 2-stufige Aufladung 2-Stufige ÖL-WT 3-stufiger AWT Keine NT-Stufe für Gemisch *) Zielwerte Stromkennzahl > 1 24

25 Danke!

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