Combined Heat & Power Production: Micro-CHP with Stirling Engine
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1 Combined Heat & Power Production: Micro-CHP with Stirling Engine Activities at Conrad Gähler, SBT, Zug (CH) Smart & Efficient Energy Council, Trento, 2009
2 (SBT) Our key figures Fiscal year 2008 Oct 07 Sept 08 SBT Total Siemens Revenue (mio. euros) 6.0 G Employees 38,500 ca. 500,000 Revenue Employees Europe CIS, Africa 60% Americas 33% Europe CIS, Africa 54% 54% 36% Americas 36% Asia, Australia Middle East 7% Asia, Australia, Middle East 10% 2 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
3 Building Technologies Areas of activity Security Fire Safety Building Automation Energy Efficiency Electrical Installation Total Building Solutions 3 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
4 BT Comfort at a glance Energy Efficiency Components for the Smart Building Boilers Chillers Lighting BACS Wind Solar Heat Pump(3 (4) Heat & Power ) Solutions Services Value Added Partners Resellers & Installers OEMs Regional companies Products & Systems HQ / production sites 4 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Just renamed from HVAC Products to Control Products and Siemens Systems Copyright
5 Agenda 1 Introduction 2 Trends in building control (HVAC+) 3 Siemens Micro-CHP Control System (MCS) 4 Micro-CHP: Research 5 Questions & Answers 5 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
6 Trends (1) Alternative energy sources, Renewables Trend to fragmentation & renewable in residential buildings Key trends & findings High Efficiency Wall Hung Boiler Wall Hung Boiler Floor Standing Boiler Heat Pump & Biogas Micro Co Heat Directives for energy- & emission reduction less heating needed Shift from oil & gas towards renewable energies Demand based heating, cooling and ventilation 80th and 90th Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
7 Trends (2) Integrating more than HVAC Automating the Room Shaping the future! Energy Management & Monitoring Smart Grid & Smart Metering Energy Storage Intelligent facades Air Quality IT & Communication µc Heat Pumps Mastering the Core 7 Oct 2009 Micro CHP Thermal Solar Photovoltaic Managing alternative Energies C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
8 Trends (3) Energy efficiency Laws, regulations, committments of communities and companies public opinion / image Desigo Building Management System: Monitoring, TABS Low exergy, Additional functionality in next release Better quantification of energetic benefit of control functions convince planners, owners, operators, and users to ask for the best available technology need for approved results for standard cases; simulation tools that can cope with innovative technology; norms... Mentioned in all printed matters 8 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
9 Agenda 1 Introduction 2 Trends in building control (HVAC+) 3 Siemens Micro-CHP Control System (MCS) 4 Micro-CHP: Research 5 Questions & Answers 9 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
10 Micro-CHP: The power plant in the own house 10 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
11 Micro-CHP Energy flow, principle Author Losses Heat exchanger Heat Fuel (gas) CHP appliance Generator Electric energy Oct C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Schweiz AG 2006 Building Technologies / HVAC Products
12 Micro-CHP Comparison of energy flows Conventional house House with m-chp unit Author Oct C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Schweiz AG 2006 Building Technologies / HVAC Products
13 Stirling engine: Operating principle and key advantages Key advantages of SE: External combustion clean exhaust gases Frequent start/stopps ok (comparing to fuel cell) Linear arrangement: Running at 50Hz no inverter needed No moving seals maintenance-free for whole lifetime The EU considers domestic heat generation with Stirling-based CHP as one of the most promising technologies to save CO2 in a mid timeline support (Taxes, feed-in tariffs) can be expected Oct C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Schweiz AG 2006 Building Technologies / HVAC Products Author
14 Micro CHP: Stirling Engine & Generator Generator Stirling engine Cooling water Burner flame Author Oct C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Schweiz AG 2006 Building Technologies / HVAC Products
15 Micro CHP product development: Partners Microgen Stirling Engine Consortium MEC: European boiler manufacturers: Remeha, Baxi, and others Pel: 1 kw Pth: 6 kw kw Large field tests 2009 Market introduction 2010 USPs of Siemens solution Complete solution: Automatic firing device (gas valve, ignition...), control (heat production, consumers), grid supervision Homogeneous product range for mchp, conv. Boilers, heat pumps, solar, wood, 15 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
16 Generator running at 50Hz no inverter needed micro CHP System Architecture DHW: Storage or Combi Up to 3 heating circuits, more with additional controllers Additional part for m-chp Standard BMU Optional: Buffer storage Author Oct C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Schweiz AG 2006 Building Technologies / HVAC Products
17 micro CHP Grid supervision The electric grid must be supervised Generator must be disconnected from the grid very quickly in case of Over-/undervoltage Over-/underfrequency Missing grid ( Islanded operation currently not supported) Hardware by Siemens A&D Norms are country specific: GB, NL, G83/1 single measurement D, A, CH, F VDE redundant measurement Author Oct C. Gähler: Micro-CHP with Stirling Engine. SEEC 09 Schweiz AG 2006 Building Technologies / HVAC Products
18 MCS: Controller tasks & challenges SuppBu EngBu Supply air flow TBoiler THead To be optimised Minimize SuppBu operation Maximize EngBu operation Without too many starts/stopps! See next topic (Model Predictive Control)! Stirling Engine (6kWth, 1kWel), Supp Burner (10..30kW) 2 Gas valves, ignition; Grid connection and supervision; boiler pump, DHW div. valve Modulate burner power via supply air mass flow To be controlled: THead (500 C), TBoiler (according to heat demand, e.g. 55 C) 18 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
19 MCS: Model-based design with Simulink Controller (Heat production) Plant model: Stirling + SuppBu + Hydraulics (+ consumers) Quant + dead times measurements Scope 19 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
20 MCS: Simulation results 6: Supp Burner ein 8: Supp Burner off 12: ca. 30 Pulses per hour, is ok 1: Engine on 2: Generator connected 10a: Supp Burner ein 3: THead controlled very nicely! 4: Fan drives EngBu back 9: Due to overshoot of TBoiler, THeadSp is reduced. Is this reasonable? Point to discuss! 11: Modulation of supp Bu is enabled after nach 10 Min 5: TBoiler remains below setp 7: TBoiler overshoots due to min heat output of SuppBu 10: Step of TBoiler setp 60 C 20 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
21 Comparison of workflows Functional specification (requirements) Functional specification (requirements) SW-Spec HVAC Manual Coding Simulink-Model =verified SW-Spec: Proof of control quality etc. Classical Implementation Device test (=Test Regelgerät) Module test Model-based design (Simulink) Code- Generation Module test Integration in appliance, at customer (England) Integration with engine, at customers (England) Device test Control problems become apparent only here Hardware-in-the-loop test Classical: Difficult to see what to change in case of problems Controller design with Simu: In case of problers with real HW: Good understanding targetted improvements possible Worked at once without changing one single parameter change! With Code generation: Changes can be made very quickly & reliably in test phase! 21 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
22 Agenda 1 Introduction 2 Trends in building control (HVAC+) 3 Siemens Micro-CHP Control System (MCS) 4 Micro-CHP: Research 5 Questions & Answers 22 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
23 Optimal control of mchp building energy system with model predictive control (MPC) Control signals Loads and climate 23 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
24 Optimization method: Performance bound with Model Predictive Control 1. The control must satisfy the requirements for room &DHW temperature PE-optimal control Cost-optimal control 2. We assume perfect a-priori knowledge of System dynamics Future wheather, hot-water draws etc. 3. We compute the best theoretically possible operation strategy with Model predictive control (MPC) Linear programming (LP) 4. This result is called performance bound 24 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
25 Focus / Questions Control strategy: What do cost- and PE-optimal operations look like? Performance assessment: Possible cost and PE savings? Impact of different parameters on optimal control and performance Sizing of Stirling engine Etc. 25 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
26 Optimization constraints; Loads, climate, and tariffs Room temperature Hot water demand Electricity demand Climate, Gas & electricity tariffs: Zurich (Switzerland) 26 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
27 Building types Three types of buildings (Old, WSV95, EnEV2000): 4 apartments, 3 occupants each Floor space = 150 m2 Sizing of SE and SB adapted to building insulation quality Nominal values Old (poor) WSV95 (medium) EnEV2000 (good) Building heat losses [W/K] Building time constant [h] Stirling Eng. heat output (η th =70%) [kw] Stirling Eng. Electr. Power (η el =25%) [kw] Supp burner heat output (η th =95%) [kw] Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
28 Simulation results: Diurnal progression (base case) Building type: Old PE optimization Night setback DHW tank charged in the evening Engine runs through All night Supp burner is used for Morning boost Hot-water draws 28 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
29 Efficiencies Stirling engine: ηel,ref = 25% (as Solo Stirling engine. Microgen has less) Reference plant: η el,ref = 50% Marginal approach, modern CC gas plant with η el,ref = 56% 10% grid losses always attributed to ref plant (import, export, in-house consumption) 29 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
30 Primary energy optimization: Energy flow diagram Optimization criterion: Numbers: MWh, from whole-year simulation WSV95 Performance assessment: Savings: = 20 Rel. Savings: 20 / 87 = 22.9% 30 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
31 Performance assessment: Whole-year simulation results Equivalent foll-load hours: ca. 270d/year 31 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
32 Simulation results: Variation of the sizing of the Stirling Engine Important savings Moderate savings No SE, stronger SB Base case Stronger SE, smaller SB More powerful SE less expensive, less PE consumption but higher investment costs Optimal sizing can be determined by including investment costs 32 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
33 Research Conclusions Method allows to determine possible savings CHP saves 20%-30% money and 20%-25% PE (with assumptions used, e.g. 56% el. Ref. plant, in optimal control operation) Results give hints and benchmark for simpler control strategies Influence of different parameters on optimal control Sizing of Stirling engine, supplementary burner Attractive prices for feed-in electricity help to exploit potential 33 Oct 2009 C. Gähler: Micro-CHP with Stirling Engine. SEEC 09
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