Top Technology for Industry, Agriculture, Business and Communities

Top Technology for Industry, Agriculture, Business and Communities

CHP The Technology with a Potential for Saving Energy Combined Heat and Power (CHP) is a highly efficient technology for the conversion of energy. CHP is defined as the simultaneous conversion of a primary energy source into power and heat. This method of generating energy guarantees the greatest possible exploitation of fuel energy and a reduction of energy losses to below 20 %. It is hardly possible for a fuel to be implemented more efficiently. For example, industries require not only low temperature heat energy, they also require large amounts of power, mechanical energy and process heat. More and more industrial organisations recognise increasing energy costs as a serious danger to their competitive position. Increasing energy costs are always a motivator for the economic application of a CHP plant. From Micro to Maxi: QiP with a Micro Gas Turbine. CHP plants with micro gas turbines achieve the highest energy efficiencies. The multiple fuel choices and the environmentally compatible production of heat, cooling and power are additional advantages. These characteristics of an energy efficient production process provide the CHP operator with decisive competitive advantages. CHP technologies, such as QiP (Quality in Power) as supplied by Babcock Borsig Steinmüller, are decentralised, reliable energy supply systems for industries, agriculture, business, trade and communities. QiP is an attractive solution for both new plants as well as for the modernisation and expansion of existing facilities. Almost the only thing that matters: Economics. QiP CHP plants with micro gas turbines are characterised by their extremely low maintenance requirements, their environmental compatibility as well as their economics. The longer the plant operates at full load, the better the investment costs can be amortised over the added heat and power production. Energy costs and the plant amortisation period are thereby reduced. For this reason, CHP plants are often designed to cover base load heat requirements: The more heat used, especially in the summer months for warm water or cooling/ cryogenics, the higher the efficiency of the plant. In Germany, tax relief can be claimed in the event the annual utilisation factor reaches 60 % (basis for mineral oil tax), respectively 70 % (basis for environmental tax). In addition, the power production from a plant producing up to 2 MW is free of tax. With QiP, plant operators profit from a system, which simultaneously produces power and heat at high efficiencies and in the immediate vicinity of the user. By this means, plant operating costs can be managed exactly according to user requirements. Everything Green: Energy Efficiency and Environmentally Conscious. QiP supports the thrifty use of primary energy and the optimisation of resource utilisation. The use of a CHP plant with a micro gas turbine results in a major reduction of emission of environmental pollutants, such as NO x and CO. In comparison with other combustion processes using natural gas, e.g. a modern condensing boiler green house gas emissions during power generation are reduced by between 70 to 80 % and during heat production by approx. 66 %. QiP is very flexible: The range of fuels which can be used is far wider than almost any other energy production technology and, thanks to the simultaneous production of heat, cooling and power, the range of possible applications is correspondingly extensive.

More than one advantage: Arguments in favour of a QiP plant QiP takes advantage of all the innovative micro gas turbine technology, such as, compact design with a noise absorbing enclosure, efficient recuperator technology and the modern burner system, with which extremely low pollutant emissions are achieved. Compared with combustion engines, the micro gas turbine has a much lower service requirement. All rotating components are mounted on a single shaft. The air bearing system eliminates the necessity of lubricating oil. The first inspection is required only after 8,000 operating hours and the first maintenance after 40,000 operating hours, which corresponds to approx. 5 years continuous operation. The advantages of a QiP CHP plant can be summarised as follows:. Reliable, modern and low emission technology Cost efficient and economic plant operation Supply security thanks to decentralised power production High availability with minimum down-time Short plant amortisation period Long lifetime Low service costs and long service intervals (air bearings, single shaft machine) Efficient fuel utilisation and corresponding low resource consumption Wide fuel range Constant, high exhaust temperature of approx. 300 C Constant overall efficiency over a wide power range Environmentally friendly operation with extremely low emission levels (NOx, CO) Low noise emissions Use of renewable energy possible Compact, low weight (no foundation necessary) Compact design with low maintenance requirement Optimum integration into existing facilities (The QiP Plug & Use-Principle) Possible tax relief depending on plant utilisation factor

Controlled Circuits: How the micro gas turbine functions Micro gas turbines are small, high-speed turbines with low combustion chamber pressures and temperatures for electrical powers of up to approx. 350 kw. QiP is a single-shaft machine, i.e. the generator, compressor and turbine are located on a single shaft, which rotates at approx. 75,000 rpm. The turbine combustion air is taken from the atmosphere and is compressed in the radial compressor to more than 5 bar. The fuel gas is normally taken from the local gas supply system and is fed to the combustion chamber via the integrated fuel gas compressor system. In order to exploit the exhaust gas energy, the turbine casing has an integrated heat exchanger (recuperator). By this means, the compressed combustion air is preheated by the turbine exhaust gas which results in increased efficiency. The fuel gas is mixed together with the combustion air in the combustion chamber, where it is ignited. The hot combustion gases are then expanded in the turbine which thereby drives the compressor and generator. Electric power is generated by a permanent magnet generator, without the use of an intermediate mechanical gear. An electronic gear is used to connect the high-speed generator to the grid, thus eliminating the necessity of a synchronising system. This gear also controls the relationship between the volume flow and the speed, thus keeping efficiency losses at part load to a minimum. After the exhaust gases have given up a part of their heat energy in the recuperator, they exit the turbine and can be further used in various processes such as warm water generation.

precision down to the last detail.

Hard Facts: Plant Technical Parameters The compact QiP plant reaches an electrical efficiency of approximately 30%. Thermal efficiency and, thereby, the overall efficiency, is dependent upon the temperature level of the heat transfer, respectively the use of the exhaust gas enthalpy. With heat transfer to a low level (reference temperature 80/60 C) a thermal efficiency of between 50 to 60% is reached. An overall efficiency of up to 90% is, therefore, achieved. The electrical efficiency remains constant, independent of the heat utilisation. Technical Parameters CHP Plant QiP 100 Electric power: 100 kw Thermal power: 200 kw Temperature indirect heating/drying: 300 C Electrical efficiency: 30 % Thermal efficiency*: up to approx. 65 % Total efficiency*: up to approx. 95 % Availability: approx. 96 % Voltage: 400 V Frequency: 50 Hz Emissions: NO x, CO: Noise: Dimensions: Width: Depth: Height: Area requirement (installation, service): Width: Depth: Service intervals: Inspection (no maintenance): Revision: Lifetime: Fuels: Natural gas Heating oil Diesel Bio ethanol Vegetable oil Propane Biogas Sewage gas Landfill gas extremely low levels 65 db(a) 3.0 m 1.5 m 2.0 m 4.0 m 3.0 m 8,000 operating hours 40,000 operating hours > 100,000 operating hours *depending upon temperature level, respectively steam data

From wish to possession: The plant components The core components of a QiP plant comprise one or more micro gas turbine-generator-modules, the turbine control system, a fuel gas compressor and the power electronics. Depending on customer requirements, both the core components and the plant specific equipment and supplies can be extended. components Basis: Micro gas turbine Turbine controls with digital service panel Gas control system with safety equipment Fuel gas compressor Power electronics Selected optional supplies: Exhaust gas heat exchanger Burner for steam generator Fuel supply system Buffer storage Exhaust gas system, etc. Additional services: Plant remote supervision system (monitoring) All core components and supplies, as well as many additional components are available as OEM supplies. The standard integration of the QiP module in your process includes connection to the available gas supply network, the connection to the local power grid, integration into the plant control system, as well as the installation of the exhaust gas system and the combustion air intake.

Tailor-made routes: From planning to installation Prior to starting work on a QiP CHP plant, we create a location specific energy concept, based on the existing and desired power profile. This concept is an important component of a sustainable operational energy supply. By this means, we are able to achieve your objectives most efficiently, such as, a higher and virtually continuous heat requirement, higher internal power supply, cooling requirements, etc., with respect to the usable base load. The concept also takes account of possible advantages from subsidies, power re-sale or tax relief. The engineering of your specific plant is included in our scope of supply. All key QiP components are OEM products, which are subjected to stringent test programmes. As a system supplier, we also undertake the complete integration of the low maintenance QiP plant into the existing infrastructure. Upon request, we can also extend our services with long-term service agreements. The extras: The QiP additional services QiP is not only a facility with high efficiency and a long lifetime. You also benefit from controllable independence from future energy cost increases. The complete plant technology is delivered from a single source: the micro gas turbine, the tailored control and regulation system, the specially designed heat exchanger and all the associated safety installations. If required, we can also take on much more: Partial or complete maintenance, inspections and service, plant monitoring, OEM spare part supplies as needed, as well as operating personnel training in the context of a service agreement. With a full service agreement, our Bilfinger service network is also at your disposal to offer local support at any time. An additional contract model includes everything from planning and engineering to long-term plant operation with service and maintenance. The professional and energy economic know-how of our specialists can be targeted to achieve risk minimisation and cost reductions.

Numerous standpoints: QiP in differing applications High exhaust gas temperatures of approximately 300 C enable numerous further usage of the heat in industrial applications. Micro gas turbines can be applied to many different industrial processes, such as, heating of fluids, drying, process steam, as well as cooling. For fluid heating, as, for example, is the case when generating hot water, tailor made QiP solutions enable very wide temperature ranges. District heating Hotels Administration buildings Workshops and commercial premises Shopping centres Storage facilities Schools Libraries Sport facilities Swimming and adventure pools Recreation parks Hospitals and clinics Sanatoria and convalescent clinics Business, office and residential buildings The direct use of the exhaust gases as combustion air in drying processes, as well as in greenhouses for CO2 enrichment due to the 18% CO2 component and the low pollutant concentrations in the exhaust, are guarantees for very high plant efficiencies. With a QiP exhaust gas temperature of approximately 300 C, it can be used directly and, therefore, efficiently in such processes. An after catalyst is not necessary. Building materials industry Food industries Agriculture Greenhouses Paper industry Timber industry Glass and ceramics industry Paint and varnish industries Sewage plants

For process steam production, the QiP exhaust gases are ducted to a steam generator. High temperature heat energy is available for use in further industrial processes. Food industry Paper industry Agriculture Textile industry Chemical industry Plastics industry Printing industry Laundries Waste disposal Hospitals Sanatoria and convalescing centres Plants for the simultaneous production of heat, cooling and power (CHCP plants) compensate the annual variations in heating requirements in so much as they, e.g. use excess heat in summer for the generation of air conditioning cooling. In this case, the QiP plant is coupled to an absorption refrigeration plant for the efficient generation of cooling. By this means, the number of full load operating hours per year are increased, which, in turn, has a positive effect on overall plant efficiency. Food industry Shopping centres Pharmaceutical industry Chemicals Hotels Restaurants Wineries Distilleries Administration buildings Storage facilities Workshops and commercial premises Electric and electronic industries Printing and media industries Schools Libraries Sport facilities Swimming and adventure pools Recreation parks Hospitals and clinics Sanatoria and convalescing centres Business, office and residential buildings CHP plants with micro gas turbine are applied, where temperatures of approximately 140 C are required. They can be combined with a thermally driven cooling plant for the production of process cooling. They are ideally suitable as pre-heaters in oven processes. Almost every industrial production process offers ideal opportunities for the installation of a QiP CHP plant. QiP. Small in Scale, Big on Power. A single source complete solution from an experienced engineering and plant construction company.

Duisburger Straße 375 46049 Oberhausen Germany Phone +49 208 4575-2387 Fax +49 208 4575-2391 info.qip@bilfinger.com www.qip.bilfinger.com