Survey of modern power plants driven by diesel and gas …

1 1 VTT TIEDOTTEITA MEDDELANDEN RESEARCH NOTES 1860 Survey of modern power plantsdriven by diesel and gas enginesSeppo Niemi Turku PolytechnicTECHNICAL RESEARCH CENTRE OF FINLAND ESPOO 1997 _____2 ISBN 951 38 5155 9 (soft back ed.)ISSN 1235 0605 (soft back ed.)ISBN 951 38 5156 7 (URL: )ISSN 1455 0865 (URL: )Copyright Valtion teknillinen tutkimuskeskus (VTT) 1997 JULKAISIJA UTGIVARE PUBLISHERV altion teknillinen tutkimuskeskus (VTT), Vuorimiehentie 5, PL 2000, 02044 VTTpuh. vaihde (09) 4561, faksi (09) 456 4374 Statens tekniska forskningscentral (VTT), Bergsmansv gen 5, PB 2000, 02044 VTTtel.

2 V xel (09) 4561, fax (09) 456 4374 Technical Research Centre of Finland (VTT), Vuorimiehentie 5, 2000, FIN 02044 VTT, Finlandphone internat. + 358 9 4561, fax + 358 9 456 4374 VTT Energia, Energian k ytt , Biologinkuja 3-5, PL 1601, 02044 VTTpuh. vaihde (09) 4561, faksi (09) 460 493 VTT Energi, Energiandv ndning, Biologgr nden 3-5, PB 1601, 02044 VTTtel. v xel (09) 4561, fax (09) 460 493 VTT Energy, Energy Use, Biologinkuja 3-5, 1601, FIN 02044 VTT, Finlandphone internat. + 358 9 4561, fax + 358 9 460 493 Technical editing Maini Manninen OY EDITA AB, ESPOO 1997 Cover figure: diesel & gas turbine worldwide.

3 October paper surveys the latest technology of power plants driven by reciprocating internalcombustion (IC) engines, from information collected from publications made mainlyduring the 1990 and gas engines are considered competitive prime movers in power production duemainly to their high full- and part-load brake thermal efficiency, ability to burn differentfuels, short construction time and fast market for engine power plants has grown rapidly, with estimated total orders forreciprocating engines of 1 MW output and more reaching the 5000 unit level, (10 GW),between June 1995 and May 1996.

4 Industrialized countries much prefer combined heatand power (CHP) interest has been shown in recent years in alternative gas fuels; natural gasappears to be the most promising, but liquid petroleum gas, gas from sewage disposalplants, landfill gas and other biogases, as well as wood gas have also been recognized asother alternatives. Liquid alternatives such as fusel and pyrolysis oil have also beenmentioned, in addition to information on coal burning percentage of gas engines used has increased and different ones are being developed,based on either the traditional spark ignition (SI), dual-fuel technology or the more recenthigh pressure gas injection cold climates, energy production is largely based on CHP plants .

5 Waste heat is utilizedfor local, regional or district heating or for industrial uses like drying, heating, coolingetc. Even radiative and convective heat from gen-set surfaces are employed, and boilersare used with exhaust outlet temperatures of below dew point. Combined cycle schemes,including turbo compound systems and steam turbines, are also incorporated into enginepower plants in order to increase output and , low-speed diesel engine plants show the highest electric efficiencies, withcombined cycle plants reaching up to 54%, while gas engine plants achieved between35% and 47%. The total efficiency of a CHP plant depends on its heat recovery system,recording at its highest rating 98% , Seppo.

6 Survey of modern power plants driven by diesel and gas engines. Espoo 1997, Techni-cal Research Centre of Finland, VTT Tiedotteita Meddelanden Research Notes 1860. 70 power plants , alternative fuels, exhaust emissions, internal combustion engines, diesel engines, gas engines4 Exhaust emissions of IC engine power plants must be reduced both by internal andpost- combustion methods. The lean-burn SI gas engines seem better with regard toengine-out emissions, while other gas and oil- driven engines with higher oxides ofnitrogen emissions are worse.

7 The paper deals only with post- combustion exhaustcleaning systems, reporting on the development of selective catalytic processes (SCR)and three-way catalysts. Data was also collected on combined oxi-cat and SCR reactorsand NO reduction concepts that utilize other media than ammonia or urea, as well as moreadvanced post- combustion gas and diesel engine power plant market has grown rapidly, particularly during the1990s. Information about state-of-the-art and development trends of plants is required forboth plant marketing and research and development activities. The technology andefficiency of internal combustion (IC) engine power stations may well have to be dealtwith more comprehensively in Finnish Universities and Polytechnics in the literature review of IC engine power plants has been carried out for VTT Energy asa technology transfer commission of the Turku Polytechnic.

8 I would like to thank Viinikainen, Research Manager at VTT, Dr. Nils-Olof Nylund, Group Manager,and Mr. Matti Kyt , Senior Research Scientist, for their confidence, for an interestingsubject, and for the opportunity to publish this Veikko V limaa, Head of the Mechanical Engineering Department of the TurkuPolytechnic, has given me much support and made it possible for me to do this work, forwhich I am most grateful. Mr. Reijo Halme, Vice-President of the Polytechnic, providedfinancial support for the final revision of this paper. My sincere thanks to him as hope, this paper would serve as a Survey of recent technology in the field.

9 I intend to usethis paper as course material in the IC engine technology area within my , April 1997 The Author6 CONTENTSABSTRACT3 PREFACE5 ABBREVIATIONS81 Chances of diesel and gas Markets for diesel and gas engine power Marine electric systems based on diesel and gas The aim and structure of the survey132 Fuel Alternative Liquid Coal163 Oil and liquid mixture burning Low-speed Medium- and high-speed Gas engine German and British engine development244 power PLANT plants with pure electricity Turbo compound systems (TCS) and unfired steam power Other combined Combined heat and power (CHP) German CHP plant at the University of Nottingham in the CHP plant in Lahti, Further concepts and Air CHP Concluding remarks and power -to-heat heat pumps4175 EFFICIENCY AND SOME OPERATIONAL Oil burning Combined Single Gas Spark-ignited (SI) Gas diesels (GD)

10 Dual-fuel Summary486 EXHAUST Emissions of diesel and gas Pollutant Emissions Exhaust Requirements of different Cleaning systems597 CONCLUSIONS 63 REFERENCES 668 ABBREVIATIONSBHKW( engine driven ) combined heat and power plant (in German: Blockheizkraftwerk)BMEP brake mean effective pressureBTEbrake thermal efficiencyCCcombined cycleCHPcombined heat and powerDCCdiesel combined technologyDCCC diesel /coal combined cycleDFdual-fuelDFOdiesel fuel oilGCVgross calorific valueGDgas dieselGIgas injectionGTgas turbineHFOheavy fuel oilHPHW high pressure hot waterICinternal combustionLCVlow calorific valueLHVlower heating valueMDEMAN Dezentrale Energiesysteme GmbHMGmining gasMHKW engine driven combined heat and power plant (in German.)