C O G E N E R A T I O N W I T H G A S E N G I N E S

2

Comparison of technologies 4/5

Cogeneration plants in general 6/7

Dimensioning 8/9

Economic eff iciency 10/11

Possibilities of combination 12/13

Selection of primary energy 14/15

Features of Jenbacher AG 16/19

Scope of supply 20/21

Engine series 22/23

Reference plants 24/25

Jenbacher - Worldwide 26/27

T A B L E O F C O N T E N T S

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C O M P A R I S O N O F T E C H N O L O G I E S

Increased ecological consciousness and the knowledge of the limited

reserves of primary energy in the form of fossil fuels make it necessary to

transform available energy sources economically. Cogeneration plants produce

electricity and heat at decentralized locations, i.e. where they are required.

They of fer optimal ef f iciency in the transformation of energy with minimum

environmental pollution.

Losses usually result from waste heat. For that reason, sensible,

thermodynamic energy converters are those which supply power (usually used to

produce electricity) and heat. This power, however, can also be utilized for the direct

drive of machines such as pumps, compressors (e.g. for refrigerating plants), etc.

The energy requirement of cogeneration plants is more than one third less

compared with separate generation of electricity and heat.

(1 - 4.33) . 100 = 42 % savings of primary energy with cogeneration2.50

(Data referring to Jenbacher power range)

Cogeneration plants are not limited to integration into centralized heating

networks, rather they can be more effectively applied for local heat supply with the

generated electricity being used to cover local consumption and/or export to the

utility. The plants also offer themselves for the replacement or addition to existing

heating plants. The total degree of efficiency of cogeneration plants is about 90%.

Since cogeneration plants are usually in the vicinity of consumers, the distribution

losses are less than in the case of central electricity and heat generation.

Combined heat and power is possible with both gas engines and gas

turbines. In comparison to gas turbines, combined heat and power plants with gas

engines indicate clearly higher electrical ef f iciency (see Illustration) and

considerably lower investment costs. Turbines can be more economically used in

applications with a large constant high value heat requirement of over 110°C or in

large multi-Megawatt installations. For both technologies the designation

„cogeneration plant“ has become established. The space requirement is considerably

smaller than conventional power stations.

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6

Construct ion - manner

of operat ion - integrat ion

Scheme of a cogenerat ion plant

C O G E N E R A T I O N P L A N T S I N G E N E R A L

A cogeneration plant consists of an engine (or turbine)/generator set with

heat exchangers for the utilization of the thermal energy in the intercooler,

jacket water, lubricating oil and exhaust gas. A boiler plant specif ically for peak

heating demand periods can augment the cogeneration modules.

Electrical connection and control installations serve for distribution of

electricity and engine management. Hydraulic distribution ensures eff icient heat

recovery.

The total eff iciency of gas engine cogeneration plants attains up to over

90% (30% - 40% electrical and over 50% thermal).

The losses brought about by energy transformation - about 10% - are comprised

of generator, radiation and heat exchanger losses and the remaining heat of the

exhaust gas.

Besides a spark-ignition gas engine, a gas-diesel (dual-fuel) or a diesel

engine can be used as drives, their main disadvantage being, however, the

considerably higher emissions. In many plants with spark-ignition gas engines so-

called mixture-turbocharging is used; here a mixture of air and gas are put under

a higher pressure in a turbocharger. In consequence, one increases the specif ic

energy density in the cylinders and hence the power in contrast to aspirating-type

engines of comparable size. In combination with the lean-burn engine principle this

results in extremely low NOx emissions without additional secondary treatment of

exhaust gas.

Jenbacher engines developed for use in cogeneration plants attain periods

of operation of 40,000 to 100,000 hours.

The energy balance of a

JMS 320 GS Jenbacher

cogenerat ion module

- Mixture intercooler

- Oil heat exchanger

- Engine jacket water heat exchanger

- Exhaust gas heat exchanger

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D I M E N S I O N I N G

Cogeneration plants are generally dimensioned to meet the heat requirement

of a particular site. For this reason, it is necessary to analyze the annual development

of the heat requirement and to determine a yearly curve broken down into exact

monthly requirements.

Here two rules of thumb are useful:

1. The thermal power of the cogeneration plant should amount to about 30% to

50% of the maximum yearly heat requirement. Experience has shown that

about 50% to 70% of the yearly heat requirement can be covered by the

cogeneration modules. The rest is supplied by boilers for peak load periods.

2. Each cogeneration module should attain at least 4,000 operating hours per

year.

Year ly heat

requirement

Year ly heat

requirement curve

Hot water for domestic requirements and other uses show here a higher

portion of base load. New housing developments are characterized by good thermal

insulation, so that no strongly pronounced peak load periods develop.

A uniform base heat load and high electricity consumption form for

these customers the ideal prerequisites for the use of cogeneration plants. In

addition to this, they can also be utilized for the supply of emergency power.

Since the heat requirement of industrial organizations f luctuates greatly

during production (e.g. breweries), consumption profiles have to be determined to

ensure that a comprehensive and economical energy concept can be achieved.

Housing developments

Hospita ls

Industr ia l companies

Typica l dai ly heat and

e lectr ic i ty requirement

in a brewer y

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E C O N O M I C E F F I C I E N C Y

To document the economic efficiency of a cogeneration plant, one contrasts

savings and returns resulting from the production of electricity and heat with

investment costs.

The specif ic investment costs of a cogeneration plant depend on the

power output range and the scope of supply.

Inf luencing factors

Investment costs of a

cogenerat ion plant

Operation of a plant:

Running savings and returns:

• Electricity tariff and connection costs• Heat tariff in the case of purchase

from a long-distance network or costs of own-production of heatwith a boiler

• Costs of power losses avoided by emergency operation

Running costs:

• Fuel• Lubricating oil• Service and maintenance• Operational personnel• Insurance• Engine inspections

Investment in a cogeneration plant:

Savings through installation:

• Costs of connection to public electricity/heating network

Investment costs:

• Cogeneration modules• Electrical equipment• Adaptation of the heating system• Cooling• Ventilation• Lubricating oil• System control• Building, foundation• Fuel• Final acceptance by authorities• Initial operation

The primary criteria for the economical operation of a plant is the assess-

ment of the generated electricity. This can be utilized for either the plant‘s own

requirements or be fed into the public grid.

The f irst option above is economically more interesting. In this way the

electricity power prices which are saved can also be credited to one‘s account.

Make up of the investment

costs of a cogenerat ion plant

Typica l comparison of

returns and costs regarding

se l f-product ion and

purchase in Germany

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P O S S I B I L I T I E S O F C O M B I N A T I O N

Cogenerat ion of heat ,

power and cold

Chilled air/f luid can be produced by conventional reciprocating chillers

or absorption chillers. With the latter type the thermal energy of a cogeneration

plant can be utilized.

Advantages through the combination of cogeneration with absorption chillers:

• increase of the module operating time through additional utilization of exhaust heat

with a summer load

• decrease of the connected electrical load and hence reduction of energy costs

Advantages of an absorption chiller in comparison to a conventional reciprocating

chiller:

• environmentally friendly cryogens (no CFC)

• longer service life due to fewer moving parts, hence also

• low maintenance and repair costs

• lower power consumption

Extreme peak demands for chilled air/f luid can be compensated by a compression-

type refrigerating machine.

Hot-cool ing

Hydraul ic scheme for

the bott le c leaning

machines in a brewer y

The cogenerat ion plant used

for heat ing the digest ion tank

and dr y ing sewage s ludge

Direct dr ive

The cogenerat ion plant and

a natural gas dr iven turbine

used for reduct ion of the

pressure potentia l

The dried sewage sludge is fed into a digestion tank where the anaerobic

fermentation process liberates the methane contained in the biomass. The thermal

energy of the cogeneration plant is used to heat the sewage sludge and therefore

promotes the production of biogas in the digestion tank.

High pressure gas lines must be reduced in pressure for local distribution.

Traditionally, pressure reducing valves performed this task however, expansion turbines

have been used which convert this pressure head into electricity. Turbines however

require the high pressure gas to be heated to prevent icing by the expansion and

a cogeneration plant heat output used for this purpose can result in an extremely

high electrical ef f iciency.

The employment of hot-cooled engines permits jacket water temperatures

above 110°C. This is interesting, for example, for hospitals and breweries. In the

latter, the temperature levels required in the supply and return lines for bottle

cleaning machines and for the brewing process can be ensured with this method.

The gas engine can be used directly to drive compressors, pumps,

ventilators, etc.

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S E L E C T I O N O F P R I M A R Y E N E R G Y

Jenbacher AG has become specialized in utilizing not only gases with an

extremely low calorific value, low methane number and hence low degree of knock,

but also gases with a very high calorif ic value.

Besides the „standard use“ of natural gas, landfill gas also represents a

signif icant potential, above all regarding the aspect of environmental protection

and preservation of resources.

Sewage gas is very well suited for the operation of gas engines, since the

knock-resistant methane and the high amount of CO2 contained in it permit a

methane number of over 130. Another opportunity to utilize the energy potential

of waste is through the process of pyrolysis (decomposition of substances by

heat). The resultant pyrolysis gas can be used in a gas engine.

The ca lor i f ic va lue indicates

the energy content

of the pr imar y fuel

The most important property regarding the use of a gas in a gas engine

is its knock resistance. This is rated according to a methane number. Highly

knock-resistant methane has a methane number of 100. In contrast to this,

butane has a methane number of 10 and hydrogen with a methane number 0 lies

at the bottom of the scale.

The methane number

determines the knock

res istance of the gas

Character ist ic

va lues of fuels

Fuel Designation, Methane number

Composition (in %)

H2 Hydrogen 0

CH4 Methane 100

C2H4 Ethylene 15

C2H6 Ethane 43.7

C3H6 Propylene 18.6

C3H5 Propane 33

C4H10 Butane 10

CO Carbon monoxide 75

Natural gas CH4=88.5 72-98

(Typical) C2H6=4.7

C3H6=1.6

C4H10=0.2

N2=5.0

Sewage gas CH4=65 134

CO2=35

Landfill gas CH4=50 136

C02=40

N2=10

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F E A T U R E S O F J E N B A C H E R A G

Jenbacher AG can look back at more than four decades of experience in

the construction of gas engines. Thousands of modules for various applications have

been installed within this period of time all over the world. In Europe alone,

Jenbacher can proudly claim to have the largest number of installed cogeneration

modules with a very low-emission combustion process.

With this combustion process which Jenbacher developed and patented

worldwide, the formation of pollutants can be reduced by 90% already in the

combustion chamber.

LEANOX lean-burn

combustion

Know-how

On the one hand, one uses a specially developed configuration for the

combustion chamber to ensure eff icient combustion and, on the other hand, the

direct connection between power output, charge pressure, mixture temperature and

NOx emission. Measurement of the oxygen in the exhaust gas with a Lambda probe

is therefore no longer necessary. The LEANOX control system corrects changes in

parameters inf luenced by NOx emissions.

Exhaust gas

turbocharger bypass

Jenbacher gas mixer

Optimal e lectr ica l ef f ic iency

Shor ter amor t izat ion

per iod thanks to

higher ef f ic iency

Interpretation: Greater electrical ef f iciency means more ef f icient utilization of the primary fuel, a considerable increase of the yearly prof it, and hence a shortening of the amortization period.

In combination with the LEANOX process, the Jenbacher gas mixer balances

out f luctuations in calorif ic value, which occur mainly in landfill gas and biogas

plants. Further advantages of the Jenbacher gas mixer are:

• high degrees of engine eff iciency through minimal pressure losses

• reliable compliance with prescribed NOx emission values

• non-problematical use of alternative gases (2-gas operation)

• simple adaptation for use of special gases

A controlled bypass is installed on the exhaust gas turbocharger. This permits:

• a greater range of air/gas intake temperatures

• optimal adaptation to ambient conditions in connection with dia.ne

• optimized behavior for island operation

The fast-running Jenbacher gas engines with their optimal degree of

electrical eff iciency offer ideal prerequisites for eff icient energy conversion: In

connection with specially adjusted generators it is possible to attain degrees of

electrical eff iciency of up to 40% - while complying with international emission

regulations.

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• the lowest CO/hydrocarbons, formaldehyde and CH4 emissions

• higher specif ic power output

• higher eff iciency

• minimal NOx emissions

• clear increase in specif ic power output

• maximal service life of the spark plugs

• optimal eff iciency

Electronic engine

management system

Systems for secondar y

t reatment of exhaust gases

andThermal af tertreatment of exhaust landfill gas

SCR catalytic converter for natural gas

Shie lded ignit ion system The high ignition voltages of gas engines generate electromagnetic

interference. To prevent this, Jenbacher developed a shielded ignition system. This

permits compliance with CE regulations with regard to electromagnetic compatibility

(EMC) and means that there is no problem utilizing Jenbacher plants in

residential areas. At the same time, the sensitivity of the ignition system to

external disturbances is reduced.

Speed control, power output control and combustion control must be

optimally coordinated for the operation of a cogeneration plant. This function is

performed by the dia.ne system - developed by Jenbacher of course - which places

great importance on user-friendly operation. A color graphic display permits an

user-friendly presentation of all relevant data. The multi-color trend display, the

alarm management function and the possibility of long-distance data transmission

all guarantee the ease of servicing the plant.

Cyl inder head serv ice l i fe

Service

Spark p lugs

Jenbacher offers its customers individually adapted maintenance contracts,

depending on whether they already have their own service and maintenance

personnel or not. Above and beyond this, Jenbacher‘s comprehensive training

program ensures that the customer is kept up to date on the latest plant-specif ic

details.

The following examples document the customer orientation of the

Jenbacher service organization:

The use of almost completely maintenance-free electronic and mechanical

high-tech components guarantees the reliability of Jenbacher plants and minimizes

down times. Jenbacher plants regularly attain availabilities of over 95%. The

maximal integration of all components leads to a very low number of necessary

components. This means easy accessibility and hence optimal servicing access.

Jenbacher cylinder heads attain a service life of up to 20,000

operating hours and can then be replaced quickly by

favorably priced replacement heads.

A service life of up to 10,000 operating hours of the spark

plug developed by Jenbacher permits longer service

intervals and a high degree of availability of the plant.

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S C O P E O F S U P P L Y

All Jenbacher modules are suited to the specific wishes and requirements

of the customer, tested as completely assembled modules regarding function and

performance, and then delivered to their f inal location.

The module control system for all monitoring, closed-loop and open-loop

control functions is produced in Jenbach.

The software is also produced in Jenbach and specially conceived for

each individual application.

Using selected components, electrical gear involving station control,

synchronization, generator control panels and mains distribution panels are

manufactured by Jenbacher as well, and tested together with the modules.

The machining center

Each individual user-specific feature is integrated already in the planning

phase, as is the consideration of local conditions. All peripheral plant components

are produced to meet respective requirements.

In the preparation of the complete concept and of profitability calculations

Jenbacher acts as both planner and advisor. In addition, we support our partners

in the selection of suitable f inancing models.

Control system

Container p lant

Rautenweg/Austr ia

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1

E N G I N E S E R I E S

Technical data:Bore/stroke 122/142 mm

Engine displacement 10.0 l

rpm 1500 min-1

Mean piston speed 7.1 m/s

Cylinders (number/arrangement) 6/in line

Technical dataBore/stroke 135/170 mm 135/170 mm 135/170 mm

Engine displacement 29.2 l 38.9 l 48.7 l

rpm 1500 min-1 1500 min-1 1500 min-1

Mean piston speed 8.5 m/s 8.5 m/s 8.5 m/s

Cylinders (number/arrangement) 12/V 70° 16/V 70° 20/V 70°

J 156

J 320J 316J 312

J 316 J 3203Series 3

Ser ies 1

J 156

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Ser ies 6

Ser ies 2Technical dataBore/stroke 135/145 mm 135/145 mm

Engine displacement 16.6 l 24.4 l

rpm 1500 min-1 1500 min-1

Mean piston speed 7.3 m/s 7.3 m/s

Cylinders (number/arrangement) 8/in line 12/V 70°

Technical dataBore/stroke 190/220 mm 190/220 mm 190/220 mm

Engine displacement 74.9 l 99.8 l 124.8 l

rpm 1500 min-1 1500 min-1 1500 min-1

Mean piston speed 11.0 m/s 11.0 m/s 11.0 m/s

Cylinders (number/arrangement) 12/V 60° 16/V 60° 20/V 60°

J 616 J 620J 612

J 212J 208

2

6J 616 J 620

J 208 J 212

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R E F E R E N C E P L A N T S

Monzón/Spain, salt extraction

Moratal/Spain, ceramic industry

Rautenweg/Austria, landfill Wellesley/USA, college

Wittenberg/Germany, municipal services

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Oue/Denmark, municipal service

Annacis Island/Canada, waste water treatmentGraveson/Great Britain, landfill

Remscheid/Germany, hospital

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J E N B A C H E R W O R L D W I D E

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•

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• Subsidiaries of Jenbacher AG• Sales and service partners

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A D D R E S S E S

Prin

ted

on

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lori

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free

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ach

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09/

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L_50

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Jenbacher AG

A-6200 Jenbach, Austria

Tel: +43/5244/600-0 . Telefax: +43/5244/63255

http://www.jenbacher.com

Jenbacher AG

Branch Vienna

Am Concorde Park 1/C3, A-2320 Schwechat, Austria

Tel: +43/1/707 95 10 . Telefax: +43/1/707 93 28

Jenbacher Energiesysteme GmbH

Amselstraße 28, D-68307 Mannheim, Germany

Tel: +49/621/77094-0 . Telefax: +49/621/77094-70

Jenbacher Energiesysteme A/S

Industrivej 19, DK-8881 Thorsø, Denmark

Tel: +45/8/69 66 78 8 . Telefax: +45/8/69 67 07 2

Jenbacher Energiesysteme S.R.L.

Via Crocioni, 46/h, Casella Postale n. 41 Aperta

I-37012 Bussolengo (VR), Italy

Tel: +39/045/6760 211 . Telefax: +39/045/6766322

Jenbacher Energiesysteme B.V.

Stationspark 709, NL-3364 DA Sliedrecht, Netherlands

Tel: +31/184/495222 . Telefax: +31/184/415440

Jenbacher Energiesysteme Ltd.

West Tech Park, 26602 Haggerty Road, Farmington Hills, MI 48331, USA

Tel: +1/248/324 4400 • Fax: +1/248/324 5000

Jenbacher Energiesysteme S.L.

Lanzarote N° 10

E-28700 San Sebastián de los Reyes, Spain

Tel: +34/91/6586800 . Telefax: +34/91/6522616