Upload
others
View
6
Download
0
Embed Size (px)
Citation preview
Maximize the Success of Methane to
Electricity -- Biogas & Renewable Projects
Peter Lau, PhD
Region Manager
Electric Power Gas Sales
Asia Pacific, Caterpillar
Page 2
Agenda
1. Options for Methane to Electricity -- Biogas &
Renewables Projects
2. Engine Technology Consideration & Selection
3. Engine Installation and Project Time Line
4. Engine Maintenance & Operations (M&O) Costs
5. Caterpillar Support of Power Projects
1. Methane to Electricity Projects
Asia Pacific offers many possibilities
& options….
Page 4
Resource Rich – Biogas & Renewables
• Agriculture Rich
– Palm oil
– Cassava
– Sugarcane
– Coconut
– Rubber
– Rice
– Wheat
– Luciana
– Jathropa
• Gasification- Syngas
– Wood Gas
– Coal / Coke Gas
• Mineral Rich – Coal
– Natural Gas
– Crude
– Shale Oil and Gas
• Live Stock Rich
– Hog
– Poultry
– Cattle
– Seafood
Page 6
Typical Biogas Plant
Key Components
Waste Collection System
Bioreactor
Gas Pretreatment System
Gas Generator
Page 8
Gas CCHP Application
Engine Low Temperature
Circuit
Fuel
Exhaust Gas
Exhaust Gas Boiler
Engine
High Temp.
Circuit Cooling
Towers Absorption
Chiller
Electric
Power
Chilled Water
4 – 6 C
Page 9
Efficiency vs Uptime
2. Engine Technology Consideration
& Selection
Page 11
Clean Power Options
• Gas Engines and Gas Turbines
– Environmental
• Low emissions, low noise, low vibration
– High Availability
• Power on demand, continuous, reliable
– Viable
• Low cost of ownership, fast payback, high ROI
– Proven
• Mature technology, growing market, bankable
Page 12
Caterpillar Gas Generator Set Platforms
CG260 CG132 G3500 CG170 G3300
Special Features
• Able to achieve high annual operating hours
• Able to run on low heating value fuels
• Able to handle corrosive gases
Page 13
Engine Design Trade-Off
High Robustness Engines (Traditional Otto, non-Miller)
• Accept higher siloxane and H2S contamination
• Efficiency below 40%
• Dirty gas forces more oil changes, higher M&O cost
• Excellent for: ‘dirty’ gas, worst-case ambient swings & quicker load response
High Efficiency Engines (Miller Cycle)
• Usually require costly siloxane & H2S removal
• Efficiency above 40%
• Lower M&O costs due to cleaner gas
• Excellent for: ‘clean’ gas, controlled environments, average load demands
OPEX CAPEX OPEX CAPEX
Page 14
Fuel Specification Guidelines
• All Manufacturers have guidelines for maximum fuel
contamination. Warranty depends on compliance.
• Miller engine users strongly advised to stay within
the limits of the ‘clean biogas’ definition
Non-Miller Engine Miller Engine
Fuel Contaminant
µg/Btu of
Fuel
Approx.
PPM*
µg/Btu of
Fuel
Approx.
PPM*
Halides (as Cl) 20 230 0.55 7
Sulfur (as H2S) 60 730 12.2 155
Siloxanes (as Si) 0.6 9.0 0.11 1.6
Ammonia 2.96 72 0.17 4
*Based on 500 Btu/scf Fuel Sample Recommendation for Optimal Engine Application
Page 15
Engine Technology Best Practice
• Run two separate economic evaluations of your methane to electricity project: – Scenario A: high efficiency engine (Miller, CCGT)
– Scenario B: high robustness engine (non-Miller, Gas Turbines, Micro GT)
• Include in your evaluation: – CAPEX: cost of contaminants removal equipment
required by high efficiency engine as well as any additional CC equipment
– OPEX: additional M&O for contaminant removal units
– Risk Factors: Reliability & Durability
3. Engine Installation Options
Building v. Pre-fabricated Module
Page 17
Container Building
Page 18
Engine Installation Trade-Off
Building Installation
• Ample space for service
personnel, cranes for safe
lifting of heavy parts,
controls & storage rooms
• Economies of scale for
multi-engine buildings
• Easier to manage dust
contamination and air inlet
temperatures
Modular Installation
• Restricted access and work
space, more time & money
on service steps
• Fast deployment, easier to
quickly add or remove units
• Easier to obtain bank loans
• High reliability: complex
systems integrated by
engine manufacturer
4. Better Estimation of M&O Costs
M&O Costing is critical to any
Methane to Electricity Project
Page 20
Estimating Maintenance & Operation Costs
• Most financial evaluation tools use just one number
for the M&O cost of a generator set
• Comparison of costs may not be appropriate
without knowing the different elements that went
into the M&O number
• Potential customers need to request separate
estimates for different combinations of service
– Window of time used for calculations is critical
– Gas type used for calculations also critical
Page 21
Cost per kWh, Cost per Running Hour
• L1-L7 are lists of different service alternatives
Page 22
Need to Break Down O&M Elements
Included in cost?
• Lube oil?
• Major Overhaul?
• Electrical Items?
• Unscheduled
Maintenance?
• System
Auxiliaries?
Page 23
Customer Service Agreements (CSA)
Inspection contract
Preventive maintenance contract
Maintenance contract
Full-service contract
CAT provides full support for service contract definition
and calculation
Full Value Chain
Page 24
Facts and figures
Storage space 12,000m²
Office and common space 600m²
Parts numbers / parts in stock Ø 40,000 / 2,000,000
Customer orders Ø 200 / day
Order items Ø 800 / day
Number of parcels Ø 200 / day
Weight shipped Ø 7,500 kg / day
Hours of operation Mo.–Fr. 7:00 am to 8:00 pm
Emergency service 24/7, 365 days / year
Orders placed by 5:00 pm (CET) will leave the logistic center the same day
CAT Service Logistic Center
Distribution Centers
• Morten and Frankfurt
• Singapore
• Shanghai
• Bangalore
• Melbourne
Frankfurt
Page 25
Caterpillar Asia Pacific Dealer Network
Australia
Energy Power System Australia
David Moore
+61-417-357-406
China (South & West)
China Engineers Ltd
Lu Yi Hong
+86-136-0289-0110
Japan Caterpillar Services Ltd.
Shinya Suzuki
+81-90-3243-6489
Singapore & Maldives
Tractors Singapore Ltd.
Sean Ang
+65-9232-7596
Bangladesh
BanglaCAT Ltd.
Zahid Islam
+880-171-309-0331
China (SW and NW)
ECI-Metro
Nicholas Thew
+86-139-8181-7050
Korea
Hae-In Co.
S.H. Kim
+82-2-3498-4572
Sri Lanka
United Tractors Ltd.
Manjula
+94-773-157-824
Cambodia
Metro Cambodia
Kim Veng Tan
+855-1251-2333
India (North)
Tractors India Ltd.
Rakesh Ananad
+91-971-133-1139
Malaysia & Brunei
Sime Darby Industrial
Chun Hoong Ng
+60-3-8068-8192
Taiwan
Capitol Machinery Ltd
CS Horng
+886-937-957-288
China (North)
Westrac China
Bill Chu
+86-10-5902-1666 ext. 6011
India (South)
Gmmco Ltd
Chandrasekaran
+91-984-096-6123
Myanmar
Myanmar Tractors Ltd.
Yee Yee Htwe
+951-547-304
Thailand & Laos
Metro Machinery Co. Ltd.
Somkiat Chawitcharoenwong
+66-848-743-642
China (Central)
Leishinghong Machinery
Johnson Jiang
+86-186-1677-2856
Indonesia
PT Trakindo Utama
Edwin Sentoro
+62-812-100-7681
Philippines
Monark Equipment Co.
Luis Diaz
+63-906-314-2735
Vietnam
Phuthai
Truong Dong Phuong
+84-903-830-498
www.catelectricpowerinfo.com/gas
Thank You For Your Attention!
Peter Lau, PhD
14 Tractor Road
Caterpillar Asia Pte Ltd
Singapore, Singapore