Current Status in Germany

KEMCO International Cogeneration Symposium

Seoul, 25.09.2003

Lindenberg-Anlagen, Germany

T. Wieck

25.09.03

www.lindenberg-anlagen.de

1

International Cogen Symposium Seoul, 25.09.2003

Presentation Contents

Technical Developments and Operation

Instances in Germany

01 Current Market Situation of Cogeneration in Germany

02 Emissions: Regulations and Technology

03 Technological Trends

04 Installation Instances

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1. Current Status

Current Status in Germany: until 1997

 more than 10.000 cogeneration units installed

 more than 300 gas turbines in cogen applications installed

5000

4500

4000

3500

3000

2500

2000

1500

1000

500

0 bis

1985 bis

1986 bis

1987 bis

1988 bis

1989 bis

1990 bis

1991 bis

1992 bis

1993 bis

1994 bis

1995 bis

1996 bis

1997

Cumulated number of installations

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1. Current Status

Current Status in Germany: 1998 - 2002

 no impulse from revised cogeneration laws kW electrical installed new

120000

100000

80000

60000

40000

> 2000 kWel

50 - 2000 kWel

< 50 kWel

20000

0

1998 2001 2002

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1. Current Status

Governmental Support:

1.) Taxation:

Ecological Tax (new since 1999):



Tax on Consumption of electrical energy

 to motivate consumers to reduce energy consumption: current tax rate

(since 01.01.2003): EUR 0.0205 (Won 27) per kWh for consumed energy, if installation exceeds 2000 kW. Also in case of self-produced energy.



Tax on mineral oil & natural gas consumption

 current tax rate (since 01.01.2003): EUR 0.0205 (Won 27) per liter on light fuel, EUR 0.00366 (Won 4.8) per kWh on upper heating value of nat. gas, also on heavy fuel oil.

Conventional mineral oil Tax:



EUR 0,00184 / kWh (2,4 Won) on natural gas

Energy produced by Cogen units is exempted from these taxes



Heat & power produced in conventional manner: extra taxes apply, heat & power produced by CHP: not taxed.



Production companies are exempted, too

 contradiction to CHP support, but politically inevitable.

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1. Current Status

Governmental Support:

2.) Cogeneration Law: higher prices for grid exported cogen power



Goal of European Community



To increase the percentage of electric power from cogeneration plants up to 50 MW el from 11% in 1998 to 18% in 2010.



German Implementation



Cogen Law (since 01.04.2002): payments for exported cogen power:

“Market price” (own production or purchase price paid by grid operator)+

- Avoided grid operation cost +

- Additional incentive 2.56 Cent (Won 33) per kWh



Heating load, not electrical load, should be the limiting factor



Degressive incentive to 75% in 2010 to encourage technical development



Refinancing by increase of prices for all customers

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1. Current Status

German Building & Energy Market Structure:



Only few large apartment buildings

 large east German apartment complexes connected to district heating

 low electricity prices due to highly integrated European HV network

(ETSO European Transmission System Operators) – cheap sources of electricity from France, eastern Europe are offering at the German market and huge overcapacities.



In contrast: Korean situation much more advantageous to CHP applications

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2. Emissions

New “TA-Luft” (German Regulations on Emissions) since 01.10.2002:

Emission limits for reference 5% O

2

ín exhaust gas:

NO x

: 500 mg/Nm³ for lean-burn gas engines, 250 mg/Nm³ else

1000 mg/Nm³ for Diesel engines < 3MW  only possible at high SCR costs – practically not feasible, Diesel cogeneration will be terminated

CO: 300 mg/Nm³

No limits for modules for emergency use or peak load.

For comparison:

Old TA-Luft was 250 mg/Nm³ for NO x

, technical disadvantages for leanburn engines

Now: Differentiation by combustion technology

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2. Emissions

Comparison: Limits in Korea:

Seoul now:



NOx: 100 ppm @ 13% O

2

= 410 mg/Nm³ @ 5% O

2

Korea now:



NOx: 500 ppm @ 13% O

2

= 2050 mg/Nm³ @ 5% O

2

Korea & Seoul from 01.01.2005:



NOx: 50 ppm @ 13% O

2

= 250 mg/Nm³ @ 5% O

2

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2. Emissions

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2. Emissions

Emissions Control:



Lambda 1 engines (rich burn):



Emission reduction is a secondary measure



Not combustion related



Depends only on size of 3-way-catalyst.



No problem to achieve NO x values of 50 ppm



Marginal cost (< 1000 Euro for engines < 400 kW)



Lambda 1 engines commonly only up to approx. 250 kWe with high speed engines

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2. Emissions

Emissions Control:



Lambda 1.6 engines (lean burn):



Typically turbocharged



Lambda 1.5 (open chamber) or 2.2 (pre-chamber)



The emission reduction depends on the combustion (primary measure)



Lower NO x temperature requires higher lambda values to reduce the combustion



Difficult to reach 50 ppm



Loss of power  higher specific investment



Loss of efficiency  higher gas consumption and higher CO

2



Reduced lifetime of spark plugs and cables



Close to combustion limit, unstable operation



Higher CO output



No data available, no approval output

 Only secondary measure to reduce NO x is SCR-catalyst (SCR = selective catalytic reduction), increases costs by 20 - 30%

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2. Emissions

Example: Lindenberg CHP 300

NOx NOX Mech.

Power mg/Nm³

500

250

205 ppm

122

61

50 kW m

340

324

310*

Mech.

Efficiency

%

35.2

34.2

33.2*

CO

2 in 10 years

(30,000 MWh el

) tons

17,800

18,300

18,800

* Estimation

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3. Technology Trends

Higher Engine Efficiencies:

Upcoming engine developments:

 increased mechanical engine efficiency

 no concessions on lifetimes or emissions

 no concessions towards availability

Research towards:



CFD studies on internal combustions process

 exhaust gas recirculation EGR

 mixture formation, mixture control systems

 l – control (AFR control) optimization

 engine electronic control systems

 higher cylinder numbers per engine – mechanical limits

 higher engine outputs, espcially at high speeds

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Non-Engine Technologies:

Besides traditional piston engines:



Micro Gas Turbines

 advantageous for small load demands (German consumer structure)

 still efficiencies low - currently only research / prototype projects available



Stirling engine

 low emissions

 various fuel possibilities (e.g. wood pellets)

 low electrical efficiency



Fuel cells

 low emissions

 low electrical efficiency

 low longtime reliability,

 difficult conversion of natural gas to hydrogen (e.g. due to sulfuric odoring contents – which is a safety feature)



Common Disadvantage: High Investment Costs

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CHP Developments:

Based on conventional gas piston engines:



Micro CHP

 advantageous for small load demands (German consumer structure)

 low power to heat ratio

Combined Heating & Cooling with Absorption chiller units:

 adaptation to different consumer requirements in winter / summer season, zero heat dissipation in summer

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Combined Heating & Cooling with Absorption chiller units:

1.500.000 €

1.000.000 €

Investment Costs

Hotel 1000 Beds

Chiller

Boiler

Heating Unit

Absorption Cooler

Cogen Modul

500.000 €

0 €

Chiller Cogen+Cold Water

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Operating Costs

Hotel 1000 Beds

600.000 €

Maintenance

Gas

El. Power

400.000 €

200.000 €

0 €

Chiller Cogen+Cold Water

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Life Cycle Cost

Hotel 1000 Beds

7.000.000 €

6.000.000 €

5.000.000 €

4.000.000 €

3.000.000 €

2.000.000 €

1.000.000 €

0 €

0 1 2

Chiller

KWKK

3 4 5 6 7 8 9 10

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Electrical Aspects on Cogen Units:

Grid Stabilization by grid parallel cogen operation:



Decentralized power generation

 less vulnerable to grid failures (New York 2003)



Grid relief



Emergency Power functionality in case of grid blackout



Grid parallel operation standard application in Germany

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Example on grid parallel operation:

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Potentials of Advanced CHP Control Systems:

Optional features of PLC based control systems:



Tariff based control



Joint operation of several locations with remote control, supervision and assistance: modem access, mobile phone access, Internet access



Integration of CHP module control into general building control systems (bus connection).



Korean language support

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Example of Advanced CHP Control:

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Goals & Plans:

Mid & long-term development goals, strategies:

 climate protection, energy ressource protection

Current R&D situation:



Increased maintenance intervals, status based maintenance



CFD based research on piston engine technology



CFD based research on combustion processes in general

Lindenberg approach:

 standardized CHP units based on well proven material with long reference lists, with service

 no prototype testing

 flexibility on electrical side: control features, grid connection, emergency power



Lindenberg developments focused on control systems

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4. Installation Instances

Stages of a typical CHP project:

1.

Identification of Potential Project

2.

Data Acquisition

3.

Feasibility Study

4.

Go-No Go Decision

5.

Detail Engineering

6.

Inquiries

7.

Order

8.

Installation

9.

Commissioning

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25.09.03

Product Range of Lindenberg CHPs

2500 kW

2000 kW

Power

Heat

1500 kW

1000 kW

500 kW

0 kW

CHP 40 CHP 65 CHP 120 CHP 220 CHP 300 CHP 400 CHP 600 CHP 800 CHP 1000 CHP 1400 CHP 2000

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CHP 400 Unit for a Public Pool and District

Heating System (Germany):

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Turboblower for Sewage Plant (China):

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Direct Drive in Cogen Technology

Screw Compressor for Heat Pump (Northern Germany)

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Current Status in Germany

KEMCO International Cogeneration Symposium

Seoul, 25.09.2003

Technical Developments and Operation

Instances in Germany