Gas-piston installations with utilization of thermal energy. Gas power plants: autonomous energy source in a wide power range

This material is intended for specialists who are faced with the task of comparing power plants of two or more various manufacturers, each of which offers its own standards and rules of comparison. The study does not answer the question of which of the manufacturers is better, however, using published standards and approaches, you can find the most acceptable option for each individual object.

Part one - comparison of manufacturers of different categories

On the market of gas piston units there are offers of completely different levels executions. Before you start analyzing the prices of equipment, you need to understand what category of quality and level a particular solution belongs to. Not a single consumer is interested in purchasing a "bare" gas piston power plant, first of all, any customer is interested in a comprehensive solution that includes main and auxiliary equipment, and it is these solutions that will be discussed.

Group No. 1 - "native" factory assembly

At present, there are only a few factories producing complete solutions, starting directly from the gas engine. Such solutions include both gas piston power plants and optional equipment, heat recovery systems, control, cooling - in a word, everything that is necessary for the operation of the facility as a whole. There are not so many such factories - Jenbacher, Siemens, MWM, Wartsila and some others. It is these companies that have the most experience in the production integrated solutions, since they produce them from the very beginning, from a gas engine, and the best way understand all the nuances of the operation of the equipment. They are the ones who care most about the quality of their solutions and the most positive feedback from the end customer.

Group #2 - Third Party Packagers

European companies that repurchase engines or generator sets from the above plants and complete them at their discretion. In addition to repurchasing engines, these companies provide packaging services to those plants that can produce engines, but do not have the experience or ability to make a complete solution, for example, Doosan, Caterpillar, Perkins. In our opinion, the products of this group are inferior in quality to the "native" factory assembly. In addition, it should be taken into account that on one day the packager buys some engines, and on the other - others. Expect full support and availability of spare parts, probably not worth it. Considering the products of this category separately, you need to take into account that there are two types of gas piston engines:

1. Engines originally designed to run on gas
2. Engines converted from diesel engines, by replacing the ignition and fuel supply systems.

Group No. 3 - Russian assemblers

most controversial category. Unfortunately, in Russia a number of integrators buy gas piston engines of dubious origin - used or remanufactured. Further, at their own discretion, they assemble around them an integrated thermal power plant on any, at their discretion, equipment. Chinese components or devices taken from other power plants can be used. We are aware of cases when a client, only after a breakdown of a GPU purchased from a Russian integrator, found out that the engine had already been repaired and was restored.

It would seem that such a big difference makes it impossible to compare power plants different category between themselves. However, this is not the case - by dividing the cost by the quality indicator, you can determine the "given price". For example, the first category is divided by 100%, the second - by 85% and the third - by 70%. And to make a comparison of already "given" prices, reflecting not only the actual cost of the equipment, but also taking into account the "adjustment for quality."

Part two - comparison under the same conditions

Rule number 1 - comparing fuel consumption with the same calorie content

When comparing any manufacturers, such a question as gas consumption comes in second place (of course, the question of cost remains in the first place). However, it should be remembered that gaseous fuel, depending on the region and delivery conditions, may have different caloric content. Accordingly, the higher the calorific value (calorific value) of the gas, the smaller the volume of this gas will be required to produce 1 kWh of electricity.

Gas calorific value (traditionally measured in kilocalories), internal energy and its calorific value (traditionally measured in megajoules) are rigidly related by the formula:

1000 kcal = 4.1868 MJ= 1.163 kWh

This means that 1 Nm3 of gas with a calorific value of 1000 kcal contains 4.1868 megajoules of energy, or 1.163 kWh.
In a proportional way, we find out that 1 Nm3 of gas with a calorific value of 8000 kcal contains 33.4944 MJ of energy, or 9.304 kWh.

The internal energy of 1 Nm3 of this gas, equal to 9.304 kWh, shows that if 1 Nm3 of this gas (with a calorific value of 8000 kcal) burns in the combustion chamber of a gas piston power plant, whose electrical efficiency is 39%, then the result is

9.304 * 0.39 = 3.6286 kWh

Thus, for the production of 1 kWh in a power plant with an electrical efficiency of 39% from gas with a calorific value of 8000 kcal (or a calorific value of 33.5 MJ), it takes:

1 / 3.6286 = 0.2755 Nm3 of gas.

As you can see, the relationship between the calorific value of gas (its calorific value) and gas consumption always has a direct relationship - the higher the calorific value, the lower the fuel consumption. Having only a part of the values, for example, only the efficiency of a power plant, it is possible to determine its consumption on gas with any calorific value, which in turn will allow comparison in the same initial data on fuel.

Rule number 2 - full efficiency - full "Effect"

Gas piston power plants used for short-term operation as backup source can be perfectly used without additional costs for the installation of a heat recovery system (cogeneration), since the cost of this system cannot be paid off due to the rare use of the power plant. In power plants designed for permanent job the situation is different.

Regardless of the desire of the owner, the gas piston power plant will produce thermal energy, as the fuel detonates (burns out) in the combustion chamber. This free heat can save a significant amount of money that would have been spent on producing the same amount of heat in a boiler house.

It is not correct to compare power plants only by electrical efficiency, since power plants produce not only electricity. It is possible and necessary to make a comparison by the sum of factors - electrical efficiency and thermal efficiency. When conducting a feasibility study in without fail the utilized heat should be taken into account, since only with such a construction of the energy center will its payback come sooner.

Example:
Power plant A has an efficiency of 41%, and power plant B has an efficiency of 39.5% (1.5% difference). However, the total efficiency of power plant A is 87.5%, while the second participant has a total efficiency of 3% higher, and is 90.5%.

Rule #3 - be realistic

The same price and the same gas consumption does not make power plants the same. There are other parameters such as resource and cost of maintenance. For example, if a domestic gas piston power plant costs two times cheaper than an imported one, and its resource is seven times less (8,000 hours versus 60,000), then its price is probably not entirely relevant. For the same period of ownership, the domestic one will have to be changed several (obviously more than two) times.

Maintenance, i.e. daily costs, is no less important than initial cost. It is very common to see how a power plant with more expensive spare parts "eats away" all of its advantage, achieved through a lower price, in just the first year of operation. If the manufacturer does not provide detailed service costs, along with a detailed maintenance program, then this should cause some concern for qualified employees conducting a feasibility study. Detailed service should consider:

• Cost of spare parts, including VAT and customs clearance
• Regular oil change costs *
• Cost of oil wastage **
• Maintenance personnel costs ***

* It should be remembered that some manufacturers are cunning, indicating the maximum oil change interval, which in reality will be reduced by one and a half to two times.

** The amount of oil for waste varies, on average, from 0.2 to 0.5 g / kWh for imported manufacturers.

*** Independent maintenance of a gas piston power plant can be much more expensive than the periodic involvement of professional personnel due to the fact that self service requires not only factory training, approvals and possession software, but also the purchase of expensive specialized tools (including expensive gas analyzers, multimeters, oscilloscopes, pyrometers, etc.).

How quickly does the GPU pay off?

The payback period of the GPU depends on several factors, such as the capacity of the energy center, its cost, the cost of gas, the cost of electricity, and thermal energy, etc. But on average, a gas piston installation pays off in a period of one to three years, with constant use. We offer to calculate the payback of a gas piston installation with your parameters.

How much does a kWh cost when using a GPU?

The cost of one kilowatt of electricity received from the GPU can be calculated using a simplified formula: Cost \u003d Gas cost / GPU consumption per 1 kW + Maintenance cost for the period / Number of kilowatts generated for this period; (excluding thermal energy).

Consider this formula on several real examples:

Paper mill, p. Chaltyr, Tedom D1200 GPU with MWM TCG2020V12 engine

Gas cost (6.23 rubles) x GPU consumption per 1 kW (0.242 cubic meters) + Maintenance cost for the period (135,000 rubles per month) / Number of kilowatts generated for this period (691,200 kW) \u003d 1 rub. 70 kop.

Casino Shambhala, p. Shcherbinovskaya, GPU Tedom D800 x 2 with MWM TCG2016V16 engine

Gas cost (7.68 rubles) x GPU consumption per 1 kW (0.246 m 3) + Maintenance cost for the period (166,400 rubles per month) / Number of kilowatts generated for this period (921,600 kW) \u003d 2 rub. 07 kop.

You can get more accurate values, taking into account the specified parameters, using the GPU payback calculation - calculate.

Can I disconnect from the network with my GPU?

Can. But you need to correctly calculate the power of the power center operating in the island and provide for redundancy in case emergencies. For example, if the capacity of an object in the third category is 1.5 MW, of which the first category is 89 kW, then it is recommended to install two machines of 1 MW each and diesel generator per 100 kW.

What is the guarantee for gas engines?

The standard warranty period is twenty-four months, during this period all cases of factory defects and defects are usually detected. If the customer has additional wishes to extend the warranty period - this is doable, we can offer extended warranty conditions for our equipment.

What is the lifespan of a GPU?

The total service life of the GPU is 240,000 m/h (30 years), while every 80,000 m/h (10 years) the engine is overhauled with the replacement of all major components.

Gas piston or gas turbine plant?

To date, the possible drives for generators for decentralized mini-CHPs are gas piston (GPE) and turbine engines (GTE).

The issues of fuel consumption and operating costs are very important for future owners of stations, which are directly related to the benefits that the owner will receive and the payback period of the station equipment.

Picture 1.

The specific fuel consumption per generated kWh is less for a gas-piston plant, and at any load mode. This is due to the fact that the efficiency of reciprocating machines is 36...45%, and gas turbines - 25...34%.

Figure 2.

The operating costs of a power plant with reciprocating machines are lower than those of a power plant with gas turbines. Sharp jumps on the GTE graph - engine overhauls. There are no such jumps in the operating costs of the GPA, major repairs require significantly less financial and human resources.

Comparison of turbine and reciprocating engines for mini-CHP applications shows that installation of gas turbines is most advantageous in large industrial enterprises which have significant (more than 20 MW) electrical loads. World experience shows unsuitability of GTPP low power for the needs of small energy.

How much GPU power do I need? How many GPUs do you need? Where can the GPU be installed?

Proper selection of the GPU, determining the installation location, determining the power, etc. can only be carried out by qualified personnel who have experience in operation and understand general principles work of our own generation, so we offer you to do a pre-project study for free, we will provide advice and help in choosing equipment. To do this, start by filling out a questionnaire.

What happens when the load exceeds the capacity of the GPU? (network, load shedding)

In the event of an increase in the consumption load above the power of the GPU (for example, during start-up loads of production equipment), automation allows you to compensate for the missing power from the network.

In addition, the GPU automation is capable, in island mode, of stepwise loading to ensure more stable engine operation, while the GPU itself determines the time intervals for switching on load groups (at the initial stage of setting, the priority of load groups is set), and on / off algorithms. This allows, in case of power shortage, not to stop the power supply due to an overload emergency event, but to turn off the least significant consumers, this automation mode is called "load shedding".

What happens if consumption is less than calculated?

Installation automation choose optimal mode operation of the equipment, and in the case of parallel operation of two or more machines, control algorithms are used that provide an optimal and uniform load on the units, their rotation in operation and the same operating time by hours.

Is it possible to sell excess heat and electricity?

Yes, in most cases it is not even necessary to obtain a tariff for the sale of electricity and coordinate with the regional dispatch service. You can get more detailed information by contacting our specialists.

In this article, we will try to understand the age-old question for power engineers: "Gas piston unit or microturbine plant?".

I'll make a small note right away. A lot of articles have been written about the advantages of certain homogeneration plants and technologies, many myths have been folded. We do not pursue commercial purposes, and this article is based solely on our experience in the design of such facilities. And also we do not set limits for ourselves regarding the object, we simply compare the settings.

First, let's get acquainted with our applicants.

gas piston power plant- this is a generation system created on the basis of a piston engine internal combustion running on natural or other combustible gas. It is possible to obtain two types of energy (heat and electricity) and this process is called “cogeneration”. If a technology is used in gas-piston power plants that also makes it possible to obtain cold (which is very important for ventilation, refrigeration, industrial cooling), then this technology will be called “trigeneration”.

Appearance of the gas piston unit (GPA)

Photo from the site: manbw.ru

gas turbine power plant is a modern high-tech installation that generates electricity and thermal energy. The basis of a gas turbine power plant is one or more gas turbine engines - power units, mechanically connected with the electric generator and united by the control system into a single energy complex. A gas turbine power plant can have an electrical output of twenty kilowatts to hundreds of megawatts. It is also able to give the consumer a significant amount (twice as much electric power) of thermal energy if a waste heat boiler is installed on the turbine exhaust.

Appearance of a microturbine (micro-GTU)

Photo from www.capstoneturbine.com

The determining criteria for owners of autonomous power plants are fuel consumption, the level of operating costs, as well as the payback period for power plant equipment. And these questions are related to the benefits and problems that the owner of the power plant can have. Therefore, we will begin to understand everything in order.

ROUND 1. PRICE

Since the price is sometimes a determining factor in the choice of equipment, let's compare the cost of GPA and micro GTU.

Specific capital costs for gas compressor units range from 600-800 USD/kW.

Micro-GTU is more expensive and this amount is already 1300-1800 USD/kW.

The cost depends on the manufacturer. Foreign installations are more expensive than Russian counterparts.

In comparison with the price, we prefer GPU.

ROUND 2. GAS CONSUMPTION

It is quite difficult to compare gas consumption for GPA and micro-GTU. Firstly, a large number of manufacturers. Secondly, each manufacturer has a wide the lineup.

For comparison, take the leading manufacturers. Firms Jenbacher (manufacturer of GPU) and Capstone (manufacturer of micro-GTU).

If we compare gas consumption, then GPA wins with a slight advantage.

2:0 in favor of GPA

ROUND 3. EFFICIENCY

Let's compare the efficiency of the same GPU and micro-GTU

Another point in favor of the GPA.

ROUND 4. HEAT OUTPUT

Cogeneration equipment is installed both to produce electrical energy and heat. Therefore, we compare which machine gives more thermal energy.

Therefore, the score becomes 3:1 in favor of the GPU. Let me remind you that the model range is wide and the numbers may change. Here are the values ​​for sample models. The average ratio of thermal load to electrical load for the GPU is 1.2. For micro-GTU - 1.5-2.2.

ROUND 5. LOAD MANAGEMENT

This is a fairly significant factor in the choice of equipment. IN real life load electrical and thermal variables. Despite the fact that the generating equipment is selected under base load, it should have flexible working hours.

Reference: Adjustment range - minimum permissible load at which the unit is capable of operating.

Reference: The GPU can operate at a lower load, but this is highly undesirable. Excerpt from the technical documentation of Jenbacher GE: when operating in a separate (autonomous) mode, it is allowed to work with partial load from 20% to 40% of the nominal, but not more than 6 times a year, and for up to 24 hours. Offline operation with a load below 50% of the nominal is allowed no more than once a day for a period of no more than 4 hours.

The micro-GTU starts to approach the GPU. Score 3:2.

ROUND 6. POWER AND AMBIENT TEMPERATURE

The electric power parameters of generating plants, according to existing ISO standards, are measured at t +15°C. Therefore, the parameters given in the technical data sheet correspond to a temperature of +15°C. Let's see how the power of the installations behaves at different temperatures:

As can be seen from the graph, the power of the GPU at low temperatures remains unchanged.

With a significant increase in temperature environment the power of the gas turbine is reduced. But with a decrease in temperature, the electric power, on the contrary, increases.

We do not assign points to anyone.

ROUND 7. EFFICIENCY UNDER DIFFERENT LOAD

Loading of installations during operation can change. The efficiency of the installations at various loads is shown in the figure. This indicator will affect fuel consumption at different loads.

It follows from the graph that the efficiency of the GPU remains stable up to a load of 40%, then it starts to decrease. In a micro-GTU, the efficiency decreases along with the load.

But let's not forget about loads below 50% for the GPU. After all, they are detrimental, and sometimes destructive for piston installations. The operation of piston units at low loads leads to the onset of overhaul not in 6 years, but in 2-3 years. This is a very high price to pay for low load efficiency gains.

Therefore, we conclude that both machines behave approximately the same in the range from 70% to 100%. Which is the working range. So the score stays the same after this round.

ROUND 8. ECOLOGY

It should be noted that gas piston units are significantly inferior to gas turbine units in terms of NOx emissions. Since engine oil burns out in significant volumes, piston units have a level of harmful emissions into the atmosphere that is 15-20 times higher than that of gas turbine units. The content of CO (at 15% O 2 ) for gas piston engines is at the level of 180-210 mg/m3, despite the presence of expensive catalytic purification of flue gases in the GE Jenbacher exhaust tract. To meet the MPC requirements, when using reciprocating machines, it is necessary to build high chimneys, which is an additional cost.

We assign a point for ecology to a micro-GTU. The score is compared, 3:3.

ROUND 9. NOISE

Noise is one of the problems in GPU operation. During the operation of the GPU, it is observed high level low frequency noise accompanied by vibration. Therefore, to eliminate the noise load, it is necessary to resort to the construction of noise-protective casings. These are additional costs. Due to the vibration effects of the GPU, it is not possible to install it on the roof of the building.

Micro-GTP also has a noise impact, but it is much lower.

We assign the ball to the micro-GTU. And now the micro-GTU is taking the lead, 3:4.

ROUND 10. LOAD LOAD

The load surge for GPUs and micro-GTUs is quite high. For a more detailed assessment, let's compare how the cars behave with a 50% throw.

The numbers are clear. The GPU gets its point. The score becomes 4:4.

ROUND 11. OIL

This round was obviously lost by the GPA. But without him there is no place.

Particular attention should be paid to the amount of engine oil used in the operation of a gas piston engine in a power plant drive. Of course, the oil must be recommended for this gas piston unit.

Reference: The actual consumption of engine oil per 1 MW of the Jenbacher GE unit can reach 15,000 liters per year. One of the recommended engine oils for gas engines is Pegasus 705 (MOBIL). Wholesale price is -4-6 dollars per liter, and a special engine oil for gas piston engines of the Mysella 15W-40 (Shell) brand costs $ 1,000 per barrel of 208 liters.

Waste oil from gas piston units cannot simply be dumped on the ground - 600 liters per 1 MW must be disposed of - this is also a fixed cost for the owners of the power plant.

A clear advantage of micro-GTU. 4:5, a micro-GTU pulls forward.

ROUND 12. FUEL

“Microturbines are not as omnivorous as their full-sized counterparts and there are a number of restrictions on the composition of the fuel gas,” this opinion can be easily found in any comparison of GPUs and micro-GTUs. However, it is not. Modern microturbines operate on almost any gaseous fuel. Of course, a special configuration of a micro-GTU will be required for operation. But after all, GPAs of mass production will not work on "sour" gas. Therefore, this expression is far-fetched in favor of the GPU.

But this round is included for a reason. The micro-GTU has a significant drawback in terms of working gas pressure. For the operation of a micro-GTU, a gas pressure of about 5 bar is required. If you do not have such pressure in the system, then you need to install a booster compressor. With the installation of a booster compressor, own needs and capital costs will increase.

Another point goes to the GPA. The score becomes equal to 5:5.

ROUND 13. MASS

GPA in terms of size-weight has a worse characteristic compared to micro-GTU.

From the presented dimensions it follows that the GPU requires more space, because. has more weight per unit of power.

The score becomes 5:6 in favor of the microturbine.

ROUND 14. COST OF MAINTENANCE AND REPAIR

This is the most controversial issue. Of course, the cost of operation depends on many factors: in what conditions it is operated, how regulatory requirements of manufacturers are observed. For our evaluation, we take ideal conditions. During operation, all requirements of the manufacturer are met.

The cost of operating a microturbine is less than that of a GPU. This is due to several factors:

• No oil costs
• No need to change filters often
• Fewer moving parts

We will not cite operational service figures. There are reasons for this. Firstly, this characteristic is separate for each model and manufacturing plant. Secondly, they depend on the operation of the equipment. Therefore, we evaluated only own experience in similar objects.

Overhaul is also a rather controversial issue. Cap cost. repair also depends on many factors. But for ideal conditions, the overhaul of the turbine will cost less than that of the GPU. The cost of overhaul of a gas turbine, taking into account the cost of spare parts and materials, is 30-40% lower than the cost of repairing a gas piston unit.

Micro-GTU gets another point. 5:7

ROUND 15. RESOURCE BEFORE OVERHAUL

The resource before overhaul is 40,000-60,000 working hours for a gas turbine. At correct operation and timely maintenance of a gas piston engine, this figure is 60,000 - 80,000 working hours. Of course, it all depends on the manufacturer.

GPU is trying to catch up with micro-GTU. 6:7.

ROUND 16. NUMBER OF LAUNCHES

A gas piston engine can start and stop an unlimited number of times, which does not affect its engine life. The gas turbine plant, due to the sharp changes in thermal stresses that occur in the most critical nodes and parts of the gas turbine hot duct during quick starts of the unit from a cold state, it is preferable to use it for constant, continuous work. The number of starts of the gas turbine plant is 300 times a year without the slightest loss of resource.

The GPA receives its point and the score becomes equal to 7:7.

Let's summarize all the results

From all this one can draw a conclusion. The two machines have both their pros and cons. It is rather difficult to compare them. And to say which one is better does not work out. It all depends on the conditions and requirements where the machines will be operated.

On the territory of the Republic of Belarus, there is a rule: cogeneration equipment is selected for the heat load. That is, if you currently have thermal load is 1 MW, then the generated electrical power must correspond to the thermal power. Based on this fact, cogeneration equipment is selected for the base heat load, you will not be allowed to emit heat from cogeneration equipment into the air. Therefore, micro-GTUs are optimally suited for facilities where there is a large need for heat. That is, where the thermal load is several times greater than the electrical load.

Let's look at a few examples:

1. Swimming pool

The pool is a great option for installing a micro-GTU in it. A feature of the pool is the need for a large amount of heat to maintain the required temperature of water and air. And the electrical load is several times less than the thermal one. Therefore, by installing a micro-GTU, you will provide yourself necessary quantity electrical and thermal energy. Secondly, the micro-GTU will provide all the necessary dips in consumption both day and night.

2. grain dryer

The grain dryer consumes thermal energy 2-3 times more than electrical energy. Perfect option to install a micro-GTU. Why is it beneficial to install a micro-GTU despite the fact that the grain dryer is running during harvesting. The effectiveness of such a project is manifested in the cost gas burner used today in most grain dryers.

Reference: The cost of a grain dryer with a power consumption of 16 kW MEPU M150k today is 37,000 euros. The cost of a gas burner is from 5000 euros. The approximate cost of the developed MTU of such a capacity is 35,000 euros.

Also, do not forget that during the operation of the drying complex, the load is constantly changing, and the micro-GTU is able to operate under changing loads.

An example of such a project

3. Shopping center

This option is suitable in the event that absorption chillers are used for air conditioning and technical refrigeration. In this case, at any time of the year a large amount of heat is needed. At night, when there are no customers, there is no need for air conditioning and electricity consumption is reduced. Therefore, a microturbine will cope better than a GPU.

4. office space

An office space is suitable only if an absorption air conditioning system is installed. refrigeration machines. Here the advantages are the same as in the shopping center.

In conclusion, I would like to say that when choosing the power units of an autonomous power plant, consultations of specialists educated both technically and economically are necessary. Consulting allows you to competently, impartially and objectively determine the choice of the main and auxiliary equipment. Also, competent consulting from energy professionals helps avoid costly design errors.

Gas piston generator sets (GPGU) are a design of a gas piston engine and synchronous generator placed coaxially on one common frame. As a rule, the units are supplied complete with cooling systems, air intake, exhaust manifold, control panel, fuel supply system, starting system, etc. GPGU-based power plants serve for continuous power supply to the consumer for a long period of time (several years or even tens of years) and require short stops only for planned after-sales service and repair. Usually this is no more than 1.5-2% of the operating time.

Main distinctive features:

Electrical efficiency can reach 50%, while the efficiency (el.) of gas turbines or microturbines does not exceed 35-37%. Therefore, if electricity generation is a priority for you, then the use of GPGU will be preferable. It is known that for the production of 1 kW of electrical energy, a gas piston generator set consumes one third less gas than a turbine driven unit.

The equipment, in fact, is an internal combustion engine (ICE) that uses gaseous fuel as fuel. Highly qualified engineers are required for operation and maintenance.

Most generating equipment is made to order. Manufacturers try to take into account the expected operating conditions (height above sea level, average temperature, gas composition, gas pressure, etc.). It is usually impossible to buy devices of the required specification directly from the warehouse. The manufacturing cycle is strictly regulated by the manufacturer and usually takes 7-8 months. Plants with a gas turbine drive are manufactured 1.5 - 2 times longer.

Operation usually does not require a fuel gas compressor, and for some manufacturers, engines can be operated at a gas pressure of 0.2 bar.

Most manufacturers regulate the time to the first overhaul at 50,000 - 60,000 hours. Some aggregates high power require overhaul after 120,000 hours of operation. Up to 3 overhauls are allowed. Thus, the average service life is 25-30 years.

Overhaul can be carried out at the site of operation of the equipment without moving the unit to the site of the manufacturer or dealer. ROLT power systems sells spare parts and maintenance tools.

The efficiency to a small extent depends on the ambient temperature. While the efficiency of the turbine begins to decrease significantly already at 300 C.

• High electrical efficiency
• Simple and clear design
• Preparation time
• Work on gas low pressure
• High resource
• On-site overhaul
• Weak dependence on ambient temperature

The cost of gas piston generators

One of the main competitive advantages is relatively low cost. The price is largely determined by its power. As a rule, manufacturers of power equipment operate with the parameter "cost installed capacity". To estimate this value, you can use the following data:

• for GPES - 400-600 $/kW;
• for turbines - $800-1200/kW;
• for microturbines - 1500-2000 $/kW.

These figures are obtained empirically and do not take into account the cost of purchasing additional engineering equipment, packaging, logistics, installation supervision and commissioning works.

To estimate the full cost of project implementation, please send your request in a form convenient for you to the e-mail address [email protected] or fill out an application (questionnaire). Within 1.5-2 hours, our specialists will send you a technical and commercial proposal (TCP) in strict accordance with your terms of reference. The TAP details:

• Power plant device:
• Basic engineering systems;
• Electrical and thermal scheme;
• Dimensional installation drawing, etc.

Commercial part, including:

• Scope and terms of delivery;
• Delivery times and offer validity periods;
• Warranty obligations.

If you experience difficulties in filling out an application for manufacturing, call 8 800 775 06 95 (free of charge in Russia) and our engineers will conduct a detailed consultation on the procedure for ordering power equipment under the ROLT brand.

Introduction

A gas piston plant with thermal energy recovery is a gas piston engine or an internal combustion engine (Fig. 1), with the help of which Electric Energy, and thermal energy ( hot water or steam) is obtained by recycling the gas-air mixture used in the engine using a heat exchanger.

In GPA, the maximum overall efficiency is 80-85% (electric efficiency is about 40%, thermal efficiency is 40-45%). The ratio of electrical power to thermal power is 1:1.2. The electrical power of a single unit of the GPU can be from 1 to 16 MW, and, given the fact that the units can operate in parallel, the power required by a potential customer is practically unlimited. It is worth noting that these parameters may differ significantly depending on the manufacturer and the specific project, incl. minimum and maximum power a single block (they can be made by the manufacturer to order).

At present, GPUs are used by various enterprises (including industrial and energy supply), medical and administrative buildings, large hotels, shopping, sports, office centers, etc.

It should be noted that GCUs are successfully implemented on drilling platforms and wells, mines, treatment facilities, as a backup, auxiliary or main source of electricity. This is due to the fact that GPUs can use the following types gas:

• propane-butane mixtures;
• natural (liquefied, compressed, trunk);
• associated gas from oil wells;
• industrial (pyrolysis, coke, mine);
• biogas;
• etc.

During the reconstruction of power facilities or new construction, several layout solutions for the introduction of GCUs can be distinguished:

• 1. Construction of gas compressor unit on a separate site, new construction.
• 2. Installation of GPU in an existing boiler house, as a superstructure.

Comparison of GPU and gas turbine
installations (GTU)

The main advantage of the GPU in comparison with the GTP is its resistance to reducing the electrical load. When the load is reduced to 50%, the electrical efficiency of the gas turbine is significantly reduced. For GPA, the same change in the load mode practically does not affect both the overall and electrical efficiency. With an increase in ambient temperature from -30 to +30 ° C, the electrical efficiency of the gas turbine falls by 15-20%. The GPU, in turn, has a higher and constant electrical efficiency over the entire temperature range.

The specific fuel consumption per generated kWh of electricity is less for the GPU, in any load mode. This is due to the fact that the electrical efficiency of the GPU is greater. With the same electrical power, the generation of thermal energy in gas turbines is higher, therefore, in some cases, for a potential consumer, this may be an important factor.

During the construction of a GPA, much more space is required than during the construction of a GTU, although there is no need to build a compressor to boost gas at the inlet to the unit. Reducing the gas pressure reduces the protective zone of the installation, thereby creating the possibility of operation in a residential area.

GPU, unlike GTU, often needs to be stopped for maintenance. As a rule, the overhaul of the GPA is carried out on site, and the GTU is transported to a special plant.

This comparison is conditional and the choice of one or another technical solution depends on the specific project and the characteristics of the equipment of various manufacturers.

Experience of CJSC Volgoelectroset-NN
during the operation of a mini-CHP
Microdistrict "October"
in the city of Bor, Nizhny Novgorod region.

The main technical and economic indicators of the mini-CHP project of the Oktyabrsky microdistrict in the city of Bor:

• 1. electrical and thermal power 4.2 MW and 14.85 MW, respectively;
• 2. generating equipment - four GPUs operating in parallel (Fig. 2);
• 3. heat generating equipment - four GPU heat recovery modules and two hot water boilers operating in parallel;
• 4. Generator voltage is 10 kV;
• 5. Recycled fuel cells are supplied to the municipal heating networks for the needs of heating, ventilation and hot water supply (DHW) of the Oktyabrsky microdistrict;
• 6. output of power to the power system of OAO Nizhnovenergo at a voltage of 35 kV: for two distribution substations 110/35/10 kV and two distribution substations 35/10 kV;
• 7. the possibility of a backup, isolated from the power system, power supply to consumers from one substation;
• 8. block-integrated layout of equipment;

• 9. fully automated technological process management, shift operational personnel - 2 people;

• 10. the construction of the facility is carried out in two technological stages; at the first stage, two cogeneration units were put into operation (electric power - 2 MW, thermal power - 2 Gcal/h);

• 11. the volume of capital costs for the construction of the facility - 160 million rubles. (first stage 80 million rubles);
• 12. composition of financial resources attracted for the construction of the facility: 50% - own funds, 50% - funds of credit institutions;
• 13. Tariffs for produced EE and TE are 10-15% lower than those approved for organizations and enterprises in the area;
• 14. equipment service life before overhaul - at least 64 thousand hours (~ 8 years);
• 15. The payback period of the project is 4-5 years, depending on the cost of energy.

Experience of JSC "Bashkirenergo"
during GPU operation

Within the framework of the program of equipping sanatorium-resort institutions of the Republic of Bashkortostan with autonomous power supply sources, in December 2003, a mini-CHP with one Jenbacher unit (J320GS-N.LC) was launched in the Yumatovo sanatorium, located near Ufa, similar to the two already used at the Krasnousolsk mini-CHP. For the new developing resort "Assy", located in the mountainous Beloretsk region of Bashkortostan, the tender for the supply of equipment similar in characteristics was won by the company "Caterpillar" thanks to a flexible pricing policy.

The commissioning of the GPA mini-CHP "Assy" with two CAT G3516 units with an electric power of 1.03 MW was carried out at the beginning of 2004.

In March 2004, the operation of a medium-capacity state-of-the-art power plant - Zauralskaya CHPP in Sibay, with an electric capacity of 27.4 MW, consisting of 10 Yenbacher units (JMS620GS-G.LC), was launched. The need to build this CHP was due to the shortage of electric power in the Bashkir Trans-Urals, powered by neighboring regions (Chelyabinsk and Orenburg). The choice of GPA technology for the Zauralskaya CHPP was made on a competitive basis in competition with alternative gas turbine units. Today it is the largest gas-piston thermal power plant in the post-Soviet space, a unique facility for the Russian energy sector. Thermal power was selected based on the possibility of year-round supply DHW loads resorts and the city of Sibay, taking into account its daily fluctuations, and in heating season- with the possibility of issuing heat to the heating circuit in parallel with the existing boiler houses.

From 2003 to 2005 the installed electric capacity of gas-piston CHPPs increased from 3.818 to 34.251 MW, the number of HP units - from 4 to 17.

conclusions

When choosing a GPU, attention should be paid to various characteristics, because depending on a particular supplier, they can differ significantly the following factors: reliability, efficiency, environmental friendliness, presence or absence of sound insulation, delivery time for equipment and spare parts in case of breakdown, etc. Special attention should be given to foreign manufacturers, because the delivery time of the equipment itself or spare parts from abroad can be quite long, which will lead to equipment downtime.

Customers are advised to hold tenders or competitions and always remember that in addition to the cost of the main equipment of a mini-CHP (not only GCU), the cost of the entire plant implementation project should be taken into account. A potential customer does not always correctly assess the costs that arise during the implementation of a mini-CHP, because the cost of the entire project (in addition to the main equipment) can be many times higher. The costs of the entire project may include the following factors: connection to gas distribution networks, installation of sound insulation, construction transformer substations and power lines, laying of pipelines for the transmission of thermal energy, water treatment and water treatment facilities and much more.

Before starting and making a positive decision on the approval of the project, it is necessary to consider the following very important tasks:

• determine the cost of connection to power supply networks, if a mode of parallel operation with the power system is planned, as well as select and agree with the owner of the network and the system operator of the points of connection to the power system, determine the mode of operation of the mini-CHP and the scheme for issuing power to the power system;
• determine cost and availability technical feasibility connection to gas distribution networks;
• determine the cost and method of FC utilization (a new source, a source that replaces the capacity of an existing one, a source with parallel operation with an existing energy facility).

In preparing the article about the GPU, articles published in the journal Novosti
heat supply" and on the portal "Trigeneration.ru" (