cogen REGION SPECIAL USA
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1 I s s u e REGION SPECIAL USA GE Energy gas engines Functional Applications as Diverse as Mother Nature CHP technology helps North America achieve its energy and environmental goals Raising the Bar for Unconventional Gas Applications GE introduces the Waukesha 275GL+ gas engine Financial Benefits from Federal Incentives Government incentives reward waste heat and renewable utilization
2 Dear Customer, This issue of coincides with the launch of the Waukesha 275GL+ natural gas engine as an ecomagination qualified product. On launch day, September 20, 2011, we are at the Waukesha, Wisconsin, factory for a comprehensive presentation on the 275GL+ including a hands-on view of the latest 12- and 16-cylinder models to demonstrate their effectiveness for our oil and gas industry customers. The high-performance, cleaner-burning 275GL+ is one of the Waukesha compression technologies that have enhanced our newly integrated gas engines portfolio, which includes Jenbacher gas engines, Waukesha gas engines, and Heat Recovery Solutions. Our business is focused on providing innovative and reliable solutions in power generation, gas compression and waste heat to power to our diverse customers throughout North America, from small towns like Auburn, New York, to major metropolitan cities like San Diego, California. These solutions operate on a broad range of fuel gases, including low-quality waste gases, and in many applications, from natural gas processing stations to dairy farms. In North America, and elsewhere, the fuel-flexible, highly efficient Jenbacher gas engines product line s synergies with the low emissions and reliability features of the Waukesha gas engines line create more solutions for the petrochemical, mining and manufacturing sectors. Our Heat Recovery Solutions portfolio meets the needs of our gas engines customers involved in renewable energy who are converting waste heat to power in smaller-scale output applications. Due to the regulatory push at the state and national levels in the U.S. for more efficient technologies that have minimal environmental impact, North America is in an excellent position to take advantage of the gas engines portfolio that GE offers. Federal policy, in particular, is providing financial incentives for innovations like the Clean Cycle TM system that recover waste heat from natural gas and biogas applications. Additionally, many regions are offering incentives for customers to install eration applications. Gas engines and waste heat recovery are a critical part of our strategy at GE to lead the global trend of maximizing energy production while minimizing greenhouse gas emissions. I am excited to be a part of it and look forward to working with you to build the next generation of energy-efficient products. Yours sincerely, Rafael Santana, president and CEO Gas Engines, GE Energy 02
3 Functional Applications as Diverse as Mother Nature 2.0 High efficiency, dependability, and the capability to operate on a wide variety of fuels including natural gas, biogas, landfill gas, and a host of other fuel sources, are just some of the advantages offered by GE Energy s Gas Engines business combined heat and power (CHP) plants. Vast resources of natural gas, biogas, and landfill gas are some of North America s greatest advantages, yet today they remain largely untapped sources of energy. Taking Advantage of the Fast Changing World. GE s gas engines CHP technology helps North America meet its ever-increasing demand for electricity from coast to coast by using the continent s abundant natural gas resources to generate power in a wide range of applications from dairy farms to office buildings; from small towns to metropolitan cities; from Auburn, New York, to San Diego, California. GE s gas engines CHP technology helps North America meet its ever-increasing demand for electricity from dairy farms to office buildings; from small towns to metropolitan cities; from Auburn, New York, to San Diego, California. > San Francisco, Calif., U.S Meeting Power Demands and Environmental Requirements. GE s gas engines CHP plants are supplying onsite heat and power to more than 450 facilities across North America, including hospitals, universities, farms, and greenhouses. And because CHP (also known as eration) plants are inherently more energy efficient than using separate systems to create heat and power, the plants generate power while using less fuel and reducing environmental effects in the process. GE s CHP plants meet power demand while also meeting increasingly stringent environmental standards and Environmental Protection Agency (EPA) regulations, helping North America toward its longterm goals of reducing emissions from power production
4 Real World Results Transforming Landfill Gas into Energy. Using GE s advanced gas engines CHP technology, a Missouri correctional facility is transforming waste gas from a nearby landfill into 3.2 MW of power to provide electricity and heat for site operations. Generating power from this previously unused fuel source produces enough energy annually to power 1,900 homes and heat water for 1,400 homes while reducing CO 2 emissions equivalent to removing nearly 3,800 automobiles from American roads. Missouri Governor Jay Nixon stated, This project creates a cleaner, reliable, and consistent source of energy from a naturally occurring by-product of our landfills. I commend this innovative partnership for the benefits it will bring our economy, environment, and communities. 1 A Greenhouse Uses CHP to make Greener Energy. A high-efficiency power plant powered by four Jenbacher gas engines eration modules is providing onsite power and heat, along with a ready supply of CO 2 to fertilize the facility s tomato crop, to a 55-acre tomato greenhouse complex operated by Great Northern Hydroponics, a division of Detroit-based Soave Enterprises, in Ontario, Canada. In addition to generating power and heat for greenhouse operations, the plant also treats the gas engines exhaust, enabling CO 2 from the exhaust to be recycled and used as fertilizer to enhance greenhouse crop production. Surplus power from the greenhouse power plant is being sold to the local grid under a contract with the Ontario Power Authority, and the plant supplies enough electricity to power 12,000 15,000 Canadian homes annually. The tomato greenhouse complex in Ontario, Canada, also treats the gas engines exhaust, enabling CO 2 from the exhaust to be recycled and used as fertilizer to enhance greenhouse crop production. The 12 MW plant operates at greater than 90 percent overall efficiency, and is one of seven Ontario Power Authority projects intended to demonstrate how advanced eration technologies can lead to energy independence and improved grid reliability, and can support Canada s clean energy goals. Our first-ever greenhouse eration project was made possible because of Ontario s commitment to energy efficiency and national initiatives to add significant amounts of energy from eration to the provincial power grid, said Guido van het Hof, president of Great Northern Hydroponics. The Figures Speak for Themselves. With overall efficiencies up to 90 percent and the ability to convert fuel into cleaner energy in a variety of applications, GE s gas engines CHP plants have proven to be tailor-made for helping North America achieve its energy and environmental goals, said Roger George, regional sales leader for GE s Gas Engines business in North America. The figures speak for themselves. GE s gas engines CHP plants have proven to be tailor-made for helping North America achieve its energy and environmental goals, said Roger George, regional sales leader for GE s Gas Engines business in North America. facts and figures: Roger george Regional sales leader for GE s Gas Engines business in North America High electrical efficiencies up to 48.7 percent Overall efficiency (electrical and thermal) up to 90 percent Wide range of power and heat outputs Reduced CO 2 emissions Compact design, small footprint Gas engines operate on alternative energy sources Enhanced operational safety and availability Low investment costs source: 1 > GE s gas engines CHP plants range from 0.25 MW to 9.5 MW 05 06
5 2.0 Raising the Bar for Unconventional Gas Applications GE introduces the Waukesha 275GL+ gas engine, demonstrating expertise in compression, oilfield power generation and mechanical drive applications, and strengthening the competitive position of GE s Gas Engines business in the emerging unconventional gas space. The 275GL+ Adds to the Tradition. Sometimes it takes a new technology to meet unconventional needs, and the 275GL+ is just that. The 275GL+ represents the combination of outstanding engine design with over 80 years of Waukesha experience in manufacturing engines for the oil and gas industry. The 275GL+ boasts the most horsepower, the best fuel efficiency and flexibility, and the lowest emission levels in its class. The combination of reduced environmental emissions and high performance qualify the 275GL+ as an ecomagination product the first product from the Waukesha gas engines line to achieve such status. The 275GL+ boasts the most horsepower, the best fuel efficiency and flexibility, and the lowest emission levels in its class. Reliable Even In Unforgiving Environments. The high performance 275GL+ is designed to drive natural gas compressors and generators in harsh environments. The 275GL+ can operate on raw, untreated gas extracted at production sites, which reduces customers operating costs by limiting (or eliminating) the need for the transportation, storage and treatment of fuel. In addition to running on fuels of varying quality, gas compression site operators also require powerful, reliable and fuel-efficient engines that operate around the clock in challenging conditions with low emissions and long maintenance intervals. Designing all of these performance requirements into a single solution is certainly a technical challenge, but the 275GL+ addresses these sometimes competing priorities while delivering increased revenues for owner and operators. The 275GL+ meets these demands with no trade-offs, as it delivers all-around performance, including improved fuel tolerance and efficiency, more horsepower in a wider range of conditions, and lower emissions. With its low NOx capability, the 275GL+ meets the current 0.5 g/bhp-hr NOx requirement for non-attainment areas and the EPA s 2010 Spark-Ignited New Source Performance Standard requirements of 0.5 g/bhp-hr NOx and 1.8 g/bhp-hr CO. Unconventional Gas A Key Fuel Source for Today, and Tomorrow. The technology behind the 275GL+ illustrates GE Energy s unwavering global commitment to provide advanced, innovative solutions to meet our customers most pressing operational and environmental challenges. The advanced technology behind the 275GL+ demonstrates the expertise and innovation of the Waukesha product line in compression, oilfield power generation and mechanical drive applications for the oil and gas industry. Brian White, president of Waukesha gas engines Brian White, president of Waukesha gas engines, explains, Unconventional gas is one of the key sources of gas in North America and successful engine performance at these sites is all about application flexibility
6 It s about being able to maximize power output on a wide range of fuel quality and composition, from 750 Btu/ft 3 in the Canadian Horn River area to over 1200 Btu/ft 3 in the Marcellus and Eagle Ford shale plays in the United States. It s about meeting evertighter emission requirements as gas compression sites move closer to larger population centers. The 275GL+ allows our customers to maximize their revenues and positions them to successfully meet the growing demand for energy and the production, transportation and storage of unconventional gas. Brian White, president of Waukesha gas engines As an example of how 275GL+ technology is being applied in unconventional gas projects, GE recently sold three 12-cylinder 12V 275GL+ models into a coal seam methane application at the Kenya production site near Queensland, Australia. This project represents the first time Waukesha and Jenbacher gas engines are being jointly deployed as a groundbreaking integrated solution to provide compression and onsite power generation in the same project. The Kenya project will be strategically crucial to positioning the Australian site as a global supplier of liquefied natural gas. facts and figures: 16-cylinder 16V 275GL+, 4,835 hp at 1,000 rpm 12-cylinder 12V 275GL+, 3,625 hp at 1,000 rpm 2 percent horsepower advantage increases gas throughput by 920 million scf per year, creating additional annual revenue of $3.6 million at a wellhead price of $3.90/1,000 ft percent fuel efficiency advantage and lower CO 2 emissions reduce carbon footprint by 9 percent. Greenhouse gas emissions advantage is equivalent to removing 380 cars from U.S. roads annually 1.2 percent greater fuel efficiency saves 3.3 million scf of natural gas per year, enough to power 46 average U.S. homes annually Brian White President of Waukesha gas engines > Unconventional gas is a key power source in North America 09 10
7 U.S. Customers Can Reap Significant Financial Benefits from Federal Incentives The charter product in GE s Heat Recovery Solutions portfolio, the Clean Cycle system provides innovative technology for capturing waste heat from small-scale applications and converting it into electricity providing a significant source of additional revenue. Adapting ORC technology to smaller-scale applications. The Clean Cycle system is an adaptation of the Organic Rankine Cycle (ORC), a process that operates like a steam power plant, but with a working fluid that has a much lower boiling point than water. This allows the Clean Cycle system to generate electricity from waste heat as cool as 250 F (121 C). The working principle is basic: An evaporator captures waste heat that converts the high pressure working fluid from liquid to vapor. This high pressure vapor is expanded over a turbine coupled to a generator, which produces electricity. Then the vapor is cooled back into liquid form to be used again in the process. For decades, ORCs have been applied to very large industrial projects, but the vast majority of wasted heat worth billions of dollars has been emitted from smaller sites by machines such as reciprocating engines, gas turbines and biomass boilers. Now, the Clean Cycle waste heat-to-power generation system makes it possible to harvest the low temperature heat from these applications and turn it into 125 kw of power that can be used onsite or sold back to the grid. In many applications, the solution can pay for itself within 18-to-36 months, and since it requires no fuel, the Clean Cycle system generates energy with no additional emissions or fuel. Big Federal Incentives for Waste Heat Recovery. Aside from the technology s distinct operational advantages, Clean Cycle customers in the U.S. can reap significant financial benefits from federal incentives that reward waste heat and renewable utilization. These include 100 percent depreciation of the capital costs in the first year for a 2011 installation or 50 percent depreciation if the project is installed in 2012; an investment grant covering 30 percent of capital costs for renewable energy projects that generate more than 150 kw (if some of the construction occurs in 2011); and a $0.022/kWh production incentive for qualified renewable energy projects including biomass facilities that generate electricity before For decades the vast majority of wasted heat estimated to be worth billions of dollars has been emitted from smaller sites by machines such as reciprocating engines, gas turbines and biomass boilers. > Government incentives reward biomass facilities to encourage waste heat utilization 11 12
8 > An agricultural enterprise in the state of Michigan, U.S. Clean Cycle customers in the U.S. can reap significant financial benefits from government incentives that reward waste heat and renewable utilization. Many states in the U.S. also have their own grants and other incentives to encourage waste heat recovery. 33 states now have renewable portfolio standards that compel operators to generate set percentages of electricity from renewables, and 13 states qualify waste heat as cleaner energy. Alterations Improve ORC Functionality. The Heat Recovery Solutions segment has improved upon the standard Rankine Cycle process so that it can be applied to smaller-footprint plants and applications such as reciprocating engines, gas turbines and biomass boilers, and still generate up to 125 kw per unit. This involves three major changes. An Integrated Power Module (IPM) housing the high-speed turbine and generator contains highly-efficient magnetic bearings that allow the shaft to spin in a magnetic field instead of riding on a mechanical bearing. This reduces friction losses and the need for expensive-to-maintain lubrication systems and signifcantly improves reliability. Once the IPM generates raw power, sophisticated power electronics convert it into usable electricity with the same frequency and voltage as the connected grid without the gearboxes or mechanical step-down techniques that can produce parasitic losses and operating issues. A constant power factor of 1 makes costly capacitors unnecessary. While most ORC working fluids are hazardous, the Clean Cycle system uses a hydrofluorocarbon that is not flamable and minimizes the environmental effects. Synergies Create New Business Opportunities. Since Clean Cycle is such an ideal complement to GE s gas engines technology portfolio, it will be a catalyst for innovative integrated solutions that drive business growth, proclaims Brad Garner, president of Heat Recovery Solutions. Indeed, the flagship offering of Heat Recovery Solutions segment can grow GE s global renewable energy footprint precisely because of its synergies with the highly efficient power generation capabilities of Jenbacher and Waukesha gas engines. Clean Cycle is a catalyst for innovative integrated product solutions that drive business growth. Brad Garner, president of Heat Recovery Solutions A textbook example of that is GE s newly announced collaboration with the Italian-based eration systems provider AB Group. Over the next three years, GE will provide a large number of Clean Cycle units to combine with AB Group s existing Jenbacher J416 gas engines in a packaged solution that will generate 10 percent more electricity, improve plant electrical efficiency to 45 percent total output, decrease biomass usage in combined heat and power applications by 10 percent, and lower nitrogen oxide (NOx) and carbon monoxide (CO) emissions. Brad garner President Heat Recovery Solutions 2.0 Now you can experience in a new dimension: 2.0 makes it possible to experience GE even more intensively when reading. You can view films, animations, videos or other materials related to the marked articles on the Internet. It s as simple as this: All you need to experience the wide range of multimedia content from is an Internet connection and a webcam that is either integrated or externally connected to your computer. Surf over to and aim the webcam at the images marked in your. All of the articles in our customer magazine that are marked with the 2.0 logo contain stored multimedia content. Then hold the icon up to the webcam. This activates 2.0 and turns your computer into a digital extension of the contributions in. There are seven marked articles in this issue. For each, you can view related videos, animations and films on the web, and enjoy the stories in in Extended Reality! Enjoy your North American special of with 2.0! Masthead Publisher: GE Jenbacher GmbH & Co OHG, Achenseestr. 1-3, 6200 Jenbach, Austria Editorial team: Nancy Deptolla, Robert L. DiCocco, Sheila Gailloreto, John Lerch, Shonodeep Modak, Debra Murphy, Anja Pegger, Ray Pelosi, Susanne Reichelt Design and Layout: Zimmermann Pupp Werbeagentur Printer: Welch Printing, Louisville, Ky., U.S Picture credits: GE Energy
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