KEMCO International Cogeneration Symposium
Seoul, 25.09.2003
Lindenberg-Anlagen, Germany
T. Wieck
25.09.03
www.lindenberg-anlagen.de
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Presentation Contents
Technical Developments and Operation
Instances in Germany
01
02
03
04
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Current Market Situation of Cogeneration in Germany
Emissions: Regulations and Technology
Technological Trends
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
4469
4500
3908
3299
3500
0
783
580
444
500
337
1000
1369
1500
1737
2000
2174
2500
2631
3000
1055
Anzahl der Anlagen
4000
4875
5000
bis
bis
bis
bis
bis
bis
bis
bis
bis
bis
bis
bis
bis
1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997
Cumulated number of installations
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1. Current Status
Current Status in Germany: 1998 - 2002
no
impulse from revised cogeneration laws
120000
kW electrical installed new
100000
80000
> 2000 kWel
50 - 2000 kWel
< 50 kWel
60000
40000
20000
0
1998
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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


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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 MWel 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:

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
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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% O2 ín exhaust gas:
NOx: 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 NOx, 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% O2 = 410 mg/Nm³ @ 5% O2
Korea now:
 NOx: 500 ppm @ 13% O2 = 2050 mg/Nm³ @ 5% O2
Korea & Seoul from 01.01.2005:
 NOx: 50 ppm @ 13% O2 = 250 mg/Nm³ @ 5% O2
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2. Emissions
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2. Emissions
Emissions Control:
 Lambda 1 engines (rich burn):
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Emission reduction is a secondary measure
Not combustion related
Depends only on size of 3-way-catalyst.
No problem to achieve NOx 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):


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
Typically turbocharged
Lambda 1.5 (open chamber) or 2.2 (pre-chamber)
The emission reduction depends on the combustion (primary measure)
Lower NOx requires higher lambda values to reduce the combustion
temperature
 Difficult to reach 50 ppm






Loss of power  higher specific investment
Loss of efficiency  higher gas consumption and higher CO2 output
Reduced lifetime of spark plugs and cables
Close to combustion limit, unstable operation
Higher CO output
No data available, no approval
 Only secondary measure to reduce NOx 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
Mech.
Efficiency
CO2 in 10
years
(30,000 MWhel)
mg/Nm³
ppm
kWm
%
tons
500
122
340
35.2
17,800
250
61
324
34.2
18,300
205
50
310*
33.2*
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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3. Technology Trends
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
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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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3. Technology Trends
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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3. Technology Trends
Combined Heating & Cooling with Absorption chiller units:
Investment Costs
Hotel 1000 Beds
1.500.000 €
Chiller
Boiler
Heating Unit
Absorption Cooler
1.000.000 €
Cogen Modul
500.000 €
0€
Chiller
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Cogen+Cold Water
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3. Technology Trends
Combined Heating & Cooling with Absorption chiller units:
Operating Costs
Hotel 1000 Beds
600.000 €
Maintenance
Gas
El. Power
400.000 €
200.000 €
0€
Chiller
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Cogen+Cold Water
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3. Technology Trends
Combined Heating & Cooling with Absorption chiller units:
Life Cycle Cost
Hotel 1000 Beds
7.000.000 €
6.000.000 €
Chiller
5.000.000 €
KWKK
4.000.000 €
3.000.000 €
2.000.000 €
1.000.000 €
0€
0
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8
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10
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3. Technology Trends
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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3. Technology Trends
Example on grid parallel operation:
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3. Technology Trends
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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3. Technology Trends
Example of Advanced CHP Control:
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3. Technology Trends
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.
2.
3.
4.
5.
6.
7.
8.
9.
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Identification of Potential Project
Data Acquisition
Feasibility Study
Go-No Go Decision
Detail Engineering
Inquiries
Order
Installation
Commissioning
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4. Installation Instances
Product Range of Lindenberg CHPs
2500 kW
2000 kW
Power
Heat
1500 kW
1000 kW
500 kW
0 kW
CHP 40
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CHP 65
CHP 120
CHP 220
CHP 300
CHP 400
CHP 600
CHP 800
CHP 1000
CHP 1400
CHP 2000
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4. Installation Instances
CHP 400 Unit for a Public Pool and District
Heating System (Germany):
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4. Installation Instances
Turboblower for Sewage Plant (China):
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4. Installation Instances
Direct Drive in Cogen Technology
Screw Compressor for Heat Pump (Northern Germany)
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