ADDED VALUE

ENHANCEMENT FOR

1,000kW-CLASS CHP SYSTEM

19 / Oct /2011

Presenter : M. Ogawa from MHI Sagamihara in Japan

OSAKA GAS CO., LTD.

&

MITSUBISHI HEAVY INDUSTRIES, LTD.

CONTENTS

1. MHI GAS ENGINE AND GAS TURBINE

(MHI : MITSUBISHI HEAVY INDUSTRIES, LTD.)

2. Added value enhancement

for 1,000kW- Class CHP SYSTEM

- Improvement of

the first step loading ratio

- Improvement of total efficiency

MHI GAS ENGINE

& GAS TURBINE SERIES

20

30

40

50

60

70

0.1 1 10 100 1000

OUTPUT POWER (MW)

EF

FIC

IEN

CY

(L

HV

%)

GAS ENGINE

GAS TURBINE

GTCC

Development trends

Output Range

10- 500MW

class

1- 10MW

class

100- 1000kW

class

Type

Gas turbine

GTCC

Gas engine

(low speed)

Gas engine

(high speed)

Customer

Gen. co.

Power Plant

IPP (Independent

Power Producer )

Large facility

Factory

Commercial facility

Hospital

etc.

What is required

High efficiency

High reliability

High total

efficiency with

heat recovery

Power supply

security for

emergency

GTCC :

GAS TURBINE COMBINED CYCLE

In combined cycle power generation, as shown above,

the gas turbine generates electric power,

and the steam produced by the exhaust heat of the gas turbine

rotates the steam turbine to generate electric power together.

DEVELOPMENT OF

MHI GAS TURBINE AND GTCC

MHI has developed more advanced high-efficiency and high power

gas turbines which MHI calls “ D, F and G series gas turbine”,

by increasing the turbine inlet temperature from 1,150 to 1,500 degree C.

WORLD WIDE EXPERIENCES

OF MHI GAS TURBINE (6 - 300MW)

MHI provides a wide range of gas turbines, from 6MW to 300MW class,

to meet various requirements from customers all over the world.

MHI has manufactured and delivered more than 500 gas turbines.

DEVELOPMENT

OF MHI LARGE GAS ENGINE (3 - 6MW class low speed gas engine)

MHI has developed more advanced high-efficiency and high power

gas engines, which MHI calls “ MACH”, by optimizing combustion.

MACH has 2 types of ignition system of spark and micro pilot.

Sales of MACH Gas engine

(3 – 6 MW class) 182 UNITS

942 MW

MHI Miller-cycle Gas engine

(1,000kW - Class)

Engine model GS16R2

Output power 1000kW

Engine speed 1200min-1

No. of cylinder 16-V type

Displacement 79.9L

Cylinder bore 170mm

Cylinder stroke 220mm

Gen. efficiency 41.7%

Total efficiency 74.1%

NOx (O2=0%) < 100ppm

(after de-NOx catalyst)

Development of MHI gas engine

45

40

35

Ge

nera

tio

n E

ffic

iency %

2000 2005 2010 year

Conventional

Lean Burn

Gas engine

+ Low speed

(Friction reduction)

+ Pme (power) UP

(researching)

Next generation

+ Long Stroke

+ Miller cycle

1995

+ Multi cylinders

MHI Gas engine keeps the best

efficiency under 1,000W class

these ten years.

MHI and OSAKA GAS

jointly developed

+ Added value

enhancement

+ high efficiency

turbo charger

+ combustion

improvement

MHI 1,000kW class Gas engine

Features and Advantages

- Lean-burn and miller cycle gas engine

with MHI original high efficiency turbo-charger

High efficiency : 41.7% at generator outputs

(The world best level under 1000kW class)

- MHI original integrated control system

and Pre-chamber combustion system

Good performance and High reliability : Stable start and fast loading

MTBF (mean time between failure) is longer

than 7,000hrs (The best level in Japan market)

MHI CHP package

Boiler with

De-NOx Catalyst

Silencer Heat Exchangers

75% total efficiency

with Heat recovery

75dB(A) Enclosure

Our CUSTOMERS ( Factory, Commercial facility, Hospital, Ship etc.)

GS12R 675kW x4

Electric propulsion ship GS16R 815kW x5 CHP package

Sales of MHI Gas engine

0

50

100

150

200

250

300

350

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

YEAR

TO

TA

L N

UM

BE

R O

F S

AL

ES

2001-2010 : total number 291units / total output 200eMW

GSR miller cycle Gas engine series

CONTENTS

1. MHI GAS ENGINE AND GAS TURBINE

(MHI : MITSUBISHI HEAVY INDUSTRIES, LTD.)

2. Added value enhancement

for 1,000kW- Class CHP SYSTEM

- Improvement of

the first step loading ratio

- Improvement of total efficiency

What’s added value of CHP ?

CHP : power supply and heat recovery

- Security of the emergency power supply

Quick power supply (within 40 sec.)

Increase of acceptable block load

(Gas engine cannot load

the full power immediately.)

- Eco-friendly (friendly to the environment)

Reduction of the emission and

waste heat for the environment

ADDED VALUE

Improvement of

the first step loading ratio GAS engine generator set can be used

as stand-by engine for emergency generator.

The acceptable block load for emergency

depends on the first step loading ratio.

1000kW-class

GAS engine gen-set

It is equal to 200kW st-by

diesel engine output.

In emergency

only 200kW output !!

(within 40 sec)

(If the first step loading ratio is 20%,)

Improvement of

the first step loading ratio

Combustion

chamber

Air / Fuel

mixtureFuel

gas

Air

Pre-chamber

gas

Exhaust gas

Air / Fuel

ratio control

Throttle valve

Gas flow

control valve

Speed control

Turbocharger

Proportional

control valve

Pre-chamber

gas control

Pre-chamber combustion system of MHI Gas engine

achieved quick start and loading within 40 sec

for emergency generator. (within 40 sec : Regulation in Japan)

Improvement of

the first step loading ratio

Pre-chamber

gas flow

Speed

Output power

Air / Fuel ratio

Controlled object

Pre-chamber

gas flow

Speed

Output power

Air / Fuel ratio

Controlled object

Pre-chamber

gas controller

Governor

Air / Fuel ratio

controller

Controller

Pre-chamber

gas controller

Governor

Air / Fuel ratio

controller

Controller

Integrated

controller

Controller

Integrated

controller

Controller

Conventional

system

Developed

system

MHI developed new control system and software with

original control logic, to improve the engine performance to

the load change such as block loading and load release.

Improvement of

the first step loading ratio

Conventional system

Development system

Time

Fuel gas flow

Block load

Speed

In case of putting

the block load

Increasing fuel gas flow

at the same time

putting the block load

Speed down

is suppressed

As MHI original control logic achieved to improve the engine

performance, the acceptable block load could be increased.

Frequency drop

It must be

less than 15%

of rated speed.

(Regulation

in Japan)

Improvement of

the first step loading ratio

By the adjustment parameters of engine controller,

the engine performance can be further improved.

0

200

400

600

800

1000

1200

1400

-5 0 5 10 15 20 25 30 35 40 45 50 55 60 65

Time (sec)

Sp

ee

d (

min

-1)

+15% of rated speed

-15% of rated speed

First step loading Engine start

The adjustment points

of engine parameters

Improvement of

the first step loading ratio

0

200

400

600

800

1000

1200

1400

0 100 200 300 400 500 600Cycle No.

Speed (

min

-1)

0

200

400

600

800

1000

0 100 200 300 400 500 600Cycle No.

Ind

ica

ted

me

an

eff

ective

pre

ssu

re (

kP

a)

First step loading

Multiple misfiring

Over 15% speed change

from the rated speed

Over 15 seconds until

the speed stabilized

NG data due to the

deviations from the

regulations

26.6 sec

17.6 %

To improve the engine performance, we investigated the

combustion state of each cylinder during block loading.

Improvement of

the first step loading ratio

0

200

400

600

800

1000

1200

1400

0 100 200 300 400 500Cycle No.

Spe

ed

(m

in-1

)

0

200

400

600

800

1000

0 100 200 300 400 500

Cycle No.

Ind

ica

ted

me

an

eff

ective

pre

ssu

re (

kP

a)

First step loading

11.9 sec

12.2 %

OK data due to

satisfying with the

regulations

Within 15% speed change

from the rated speed

Within 15 seconds until

the speed stabilized

Stable combustion

(no misfiring)

By stabilizing the combustion, it was found that the engine

performance also improved .

Improvement of

the first step loading ratio

0

200

400

600

800

1000

1200

1400

1600

0 20 40 60 80 100 120 140Time (sec)

Speed (

min

-1)

0

200

400

600

800

1000

1200

1400

1600

Genera

tor

outp

ut (k

W)

Conventional system

Development system

Engine Speed

Step loading

35%20%

First step loading ratioof the development system

Conventional system

By developing control system and stabilizing combustion,

the first step loading ratio is improved from 20% to 35%.

Improvement of total efficiency

The heat release from GAS engine can be used for

boiler, chiller and hot water by heat recovery system.

Improving total efficiency contributes to reduction of

CO2 emission as well as economic efficiency.

Generator

Gas Engine

Hot Water

Heatexchanger

Fuel Gas Water Supply

Electricity Exhaust Gas High Press.

Steam

Exhaust Gas Boiler

Jacket Water

Improvement of total efficiency High temperature cooling water system

with heat recovery (New system)

Engine cooling

jacket

Oil cooler

（1st stage）

Inter cooler

（1st stage）

Low temperature cooling water system

with heat release (the same as Existing system)

Inter cooler

（2nd stage）Oil cooler

（2nd stage）

Additional parts in this development

By using 2-stage cooling system, the total efficiency is

improved.

Improvement of total efficiency H

EA

T B

AL

AN

AC

E (

%)

TOTAL EFFICIENCY

80.3%

Conventional heat

recovery system

Heat recovery system

with 2-stage cooler

Mechanical

output

Exhaust

gas

Jacketcooling

74.1%

I/C cooling

The heat balance of

GS16R2 gas engine

Oil coolingRadiation

Electric

output

Heat

recovery

Heat

recovery

Electric

output

Additional heat recovery

Steam

Hot water

By using 2-stage cooling system, the total efficiency is

improved from 74.1% to 80.3% achieving the world best

level for 1000kW class CHP system.

Summary

1. MHI 1,000kW class Miller-cycle Gas engine (MHI : MITSUBISHI HEAVY INDUSTRIES, LTD.)

High efficiency,

Good performance and High reliability

2. Development of MHI Gas Engine

By developing control system and stabilizing

combustion, the first step loading ratio is

improved from 20% to 35%, enhanced added

value of CHP as the emergency power source.

By using 2-stage cooling system, the total

efficiency is improved to 80.3% achieving the

world best level for 1000kW class CHP system.

Thank you for your listening !!

When ordering, Please contact our agencies of MHI !!

http://www.mhi.co.jp/global/

Presenter : M. Ogawa from MHI Sagamihara in Japan