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CHP plant

Construction works from SENER power plant to Gondi Group.

Mexico City, Mexico, July 10, 2019 – The SENER engineering and technology group has signed a contract with Gondi, a leading Mexican group in the manufacture of paper for cardboard packaging, to build phase 1 of a steam and electricity service plant in Guadalupe Nuevo León (Mexico). The facility is designed to supply electricity, steam and cold water to the most modern paper plant in the country.

Phase 1 involves a steam plant with two boilers and an electric substation, which is scheduled to go into operation in early 2020. There is a future option to execute Phase 2 to develop the cogeneration scheme in 2021-2022.

Under this contract, signed as a turnkey or EPC (engineering, procurement and construction) contract for Phase 1, SENER will be responsible for the basic and detailed engineering, the overall procurement of materials, general project management, construction and start-up, as well as for training the operations personnel for two backup boilers.

SENER has extensive experience in the Mexican energy sector, where it has implemented 29 projects in the combined cycle and cogeneration, oil, gas and mining sectors, 16 of them of the EPC or turnkey variety. Specifically, in cogeneration, SENER led the construction of one plant for Cryonfra-Afranrent, two for the CYDSA group, a fourth for Alpek and a fifth, called TG-8 Madero, for Pemex, all of them as EPC construction contracts.

With offices in the country since 2006 and employing a multidisciplinary team of more than 400 Mexican professionals, SENER develops engineering and technology projects in the areas of Infrastructure and Transport (such as the passenger train between Toluca and México City, Guadalajara Metro Line 3, the General Hospital of Mexico and various works in Intelligent Transport Systems (ITS) throughout the country, for clients such as SCT, BANOBRAS and CAPUFE), and Renewables, Power, Oil & Gas, with, in addition to the aforementioned cogeneration plants, contracts such as the Agua Prieta II combined cycle plant, the La Cangrejera petrochemical plant and the diesel hydrodesulphurization units at the refineries in Tula and Salamanca for PEMEX, the Empalme I combined cycle plant and the compressor stations in Frontera and Los Ramones for Gasoductos del Noreste.

Source: SENER

MAN Energy Solutions has won an EPC-contract to set up a highly efficient, combined-heat-and-power (CHP) plant for Progressive Energy, the energy arm of the ElcaTex Group in Choloma, Honduras. The plant will be powered by 3 × MAN 18V51/60 engines with an overall capacity of 54.8 MW, generating power and steam for a nearby textile factory.

MAN Energy Solutions will take an EPC (engineering, procurement and construction) role in the project and will be responsible for the construction of the entire plant.

For textile manufacturing, steam is as important as power, which is why Elcatex Group were looking for a solution to efficiently produce electricity as well as steam to drive its manufacturing footprint. Thanks to the new plant, the company will be able to increase its energy efficiency while becoming more autonomous in its steam supply chain.

While the MAN 51/60 engines will operate on heavy fuel oil (HFO) once the new plant opens, Progressive Energy plans to convert them to gas operation as soon as a secure supply of LNG (Liquid Natural Gas, LNG) becomes available. The switch to gas will reduce the plant’s emissions even further.

Source: MAN Energy Solutions

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Rolls-Royce has signed a contract with EPC contractor Energyco for the supply of four gensets to a cogeneration plant in Kosice, Slovakia. Based on the medium speed gas engine B35:40V20AG2, the plant will generate a total of 37 MWe heat and power for the district heating company Teplaren Kosice a.s. The contract will also include a service agreement for 5 years. The engines are produced at Bergen Engines AS, which is part of Rolls-Royce Power Systems.

One of the critical parameters required by TEKO was 3 minutes start to full load to comply with Slovakian grid support service.

The medium speed engines from Rolls-Royce are flexibly designed for different operating modes, and can be used to generate base-load, peak power or operate in combined cycle. Already three minutes from start, the engines can operate with 100 per cent load to the rated speed of 750 rpm, and are in this aspect well suited to balance changes in the grid parameters. Furthermore, by utilizing hot water from the engines, the plant will be used for district heating for the region. Heat from the engines can also be used to generate steam in the heat recovery steam generators, to supply industrial customers.

Cogeneration plants based on our medium speed gas engines are a reliable alternative to coal-based plants and significantly more environmentally friendly. In addition, the engines’ flexibility will enable Teplaren Kosice to operate efficiently, both in terms of cost and time”, said Jeff Elliott, Managing Director of Bergen Engines.

This will be Rolls-Royces first delivery of medium speed reciprocating engines to Slovakia, complimenting the installed base of 96 MWe in central Europe. The plant is scheduled to be commissioned early 2019.

Source: Rolls Royce

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Rolls-Royce has signed a contract with Tuinbouwbedrijf Marc Pittoors (T.B.M.P) BVBA, for the supply of a 7 MWe combined heat and power plant (CHP). The plant will be powered by two gas-fired gensets based on the new medium-speed Bergen B36:45L6 engine and will provide heat and power to a new tomato greenhouse in Belgium. The contract also includes a service agreement for 10 years. The gensets are scheduled to go into operation early November 2018.

Marc Pittoors will use the generated electricity to power the greenhouse artificial lighting and the heat extracted from exhaust gases and engine cooling systems to heat up the facility. In addition, cleaned engine exhaust gases will be injected into the greenhouse to increase the level of CO2 and boost plant growth.

For the tomato producing company, three factors were crucial in taking this decision: electrical efficiency (best in the current market), expertise (Rolls-Royce developed a gas engine in the early 90s and was the pioneer in lean-burn technology) and optimum heat balance (5 hectares of greenhouse space are illuminated and 3.5 hectares are not).

Rolls-Royce will be supplying the complete CHP plant for this greenhouse, consisting of the power generator sets, the exhaust gas systems including a selective catalytic reduction (SCR) system and heat exchangers, and the electronic control system. In total, the technology achieves efficiency rates of more than 96%. Rolls-Royce has many years of experience with CHP plants and has since 2005 delivered 52 CHP plants with a total installed capacity of 270 MWe for greenhouses in Holland, Belgium, Russia and the UK.

Source: Rolls-Royce

Grupo Porcelanite Lamosa, via its subsidiary LEMSA (Lamosa Energía de Monterrey) has supported the investment required to construct a CHP plant installed in its ceramic tiling factory located in Benito Juárez (Monterrey – Nuevo León). This investment is a clear example of the commitment of Grupo Porcelanite Lamosa to the environment, improving energy efficiency through cogeneration systems. The project will be able to generate over 57.000 MWh of electricity per year, of which 46% are fuel free, making this one of the most efficient CHP projects in the whole of Mexico.

Entering into operation in late 2016, the plant is based on a single cycle with a gas-fired turbo genset offering an onsite output of 7.5 MW. It uses the heat from the turbine flue gas produced in the processes to dry ceramic dust by the factory’s two existing sprayers.

 

To build the plant, LEMSA has been supported from the outset by Asesoría Energética CHP México S.A. de C.V., a subsidiary of AESA (Barcelona) to undertake the design, project management and complete integration engineering, purchasing management for the gas turbogenerator, legal requirements and the turnkey supply of the Balance of Plant (BOP). Read more…

Àlex Almazán, AESA
José Manuel Loera, Asesoría Energética CHP México, SA de CV

Article published in: FuturENERGY July-August 2017

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MAN Diesel & Turbo has been commissioned with the planning and, upon investment approval, the construction of a 30 MW  gas engine power plant by Energie Baden-Württemberg AG (EnBW). The combined heat and power plant (CHP) at the Stuttgart-Gaisburg site will be operated using three MAN type 20V35/44G gas engines and will not only supply electrical power but also an additional 30 MW of district heating.

Commissioning is scheduled for 2018.  “This is our second engine CHP plant in Germany and an important milestone in further establishing the highly efficient gas engine technology”, says Wayne Jones, Member of the Executive Board for Global Sales and After Sales at MAN Diesel & Turbo. “The new plant, consisting of boilers, heat storage and gas engines, will serve to replace a mainly coal-fired thermal power plant at the same location and has a particularly high fuel utilisation rate due to its overall efficiency of more than 85% (without tolerance). Switching from coal to gas will reduce CO2 greenhouse gas emissions by up to 60,000 tonnes per year.”MAN2

With an increasing share of renewable energies in electricity production, flexible gas engine power plants with cogeneration are the perfect solution for security of supply, efficiency and the reduction of emissions. The combination of gas engines with CHP and district heating storage makes it possible to decouple electricity and district heating supply, meaning that the operator can respond flexibly to pricing signals. “We are investing in climate protection and security of supply,” states Diana van den Bergh, Project Manager at EnBW. “The new gas engine power plant will significantly reduce site emissions and contribute to improving the air quality in Stuttgart. The site in Gaisburg has been generating heat and electricity for the Stuttgart area for over 60 years. The modernisation will ensure that the site can fulfil these tasks even more efficiently and environmentally friendly in future.” Large gas engines are particularly well-suited when it comes to the supply of district heating and they are superior to other generation technologies of this plant size. This was confirmed in a recent study by the University of Duisburg.

 

Source: MAN Diesel&Turbo

 

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Stora Enso Timber Ab and KPA Unicon Oy have signed a contract of a biomass-fired hot water boiler plant delivery to Stora Enso sawmill Ala in Ljusne, Sweden. The new Unicon Biograte 15 MWth boiler plant will utilize bark and wood residues from the Ala sawmill as fuel, and it will produce hot water to the sawmill´s drying kilns. The new biomass boiler plant is scheduled to be in operation in November 2016. The value of the contract will not be disclosed.

The delivery is a turnkey delivery excluding civil and foundation works. The contract includes all process equipment, installations, commissioning and training of the operational personnel. The heart of the new biomass-fired boiler plant is Biograte combustion technology which is especially planned for utilization of wet biomass fuels for effective energy production.

The plant also includes KPA Unicon`s PlantSys system for local and remote control of the plant. PlantSys system collects data from the process equipment’s and makes an easily outlined and controlled entity of the data. PlantSys system also enables a reliable and trusted remote access to the plant, optimizes the parameters and predicts the future service and maintenance needs.

“This boiler plant project is a great example of a case where process hot water is produced in a sustainable way. It is important that the boiler plants at sawmills get to utilize the least valuable by-product bark as fuel. Biograte combustion technology is the most capable solution in the market for burning wet biomass with high efficiency and usability”, says Teemu Koskela, Sales Director, KPA Unicon.

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Abengoa, the international company that applies innovative technology solutions for sustainability in the energy and environment sectors, has been issued a Letter of Award (LOA) by Emirates Global Aluminium (EGA) to carry out the engineering and construction work for a 220 MW cogeneration plant at EGA’s Al Taweelah facilities in the Emirate of Abu Dhabi (UAE).

The LOA enables Abengoa to undertake preparatory works worth approximately $50 million comprising the mobilization, the basic and detailed engineering and the purchase of long lead items. The overall contract is worth approximately $215 million.

This work is part of EGA’s growth development strategy. The plant that Abengoa will construct will have a capacity of 220 MW and will generate up to 600 tons of steam per hour. Abengoa will be responsible for the engineering, design and construction of the power and steam plant, which is expected to create 750 jobs during the construction phase.

This will be the first cogeneration plant that Abengoa has developed in the United Arab Emirates, effectively positioning the company as one of the major players in the energy sector in this region. Abengoa has previously constructed a 100 MW solar plant in Abu Dhabi, the largest in the Middle East.

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New challenges and solutions for CHP

GESTIÓN DE PLANTAS DE COGENERACIÓN. NUEVOS RETOS Y SOLUCIONES PARA LOS COGENERADORES

The application of RD 413/2014 and the new payment scheme for the special regime technologies has led to uncertainty and a reduction in income there which makes it necessary to implement new solutions aimed at ensuring adequate compensation, and reducing the risk associated with the volatility of market prices. In the case of CHP plants, under RD 661/2007 it was valid to run the maximum number of hours, today is absolutely unthinkable, and we now need optimized management solutions that enable plants to continue to operate within profitable margins.

A recent example of how regulatory changes affect such plants is found in the first quarter of 2014, when the very low prices of electricity made it extremely complex to operate CHP plants, which were even were forced to stop working, losing a great deal of money.

Proper management of CHP plants is crucial to their survival. Here is a graphic example of how a CHP plant should no longer be operated.

Article published in: FuturENERGY July-August 2014

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