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Cars equipped with electric engines or other alternative drives are making major inroads. Scientists at the Centre for Solar Energy and Hydrogen Research Baden-Württemberg (ZSW) set out to develop a suitable filling station for these vehicles. Launched in mid-February 2018, this project goes to create a fuel ‘pump’ for the future. This dispenser is to deliver renewable electrical power, hydrogen and methane in the most efficient, cost-effective and purpose-driven way possible. The Federal Ministry for Economic Affairs and Energy is funding this project with around €1.3 million. It will run for five years as part QUARREE 100, an initiative to test an urban quarter’s fully renewable power supply.

Vehicular mobility is sure to change markedly in the years ahead. Far more cars running on electricity sourced from wind and the sun will soon be out on the road. The same goes for fuel cell vehicles powered with renewable hydrogen and natural gas vehicles that run on methane, another climate-friendly fuel produced using solar power. The network of charging points and hydrogen filling stations is expanding on a massive scale. Some stations furnish both electricity and hydrogen, but none dispenses electrical power, hydrogen and methane. ZSW aims to change that with this project.

Tiered use of renewable energy

What the Stuttgart-based scientists have in mind is to develop a multi-energy dispenser. The idea is to use the grid to charge electric cars’ batteries with renewable electricity sourced from wind power plants and the like. A large stationary battery will store unused power when supply is greater than demand, and dispense it when demand is greater than supply. “If the battery is full and recharging electric cars cannot deplete it, this green electricity will be converted into hydrogen in a second step,” says ZSW’s Dr. Ulrich Zuberbühler by way of explanation. Fuel cell vehicles run on this type of energy. And if hydrogen production exceeds demand, the surplus gas goes into a storage tank.

Tomorrow’s filling station will include third stage to produce methane when the hydrogen storage tank is full and demand from fuel cell cars is low. Carbon dioxide will then be added to the hydrogen to convert into methane. Both gases react to a catalyst to form methane. This fuel is the main component of natural gas, so natural gas cars can readily use it. If refueling cars do not deplete the methane supply, the surplus gas is stored and then piped into the natural gas grid when the storage tank fills up.

With our project, the coupling of the electrical grid with mobility will not be limited to electric cars,” explains Zuberbühler. “The other alternative drives will also benefit from it.”

ZSW’s researchers are talking about tiered use of renewable energy. Their priority is to make the most of resources by minimizing energy losses. Stage one is the first choice and remains so until its potential is exhausted. The most efficient use of regenerative electricity is to power electric motors. None of the energy is lost in translation, and battery storage loss amounts to no more than ten percent. Stages two and three—conversion to hydrogen and then methanation—are only an option once demand for electrical power has been met. Electrical power can be converted to hydrogen at around 75 percent efficiency; the figure for methane is roughly 60 percent. These gases are long-term, zero-loss stores of energy. Efficiency increases by a few percentage points when the waste heat generated during the conversion process is put to use.

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Efforts to enhance components

With this project, ZSW aims to improve the efficiency, service life and cost-effectiveness of the two main components, a high-pressure alkaline electrolyzer and a plate methanation reactor. Scientists want to advance the state of the art for both on a 100-kilowatt scale. Electrolysis and methane synthesis will have to take place separately, which requires some form of hydrogen buffer or intermediate storage facility. The institute will develop a concept for this and assess its safety.

The researchers have three years to develop the technology, work out a safety concept and clarify all the details for approval. The results will be tested at an on-site demo facility starting in 2020.

Stepping up ‘sector coupling’

Green electricity accounts for around a third of the power in Germany’ grid, and its share is growing. This figure expected to rise to 65 percent by 2030. Off-grid use—for example, in electric cars and as an alternative fuel—would help make the transportation sector more climate-friendly. Little progress has been made on this front. The alternative fuels hydrogen and methane also have great advantages. They can serve as chemical media for long-term, loss-free energy storage. On top of that, they can be fed into Germany’s natural gas grid and used to heat buildings without leaving a carbon footprint. The term coined to describe this convergence of electricity, fuel and heating across industries is sector coupling.

The funding for this project is part of a joint initiative of the Federal Ministry of Education and Research and the Federal Ministry of Economic Affairs to promote solar in building projects and energy-efficient urban development.

The Zentrum für Sonnenenergie- und Wasserstoff-Forschung Baden-Württemberg (Centre for Solar Energy and Hydrogen Research Baden-Württemberg, ZSW) is one of the leading institutes for applied research in the areas of photovoltaics, renewable fuels, battery technology, fuel cells and energy system analysis. There are currently around 235 scientists, engineers and technicians employed at ZSW’s three locations in Stuttgart, Ulm and Widderstall. In addition, there are 90 research and student assistants.

Renault has revealed its new R110 electric motor and the 2018 model-year ZOE, Europe’s best-selling electric vehicle, which will be the first Renault EV to feature this 80kW powerplant which combines extra power with even greater driving enjoyment. Despite being the same size as the R90, the R110 is 12kW (16hp) more powerful than its predecessor. Drivers will benefit from crisper acceleration performance on trunk roads, since the new motor shaves almost two seconds off ZOE’s 80-to-120kph time. This is a significant improvement which provides even greater peace of mind at higher speeds.. At lower speeds, meanwhile, the R110 packs the same punch as the R90 from which it is derived thanks to the instant availability of peak torque of 225Nm, making ZOE as nimble as ever in urban areas.

“Thanks to this power boost, ZOE is even more responsive and versatile when used for journeys out of town,” says Elisabeth Delval, Assistant Director, Renault ZOE Programme. “In addition to being able to enjoy the pleasure of driving a ZOE, drivers will also benefit from the longest range available for a mass-market electric car.”

New R110 motor: Renault’s electric vehicle expertise

The new R110 motor is the latest fruit of Renault’s electric motor development and production strategy and further evidence of the expertise in this field of Europe’s number one electric vehicle manufacturer. The all-Renault R110 – an evolution of the R90, developed in just two years – is made in France at the make’s Cléon plant in Normandy and was designed by engineers working out of the Renault Technocentre, southwest of Paris, as well as in Cléon. In addition to carrying over the R90’s outstanding energy efficiency, the R110 packs a combination of electrical machine- and power electronics-related innovations that have yielded an extra 12kW with no increase in either weight or volume.

The introduction of the R110 takes the number of variants of the Renault motor available for Kangoo Z.E., Master Z.E., ZOE and Daimler’s Electric Drive Smart to five (44kW, 57 kW, 60 kW, 68 kW and 80 kW).

Android Auto for ZOE

Android Auto-enabled R-LINK Evolution is now available for ZOE, which means drivers will be able to display driving-compatible Android applications stored on their smartphone (including Waze, Deezer, Spotify, TuneIn, Skype, Messenger, Audible and many others available from Google Play Store) on their car’s multimedia screen.

Even more refined

The 2018 model-year ZOE range features a stylish new, dark, metallic body colour: Blueberry Purple. The high-end INTENS version of the popular electric city car can be specified with the new exclusive Blueberry Purple Pack which combines a purple exterior with a violet satin finish for the dashboard trim strip and air vent, gear lever base, loudspeaker surrounds, top stitching along with black and violet fabric upholstery.

Order books for ZOE equipped with the new R110 motor, Android Auto compatibility and Violet Blueberry Pack will open in France in March 2018.

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As 2017 comes to a close, the KSB Group has finished the prototype of a super-compact high-efficiency motor with an integrated frequency inverter.

The 22-kW synchronous reluctance motor is a prototype featuring new semiconductor technology that provides completely new cooling management for eliminating heat from power electronics. By integrating the frequency inverter into the motor, developers were able to reduce the unit volume by over 25 percent compared with the traditional design.

Besides Italian, German and French specialists from the pump manufacturer, scientists from the Karlsruhe Institute of Technology (KIT) were also involved in developing this prototype. The aim of developing this demonstration drive was to highlight the potential that modern silicon carbide components offer in terms of higher motor ratings.

Today, almost 70 percent of all standardised pumps operate at a constant motor speed. To adjust the pump to the desired operating point, the impeller can be trimmed. In the future, Industry 4.0-ready motors will do this by way of “virtual impeller trimming”. This can be done even after the pump set is commissioned.

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MAN has revealed the latest addition to the company’s 4x line of high-performance diesel engines: the MAN 20V45/60 comes with a limit-pushing power output of 26 MW. Furthermore, the company was able to considerably reduce fuel consumption compared to its predecessor, the MAN 48/60.

The 20V45/60 expands the current performance range of MAN’s 4x family of diesel engines by more than 4 MW, while offering a best-in-class fuel efficiency of more than 50%. Hence, it allows customers to save both investment and operational costs.

 

Next to a frontloading approach, using thermodynamic engine process calculations, MAN used computational fluid dynamics to simulate and optimize the combustion process. Also finite elements analysis was used to optimize the engine’s mechanical strength and vibration behavior. Then, MAN put the power unit to the test on the world’s largest four-stroke, single-cylinder test bed and started the experimental optimization and validation phase.

The new engine is also a new centerpiece of MAN’s extended systems approach which reflects in the company’s latest generation digital Safety and Control System, SaCoS 5000. Following a decentralized design concept, SaCoS 5000 offers unprecedented data availability and optimized alarm visualization and diagnosis.

The two-stage turbocharger module rounds off the MAN 20V45/60’s superior profile. MAN Diesel & Turbo is the pioneer in developing and operating two-stage turbocharging for large-bore engines, a concept which achieves excellent efficiency thanks to a low-pressure and a high-pressure turbocharger arranged in series.

Perfect fit for power generation in remote locations

The 20V45/60 is a perfect fit for power generation in remote locations and islands where a gas supply is not available. Its sturdy design and construction withstands extreme site conditions like hot ambient temperatures and high altitudes, and makes the engine an excellent solution for captive power applications in climatically-demanding locations. The two-stage turbocharging prevents derating even at 2,500 meters above sea level and the engine shows no decrease in output even in ambient temperatures of up to 53 ºC.

Plant operators benefit from the engine’s high power-density, which significantly reduces capital expenses, as fewer engines and less space are needed to reach a plant’s desired overall output. An extremely competitive fuel-oil consumption adds to the sustainability of the engine’s environmental footprint, which meets the World Bank 2 (2007/2008) emission standard for heavy fuel oil (HFO), marine gas oil (MGO), and marine diesel oil (MDO). A solution with integrated selective catalytic reduction (SCR) is under preparation and will further reduce NOx emissions by up to 80%.

The worldwide rise of decentralized energy generation and renewable energy has significantly changed the capability profile that thermal power plants need to match. Consequently, the new 45/60 is ideally suited for base load as well as peak-shaving applications. Operational flexibility has become essential for power plant operators these days, and state-of-the-art plants need to be able to master repeated and rapid startups and the ability for load-following operation. The 45/60 reaches full load in a short time, effortlessly handles load reversals, and allows for high fuel-efficiency even when operated in partial load.

Gas and dual-fuel versions of the engine are currently under preparation. Also, more cylinder configurations will be added to the 45/60 engine family in the future.

Source: MAN

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35/44G, 35/44G TS, 51/60G, 51/60G TS

The most comprehensive gas engine portfolio available in the market and a highly efficient gas and steam turbine range – flexible energy solutions are in the focus of MAN Diesel & Turbo’s 2015 Power-Gen Europe attendance. Europe’s major energy trade fair will take place at Amsterdam Rai in Amsterdam from June 09-11, 2015. “This year’s Power-Gen theme ‘The energy transition is changing…Europe’ could not be closer to the truth”, says Dr. Uwe Lauber, CEO of MAN Diesel & Turbo.

“Today, power plant operators and investors in Europe are confronted with both technical requirements and business cases that are much more complex than a few years ago. Expert advice, in depth consultation and an experienced technology partner are essential to identify the right generation solution for each customer’s individual energy challenge. We welcome PowerGen Europe as another opportunity to showcase the solutions we have to offer and to invite customers, prospects and industry experts alike: Visit our booth and discuss your energy needs with our experts.”

Once again the company puts special focus on the themes of “Natural gas” and “Decentralized power generation” and presents a portfolio of natural gasdriven engines and turbines, added up by a comprehensive portfolio of service solutions, to help and master the European energy transition: “Europe consists of 28 energy markets, each of which has its own, grown energy system and established power generation mix”, says Dr. Hermann Kröger, Senior Vice President and Head of the Business Unit Power Plants at MAN Diesel & Turbo. “All those markets however share a common goal to reduce greenhouse gas emissions and to increase the share of renewable energies. Gas generation is an ideal technology to achieve this: It is low in CO2- emissions and suited perfectly to back up renewables and work towards a low carbon economy.” However the political framework to support the planned transition was not yet fully in place, says Kröger: “If Europe is serious about reducing CO2-emissions, it will need to make those emissions more costly and hence provide a competitive advantage for cleaner forms of energy, e.g. natural gas.”

“There is definitive demand for additional gas generation capacities”, seconds Howard Barnes, Senior Vice President at MAN Diesel & Turbo and Global Head of Power Plant Sales. “We are currently building an 80MW gas fired power plant in Gibraltar featuring our 51/60G gas engine. Our gas engines offer a fuel efficiency of more than 50 percent. They reach full load within minutes, allow fast starts, stops and ramp-ups, all of which are essential capabilities when it comes to integrating large amounts of renewable energy into the system.”

At Power-Gen Europe, MAN Diesel & Turbo introduces its new line of twostage turbocharged gas engines. Both of the company’s gas engine models 35/44G and 51/60G are now also available with two-stage turbochargers. Two-stage turbocharging achieves excellent efficiency thanks to a lowpressure and a high-pressure turbocharger arranged in series. The 35/44G TS and the 51/60G TS are spark ignited two-stage turbocharged gas engines. The 35/44G TS is available in 12V and 20V-cylinder versions with mechanical outputs of 7.4 MW and 12.4 MW. The 51/60G TS can be delivered as an 18-cylinder version with outputs of 18.9 MW and 20.7 MW. While the 18.9 MW aggregate reaches a mechanical efficiency of more than 50%, the 20.7 MW machine is the most powerful gas engine currently available on the market. Also on display at the MAN booth is the company’s MGT gas turbine family, which recently premiered in the Chinese market. “As our youngest member in the range of energy-related turbomachinery, the MGT gas turbine family marks an important step in terms of efficiency and flexibility,” states Dr. Christopher Antes, Senior Vice President and Head of Business Unit Turbomachinery. “Whether it’s highly efficient steam turbines, gas turbines or compressors for processing and transport of natural gas, our comprehensive portfolio of turbomachinery and the related services by MAN PrimeServ supports a whole range of applications in the energy sector”, he adds. This is underlined by the most recent order for four 6.9MW MGT 6200 gas turbines. With 6.9 MW each, they will soon provide electric energy and process steam for Shanghai Volkswagen Automotive Company Ltd. The MGT family offers optimized turbine versions for both energy generation and as mechanical drive. In Combined Heat and Power (CHP) applications, overall efficiencies of up to 90 percent can be reached, which makes the MGT an ideal partner for captive power applications.

Efficiency is also the guiding principle for MAN Diesel & Turbo’s steam turbine portfolio, supporting the sustainable generation of energy. Ranging from 1- 160MW the company offers steam turbines for almost any application, e.g. energy generation from residual heat, Concentrated Solar Power (CSP) or biomass. Also, the company has developed a special expertise for Waste-toEnergy applications and has recently supplied a 50 MW DK 100/400 R steam turbine for the UK-based waste incineration pant „Wilton

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Rolls-Royce will be showcasing its portfolio of power supply solutions at the Powergen Exhibition in Amsterdam (Stand 1C20). Products from MTU Onsite Energy and Bergen Engines include high-speed and medium-speed diesel and gas gensets ranging from 24 to 9,400 kWe. MTU Onsite Energy and Bergen Engines are part of Rolls-Royce Power Systems within the Land & Sea Division of Rolls-Royce.

At Powergen Europe 2015, MTU Onsite Energy is presenting its product portfolio for high-speed gas engine systems up to 2,530 kWe and diesel gensets up to 3,250 kWe. The exhibition stand will include a model of a gas genset based on MTU Series 4000 engines. The heat and power generating systems produce 1,010 to 2,530 kWe and are available in 8, 12, 16 and 20 cylinder configurations. The exhibits also include a diesel genset model based on the new generation of MTU Series 2000 engines. The new genset is quieter, more efficient and more compact than previously available gensets. It is equipped with common rail technology and generates up to 1,120 kWe, providing a 12% increase in range compared to its predecessor. Distributed power plant solutions from MTU Onsite Energy cover both continuous power generation needs as well as emergency and peak generation applications. They perform a critical function in special-purpose applications such as airports, hospitals and computer centers and can also be used as base and peak load power supply plants.

The medium-speed power generation solutions in the Rolls-Royce range come from Bergen Engines. At Powergen Europe 2015, Bergen Engines is showcasing a model genset based on the 20-cylinder, Type B35:40 gas engine. Electricity generation systems based on these gensets are in operation in greenhouses and power plants in Holland, the UK and the Czech Republic. Diesel and gas-powered gensets from Bergen Engines cover a range from 3,700 to 9,400 kWe while complete electric power generation systems can offer total outputs in excess of 200 MWe.

Their proven technology, high levels of availability and low operating costs mean that these engines are popular with operators around the world. Their robust construction and superior electrical efficiency ratings of up to 48.5% are particularly important features. Typical applications include base-load generation for electricity providers; grid load-balancing and peak-load supply; combined heat and power generation; combined heat, power and cooling plants; emergency power and mechanical drive power in the oil and gas industry.

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