Overview of Gas Products & Applications

Caterpillar Energy Solutions

Tobias Wedemeier & Michael Dressler

Agenda

• Why Gas Engine Power Plants — Market Trends

• What is important for our Customers
• Products and Technologies
• Applications
Why Gas Engine Power Plants
Market Trends
Caterpillar Energy Solutions

Tobias Wedemeier & Michael Dressler

 Why Gas Engine Power Plants
Key drivers
• Gas is widely available
• Support Renewables growth
Nat. gas production by
source:
by stabilizing grid
1990-2040 [tfz³] Source:
EIA (2013): Market Trends
• Great technology to convert
Source:
US Census Bureau
– Nat. gas waste to power
• Gas is cleaner than any
other fossil fuel
• Gas is cheaper than
traditional source of energy
• Gas is perfect for load
Source:
Nat. Gas Price. Source:
EPA, « CHP , A clean
US Energy Information management and energy
Administration
energy solution » storage
Global Gas Genset Market by Regions – a good business to be in
Key drivers
• Global Gas Market Growth – big opportunities
in decentralized power generation
• New Markets / Applications requires new
products
• Potential at every level
• Increasing share of load Increasing share of
Load management, Stand-by, CHP and CCHP
What is important for our Customers?

Caterpillar Energy Solutions

Tobias Wedemeier & Michael Dressler

Advantages of Gas Gensets for Power Production

CHP – Independency
Decentralized energy production –
with higher efficiency production of energy for own use
• The energy is produced were it is needed and according to the
consumers needs (heat led or power led)
• Total efficiency up to 95%. Cost decrease through higher
efficiency of the complete energy supply
• Independency from the power grid – load management or
flexible operation
• Use of waste heat for heating, cooling, steam or heat recovery
for power generation
Advantages of Gas Gensets for Power Production

Use of waste energy sources Possibility to use energy resources which are
not used otherwise – waste to power
• Landfill and sewage gas
• Coal mine gas
• Digester biogas from food waste or other
waste
• Propane
• Pyrolysis gases from waste
Advantages of Gas Gensets for Power Production

Emissions Diesel vs. Natural Gas Lower basic emissions of gas engines
• Much stronger emission requirements for
diesel engines within the next few years,
which are increasing the investments for these
engines
Key buying criteria

Differ for customers, markets and applications:

• Life cycle costs like Efficiency, Maintenance costs …
• Investment
• Fuel availability or earnings on gas or biomass utilization
• Availability
• Subsidies
• Others (Dynamic load response, emissions, …)
Consequences of LCC / project driven approach

• Optimization of products/projects for lowest LCC (Life cycle costs) - Get the best
efficiencies
• Designed to customer and project specific requirements – The goal is not to “derate”
• Use design temperature
• Options and Variants for best performance:
• Different compression ratios
• Different gas mixer, gas trains
• Optimization of charge air cooler inlet temperature and reduction of parasitic loads
• Special scopes of supply (Fuel preparation, heat recovery, balance of plant …)
Why Optimisation? Importance Of High Efficiency
Ty p i c a l g a s p r i c e s USA: Europe:
~ 0,10 €/Nm³ ~ 0,40 €/Nm³ Key drivers
fuel consumption
• Profitability highly depends on efficiency
because the largest cost share – whether low
or high gas price – is fuel consumption.
Operating costs

~ 60%
• A difference of 2 to 4% efficiency is equal to the
maintenance
~ 85% full investment cost for the genset making a
LCCA (Life cycle cost analysis) over 8 years
lube oil
consumption
~ 18%
Investments

~ 2%
purchase and
financing ~ 7%
~ 20%
~ 1%
~ 7%
Gas Engines vs. Turbines

Criteria Engines Turbines

Emissions Low emissions Low emissions
Best efficiency Electricity Heat
Operation mode Variable load / load management Better for constant operation
Revenue driver Electricity Heat / Steam
Heat extraction Preferable Hot Water Preferable Steam
Fuels Low BTU and pipeline Pipeline and high BTU Fuels (low sensibility to MN)
Costs Lower initial costs Less maintenance costs
At Site conditions Better for HA Low weight and minimal space
Products and Technologies

Caterpillar Energy Solutions

Tobias Wedemeier & Michael Dressler

One Unified Product Portfolio of the Cat® Gas Engines
GCM34-20 9.750
GCM34-16 6.550
CG260-16 4,500
CG260-12 3,333
G3520 2,500
CG170-20 2,000
G3516 2,000 Covering a range up to 10 MW.
CG170-16 1,560 Available for various gas types
CG170-12 1,200
Wellhead
CG132-16 800 Gas

Coal Mine
CG132-12 600 Natural Gas
Gas

Agricultural
G3412 500 Biogas

Sewage and
CG132-08 400 Landfill Gas

G3406 217 Generator Set output may vary based upon site
conditions, fuel type and frequency.
G3306 143
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
Rating in kWe
CG132B – No better way to power
CG132B V8, V12, V16 Available end of 2017
Power range 400 – 800 kWe Flanged genset with service
Electrical efficiency 43.0% - 43.5%
aligned lube oil management
Thermal efficiency 40.0% - 44.7%
First service interval 4,000 Oh
Major overhaul Up to 80,000 Oh
Useable gases NG, CMM, Biogas, Syngas
• Increased robustness ensures higher reliability and availability
• Reduced maintenance costs through extended intervals and
lifetime
• Lower lube oil consumption helps operators save operational costs
• Decreased gas consumption due to higher efficiency and
enhanced fuel flexibility
CG132B – Both Robust and Flexible

TPEM
- New control system Turbocharger
- Water cooling for all cylinder numbers
Mixture cooler and management - Increased maintenance intervals (20,000 Oh)
- Redesigned mixture management
- Suitable for special gases
- Improved coolant supply Exhaust waste gate
- Charge group prepared for waste gate application
Closed-coupled generator - Improved performance for flexible operating
- No torque transmission to the base frame conditions.
- Grid code generator (flanged version)
Shock absorber Torsional shock absorber
- Low vibration emission - Front flange connection is basically reworked

Oil cooler Base frame A side

- Reduction of lube oil temperature - Oil reservior
- Increase oil life time
External lubrication system
- Uniform assembly for all
Core engine
- Stiffening of crankcase cast for less deformation cylinder numbers
- Homogenized cylinder cooling Base frame B side
- Improved combustion through optimized piston geometry - Extended lubrication circuit
- Oil consumption: 0.1 g/kWhel - Increased lubrication oil life
CG170 – Different Versions for Customer Needs
CG170 V12, V16, V20 Installed capacity of more
Power range 1,000 – 2,000 kWe than 6,220 MWel with over
Electrical efficiency 40.0% - 44.4%
4,266 gensets worldwide
Thermal efficiency 43.2% - 47.0%
First service interval 4,000 Oh
Major overhaul 64,000 Oh
Useable gases NG, CMM, Biogas
• Higher return on investment due to improved efficiency utilizing the miller
combustion cycle
• High altitude and temperature capability on the otto cycle version of the CG170
• Gear box utilization at 60Hz provides improved cost of ownership and higher
availability
• Flexible application with fluctuating gas composition and quality
CG260 – Proven Reliability
CG260 V12, V16 Installed capacity of more
Power range 3,000 – 4,500 kWe than 3,076 MWel with over
Electrical efficiency 40.0% - 44.4%
753 gensets worldwide
Thermal efficiency 43.2% - 47.0%
First service interval 4,000 Oh
Major overhaul 80.000 Oh
Useable gases NG, CMM, Biogas, Syngas
• High reliability and low maintenance costs due to open combustion chamber
technology
• Low operating costs due to 30% lower lube oil consumption in comparison to
similar products
• Increased exhaust heat recovery options and full power at extreme ambient
conditions
• Optimized engine and plant control enables the use of different gas types and
fluctuating gas qualities
CG Series Gas Genset Technology

• 4-stroke SI-gas-engine • NOX control by combustion chamber

• Homogeneous lean-burn operation temperature
• Turbo charging and Miller cam- • Single cylinder head units, 4 valves per
timing cylinder
• Controllable gas-mixer • Combustion chamber optimized for gas
• Swirl pre-chamber spark plugs operation
• 2-stage mixture cooling • Single exhaust gas primary modules
• Flame-filter in receiver • Cylinder-selective anti-knock
control/detonation sensors
• Electronic engine and plant control
G3500H – Lowest Lifecycle Costs

G3500H V12, V16, V20 20% Reduction of Maintenance

Power range 1,500 – 2,500 kWe & Overhaul Costs Compared to
Electrical efficiency 44.5% (HR) – 45.3% (HE)
the G3520E
Thermal efficiency 43.1% (HR) – 41.0% (HE)
First service interval 2,000 Oh
Major overhaul 80,000 Oh
Useable gases Natural Gas
• Top tier electrical efficiency
• Lowest maintenance and overhaul costs
• Low oil consumption
• Extended service intervals
• High Efficiency version optimized for fuel efficiency
• High Response version optimized for altitude and ambient
capability and transient response
G3500H Series Gas Genset Technology

Engine Technology Available Installed Options

• Long stroke design with 21 Bar Brake Mean • EMCP4.3 for 400 - 11,000V generators
Effective Pressure • Generator mounted circuit breakers
• Cuffed Liners to Manage Deposits for Long Life • Engine driven water pumps
and reduced Oil Consumption • Corrosion resistant
• High Efficiency Turbo with active turbo bypass
• Iridium Electrode Pre-Chamber Spark Plugs
• Canister style oil filter to Extend Oil/Filter
(Change after 2,000h)
• Package mounted air cleaner option
G3512 – Gas Genset runs like a Diesel

G3512 V12 Available Q2 2017

Power range 750 – 1,000 kWe Stand-by and Load
Electrical efficiency 35.8%
Management
Start Time Ready to Accept Loads 6.5s
Load Step Increase 40% (ISO
Transient Performance
8528 G2)
Frequency 60Hz
Useable gases Natural Gas
• Multiple Applications – Emergency Power Supply Gensets, Load
Management, Hybrid = Emergency Power + Load Management
• Certification and Compatibility – EPA Certification (2.0 g/bhph NOx
Setting Only), UL 2200 Listing, NFPA110 Type 10, CSA Certification
• High Level Transient Response Capability – 100% Block Load Capable
Maximum Efficiency
With continuous and secure emission regulation

Regulation of NOx-emissions by
combustion chamber temperature
• Measurement of the average temperature in the combustion chamber
every cylinder
• This results in a quick regulation of the combustion chamber mixture
• Continuous operation with optimum efficiency
• Quick response to varying gas qualities without affecting emissions
Maximum Efficiency
Via effective and reliable anti-knock regulation

• Using the full engine potential

• Knocking combustion can occur e.g. at varying gas
qualities
• Therefore every cylinders is controlled for knocking
combustion by a detonation sensor
• Based on the measured knocking the ignition time is
individually adapted for every cylinder
• Operating at the knocking limit means exploiting the
maximum potential of the engines
Less Load at Higher Performance
By combustion temperature based cylinder balancing

Individual peak loads of cylinder are

• reduced by even load distribution on all cylinders
Without cylinder balancing
• Less variations of temperature and mechanical load for Range of individual cylinder
components by variable adjustment of the ignition time temperatures

• This leads to slight improvements in the efficiency because

the average load on the cylinders can be increased due to
the greater distance to the knock limit
With cylinder balancing
• Equal mechanical stress for each component Even temperature and load
distribution caused by cylinder
balancing
Controls Landscape

Description Unit DIA.NE XT4 EMCP 4.3 / 4.4 TEM Evo TPEM
Status - GE Jenbacher Competition Current US EPD solution Current MA EPD solution Future MA EPD solution
Operating computer Operating computer
Function Operating computer
Components Genset mounted cabinet Operating computer Genset cabinet
units Cabinet with I/O Controller
Cabinet with I/O Controller I/O controller
Scope of Supply Layout Floor standing cabinet Integrated in dog housing Additional genset cabinet Floor standing cabinet
Genset Synchronization - Yes Yes Yes (optional) Yes
Engine Monitoring and Protection - Yes Yes Yes Yes
Protection Relay for gas train - Yes No Yes Yes
Controlling and Monitoring of
- Yes No Yes Yes
auxiliary components “CHP”
Electronic operations diary - Yes No Yes Yes
Remote access - Integrated full access Optional – read only access Optional – full access Integrated full access
User Level authentication - Different user levels One user level Different user levels Different user levels
Expandability - more functions Type Yes via software Yes via hardware Yes via hardware / software Yes via software
Best for applications Type CHP Electricity only and Standby CHP CHP
Used on gas genset Series 3, 4, 6 and 9 series G3400 and G3500 CG132, CG170 and CG260 CG132B, CG170B and CG260B
Controls TPEM – Economical, Efficient and Holistic

Key drivers
• Total Plant & Energy Management - Built-in
Control System
• One embedded control system to run a
complete power plant
• Use the full power capability of the genset
without loosing reliability
• Standardized hardware configuration combined
with upgradeable software through online
updates
• Building on many years of experience as an
engine manufacturer of TEM control system
System Components – More than just Gensets
Containers for CG132 and CG170

• Modularized system – high level of flexibility combined with full product

support and reduction of planning time
• Safe operation and maximized efficiency
• Reduced costs by capable transport of roof installations in 40-foot ISO
container (total package in 2 containers)
• Components are standardized and flexible at the same time
Container design – CG170 Series “CHP"

Switchgear room
Container design – CG170 Series “CHP"

CG Genset
Container design – CG170 Series “CHP"

Cooling module
Expansion vessels
Container design – CG170 Series “CHP"

Gas train
Container design – CG170 Series “CHP"

Air outlet Air intake

Recirculation duct
Container design – CG170 Series “CHP"

Air conditioning Cable ducts Waste oil tank Fresh oil tank
 Radiator Heating circuit
connections connections

Fuel gas inlet Exhaust outlet

Dump radiator Mixture cooling radiator
 Exhaust heat exchanger

Silencer Bypass Stack Bypass flaps

 Exhaust unit
fits in 40‘ ISO
container
Applications

Caterpillar Energy Solutions

Tobias Wedemeier & Michael Dressler

 Applications Overview
Combined Heat Electrical Power Biogas Landfill Stand-by and Others
and Power (CHP) Mission Critical CHP — Natural Gas
Applications with critical heat use

OpEx — Operational CapEx — Capital

Expenses (Fuel Gas, Expenses are more
Maintenance, Lube Oil) critical to the customer
Products • CG • G3500 • CG • G3500 • G3400 • CG are more important than operational
• G3500 • CG • CG • G3500 • G3500 than genset purchasing expenses
price
Customer • Utilities • Energy • Agriculture • Landfills • Industrial • Mining
types • District heating services • Food industry • Utilities • Hospitals • Oil & Gas
• Industrial • IPP • Sewage • Airports • Waste Electrical Power — Natural Gas
• Hospitals • Utilities • Waste Water • IT companies • Industrial Applications with primary use of power
• Airports • Industrial Treatment • E-commerce
• Greenhouses • Banking OpEx — Operational CapEx — Capital
Expenses (Fuel Gas, Expenses are more
Key • TCO • TCO • TCO • TCO • “Runs like • Fuel flexibility Maintenance, Lube Oil) critical to the customer
buying • Total efficiency • Electrical • Biogas • Landfill gas Diesel” are more important than operational
efficiency • First Cost than genset purchasing expenses
criteria price
(Stand-by)
Gensets for base load – IPP
Load management plants
Standby
Small Distributed Power Generation (DG)
Combined Heat & Power (CHP)
Trigeneration
Steam
Greenhouses
Biogases (AG, Landfill, Wastewater)
Propane
Pyrolysis gases
Questions ?
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