Gas Engines Fundamentals
Gas Engines Fundamentals
Gas Engines Fundamentals
Engine IQ
Table of contents
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air (Thermal Efficiency)
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Therm From Rejected
al Energy via Heat
Combustion (kWth Out)
(Engine)
(Mechanical
Efficiency)
Mechanical
to Electrical Electric Energy
Oil Energy (KWe out)
Conversion
(Generator)
(Electrical Efficiency)
Landfill gas
Coal mine gas
Sewage gas
Industrial power
plant options Island mode Oilfield
applications
(Associated
petroleum gas)
Special gas
Cogeneration
(Natural gas)
Biogas
Greenhouse application
Typical Landfill 55% CH4 / 40% CO2 / rest N2, O2 Siloxanes, H2S
Characteristics
Engine design and engine version are determined by the following characteristics
Coalmine gas
Pyrolysis gas
Sewage gas
Natural gas
Gases from
Landfill gas
Wood gas
chemical
Coke gas
Flare gas
Propane
City gas
industry
Bio gas
Butane
0 Logarithmic scale 5 10 15 20 30
• Methane number
• Parameter determining the knocking resistance
(potential to ignite) of a gas.
• Comparable to the octane number of gasoline.
140
120
100
80
60
40
20
0
H2 Methane Propane Butan Natural Gas Biogas
• (Density (kg/m3))* (Lower Calorific Value (kJ/kg)) / (3600 KJ/KWh) = (Lower Heating Valve (KWh/m3))
• (Lower Heating Value (KWh/m3))* (1 m3 / 35.314 scft)* (3412 btu / KWh) = (Lower Heating Value (btu/scft))
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
Each of the four working steps takes place during one stroke. In this context,
"stroke" means a travel stroke of the piston, in other words an upwards
or downwards movement by the piston. During the four strokes "intake",
"compression", "power" and "exhaust", the crankshaft rotates twice.
symbolic picture
1-2 Compression
2-3 Ignition
Power Stroke
3-4 (Expansion)
Heat Rejection
4-0 & Exhaust
Rich-Burn
Operation
Lean Misfire
Not enough fuel to
Flexibility for fuel
BMEP
burn, lean air/fuel,
fluctuation, changes
retarded ignition
in site conditions, NO timing
changes in
X
CO, HC
speed/load
Rich
Misfir
0.75
e 1.0 1.25 1.5 1.75 2.0
Stoichiometric Lean-Burn
(Rich-Burn) Lambda (λ)
DIA.NE*
LEANOX*
controller
P-controller
nP-controller
temperature
PIST (power)
t2' (mixture
P2' (boost
pressure)
)
exhaust
gas
fuel gas
generator
intake air
gas engine valve with
position controller heat exchanger
compressor
valve with position controller
Compression ratio
⁄ The ratio between the volume of the cylinder,
when the piston is at the bottom of its stroke,
and the volume
when the piston is at the top of its stroke.
⁄ High compression ratio is desirable, allows an
engine
to extract more mechanical energy from a
given mass
of air-fuel mixture.
⁄ High ratios place the available oxygen and fuel
molecules into a reduced space so the
combustion is done quicker (smaller volume).
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
Voltage - LV 50 Hz 60 Hz
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
HEX 3
losses ~10 %
Process Outlet
Temperature
Mixture Temp
Options
Mid Return
Temp
Mid Outlet
Temp
Low Return
Temp
Mid Outlet
Temp
Mid Return
Temp
High Outlet
Temp
High Return
Temp
High Outlet
Temp
Mid Return
Temp
Mid Outlet
Temp
Hot water
Total heat single stage
COP 0.7 – 0.75
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
Ar ~ 1% CH2O Formaldehyde
OxiCat CO NOx
CH2O THC (CH4)
SCR NOx CO
CH2O
THC (CH4)
Greenhouse NOx THC (CH4)
(SCR + Oxi) CO
CH2O
C2H4v
Cl. Air CO NOx
CH2O
THC
NOx emissions:
• A. Open loop:
• Load curve needs to be adjusted during commissioning
NOx = 100mg/Nm³ @ 5% O2 possible
• B. Closed loop:
• Online NOx analytics required!
• Maintenance, calibration and higher invest will be necessary
NOx = 20mg/Nm³ @ 5% O2 possible
Exhaust Gas
Emissions and
un-utilized
Heat
Energy Input
(Fuel)
(kWen IN) Chemical Energy
to Thermal Energy
Mechanical/Ther From Rejected
mal Energy via Heat
Combustion (kWth Out)
(Engine)
Air
Air (Thermal Efficiency)
Mechanical to
Electric Energy
Electrical
Oil (KWe out)
Energy
Conversion
(Generator)
(Electrical Efficiency)
3.412 ((Mbtu/hr)/KW)
Unit type Installation type Mode of operation (e.g.) Type of fuel gas
M co-generation plant
S stationary GS Gas engine, N Natural gas
G generator set C in a container turbocharged B Biogas
L Landfill gas
P Propane gas
S Special gas
N/B Natural gas/Biogas
2-gas operation
generator engine
unit
2 3 4 5 6 7 8
1
15 16
12 13 14
11
9 10
non drive
end
drive end
⁄ Since 1976 in the product program, delivered engines: more Further technical data
than 1,300 ⁄ Bore: 135 mm
⁄ Electrical output from 250 to 330KW (50 Hz), 335 kW (60 Hz) ⁄ Stroke: 145 mm
⁄ 8 cylinder in-line engine ⁄ total displacement: 16.6
⁄ 1,500/1,800 rpm ⁄ Mean piston speed: 8.5 m/s (1,500 1/min)
⁄ Built into 20 ft or 40 ft container as complete set ⁄ Scope of supply: Generator set, cogeneration system;
⁄ Approx. 2 l displacement/cylinder generator set,
cogeneration system in container
⁄ Applicable gas types: Natural gas, flare gas, propane,
biogas, ⁄ Dimension l x b x h: Generator set 4,900 mm x 1,700 mm x
landfill gas, sewage gas 2,000 mm*
⁄ Weight empty: Generator set 4,900 kg*
⁄ 2 valve cylinder heads same as type 3 but narrower
⁄ electrical engine cooling water pump
⁄ single-stage intercooler
⁄ aluminium piston
⁄ ignition system: MIC940 (old: IC100) J 208
⁄ toothed con rod
J 208
⁄ Since 1988 in product program, delivered engines: more than 9,000 Further technical data (J 320)
⁄ Electric power output 526–1,063 kW (50 Hz), 633–1,059 kW (60 Hz) ⁄ Configuration: V 70°
⁄ Manufactured as V12-, V16- and V20–cylinder engine ⁄ Bore: 135 mm
⁄ 1,500/1,800 rpm ⁄ Stroke: 170 mm
⁄ Built into standard (2,5m) or wide (3m) 40 ft container as complete set
⁄ total displacement: 48.7
⁄ Approx. 2.5 l displacement/cylinder
⁄ Mean piston speed: 8.5 m/s (1,500 1/min)
⁄ applicable gas types: Natural gas, flare gas, propane, biogas, landfill gas,
sew- ⁄ Scope of supply: Generator set, cogeneration system,
age gas, special gases (e.g., coal mine gas, coke gas, wood gas, generator set,
pyrolysis gas) cogeneration system in container
⁄ Dimensions l x b x h: Generator set 5,700 mm x 1,700 mm x
⁄ Collar on crank case for longer stroke 2,300 mm*
⁄ Oil pump lifetime 60,000 oph ⁄ weight empty: Generator set
⁄ Mechanical/electrical jacket water pump
⁄ Aluminium piston
J 320
throttle
valve intake air
line
valve
timing
intake air collector gas mixer exhaust
actuator heat exchanger gas
mixture/water throttle heat exchanger manifold
valve engine oil/water
exhaust gas
turbocharger
cylinder head piston
generator camshaft
starter crankcase coupling
crankshaft
engine oil filter
oil pump
oil pan
⁄ Since 2002 in product program, delivered engines: more than 3,300 Further technical data (J 420)
⁄ Electric power output 844 – 1,560 kW (50 Hz), 850 – 1,426 kW (60 Hz) ⁄ Configuration: V 70°
⁄ Manufactured as V12-, V16- and V20–cylinder engine ⁄ Bore: 145 mm
⁄ 1,500/1,800 rpm ⁄ Stroke: 185 mm
⁄ Approx. 3 l displacement/cylinder
⁄ total displacement: 61.1
⁄ Applicable gas types: Natural gas, flare gas, biogas, landfill gas, sewage
⁄ Mean piston speed: 9.3 m/s (1,500 1/min)
gas, special gases (e.g., coal mine gas, coke gas, wood gas, pyrolysis gas)
⁄ Scope of supply: Generator set, cogeneration system,
⁄ Flexible bell house for J420 and J416 generator set,
cogeneration system in container
⁄ Only available with Atk-LIVC cycle
⁄ Dimensions l x b x h: Generator set 7,100 mm x 1,900 mm x
⁄ bmep = 20 bar as standard
2,200 mm
⁄ Cracked con rods
⁄ weight empty: Generator set 14,600 kg*
⁄ Electric jacket water pump
⁄ Oil pump lifetime 60,000 oph
⁄ 1 starter (2 x J420)
⁄ Ignition system: MORIS (old: MIC950/IC920))
⁄ Aluminium/steel piston
⁄ ABB TPS turbocharger
J 420
J 420 intake
line engine
cooling
water
manifold
valve timing
heat exchanger
blow-by
mixture/water
gas mixer intake air filter
cylinder head
housing exhaust gas exhaust gas
manifold
turbocharger
piston
cylinder
generator liner
coupling
starter actuator connecting rod
crankcase
camshaft
oil pan
⁄ Since 1989 in product program, delivered engines: more than Further technical data (J 620)
4,800 ⁄ Configuration: V 60°
⁄ Electric power: 1,500–4,400 kW (50 Hz) ⁄ Bore: 190 mm
⁄ V12-, V16-, V20- and V24–cylinder engine ⁄ Stroke: 220 mm
⁄ 1,500 rpm/1,800 rpm only with gear ⁄ total displacement: 124,8
⁄ Approx. 6.24 l displacement/cylinder ⁄ Mean piston speed: 11 m/s (1,500 1/min)
⁄ Applicable gas types: Natural gas, flare gas, biogas, landfill ⁄ Scope of supply: Generator set, cogeneration system
gas, sewage gas, special gases (e.g., coal mine gas, coke gas,
wood gas, pyrolysis gas) ⁄ Dimensions l x b x h: Generator set 8,900 mm x 2,200 mm x
2,800 mm*
⁄ weight empty: Generator set 28,000 kg*
⁄ Ignition system MORIS/MIC950 (old: IC920, IC922)
⁄ aluminium/steel piston
⁄ electric jacket water pump
⁄ four-valve cylinder head: centrally located purged pre-
combustion chamber
⁄ type 6 E gas mixer
⁄ type 6 F/G/H TecJet/gas metering valve
⁄ special gas mixer: specific version for special gases with low
calorific values J 616
⁄ toothed con rod
All rights reserved May 19
Type 6: engine views
J 620 intake
chamber
camshaft
valve
intake air filter generator timing
coupling
piston
starter blow-by
crankcas cylinder liner
exhaust gas
e connecting
turbocharger
rod
engine cooling
water pump
crankshaft
oil pan
The case crankcase is fitted with openings to permit access for dismantling and assembly
work.
On the flywheel-side, the crankcase is sealed off (oil tight and dust proof) by the gear train
and on the opposite side by the crankcase end cover.
Oil pan
connecting main
rod bearing oil ducts bearing
crankshaft
toothed gear counter weight
Vibration damper
Type 6: piston
Version E Version F
aluminium piston steel piston