- GE Power Generation

coJen

GE Energy • Jenbacher gas engines • Issue 2/2008

J624 North America Service

First 24-cylinder gas engine in operation at pilot customer site

Energy trends and solutions

Closer to customers thanks to new Global Service Organisation

02

Content 02

editorial



CEO story

03

A focus on Service



product news

05

Full steam ahead with the first J624

08

Pilot customer with vision

09

Efficiency and power output of large gas engines



industry news

11

The keys to business success

13

Renewable energy – opportunity or challenge?



applications and solutions

15

The gas that comes from oil

18

Jenbacher gas engines powered by associated petroleum gas



boost Argentina’s energy supply



distributors and service providers

19

Do you speak Bengali?

21

Jenbachers shine light into the darkness



region special

23

North America‘s changing landscape

31

First North American greenhouse application



service

33

When the genset calls for the doctor

35

Tailored customer solutions



supply chain

37

Jenbacher goes China



personality story

39

An interview with Axel Dancker, Global Service Leader

41

feedback and masthead



home base

42

Long road to Jenbacher gas engines

editorial

coJen

Dear Customers and Readers! C

oJen has gone into the second round! Once

gas for energy production or renewable energy

again, our magazine for the worldwide Jenbacher

sources in general. In addition, in this issue you

gas engine community covers many areas of in-

will once again find an extensive article on our

terest to you. And, starting with this issue – which

latest engine – the first 24-cylinder gas engine in

includes a regional focus on North America – we

the world – which has in the meantime gone into

offer you greater insight into specific areas of the

operation for a pilot customer in the Netherlands.

gas engine and energy industries. This issue also includes interesting contributions We started this new section in part because of

by guest writers in the industry. For example,

the plentiful and extremely helpful feedback we

you will find a report on technical developments

received from you following the first issue of

in the field of efficiency improvements to gas

CoJen. Thank you to the many readers who took

and automotive engines. At the end of the

the time to fill out our survey. The proud winner

magazine, we invite you to pay a historic visit to

of an Apple iPod Touch is our customer Gerhard

Tyrol – the headquarters of the gas engine divi-

Aschauer from Bioenergie Kallham GmbH in

sion of GE Energy.

Austria. The soccer balls went to readers from Germany, Austria, Great Britain, India and the U.S.

On behalf of the entire editorial team, I wish you an enjoyable read and look forward once again

Your feedback has definitely encouraged us

to receiving your feedback.

to continue down this path. In addition to the English and the German version of CoJen, we will publish the region specials in the language of the region being featured. What awaits you in this issue of CoJen: First, we introduce you to Orient Energy, one of our international distributors. We also look at global

Martina Streiter

trends, such as the use of associated petroleum

Jenbacher Communications

02

CEO storyen

coJen

A Focus on Service GE Energy’s Jenbacher team is translating its dedication to innovation – demonstrated by continuous launches of world firsts in the gas engine industry for more than 50 years now – into the Services arena. This focus on the Services business will benefit Jenbacher engines customers around the globe. Not only can they refer to GE’s expert Service personnel, they also can turn to the highly trained professionals from the more than 40 Jenbacher Service providers around the globe.

I

n early 2008, GE’s Jenbacher gas engines division created a

dedicated business unit entirely focused on service offerings, innovations, and worldwide coverage. “As our Jenbacher engine fleet is growing and becoming more global, the importance of continued world-class customer service from us and our Service providers – who focus on smooth processes, strong expertise, and global presence – is key to customer satisfaction,” says Prady Iyyanki, Jenbacher gas engines CEO. Building up Growth Structures. Coinciding with the new approach in the organization, Axel Dancker was named Global Service Leader for GE’s Jenbacher gas engines division. Dancker has a proven track record of expanding businesses and building up organizational structures in growing business environments. Before joining GE, Dancker was highly focused on strategy and retail, as well as Service businesses in various German companies. “With Axel’s strong expert background, experience and leadership, and the great team we already have in place, I am excited about the future of our Service business,” Iyyanki says. The key elements of the business are strong customer focus, value added offerings, local support and remote service capabilities around the world.

The key elements of the Service business are strong customer focus, value added offerings, local support and remote service capabilities around the world. 03

JCEO story

coJen

“As our Jenbacher engine fleet is growing and becoming more global, the importance of continued world-class customer service is key to customer satisfaction.” In addition to the emphasis on service capabilities, the Jenba-

24-cylinder J624 GS 4 MW Jenbacher engines are in full opera-

cher team’s goal is to reach out to customers globally and bring

tion for the first pilot customer in the Netherlands, powering the

tailored local solutions into new growth regions. This includes not

tomato growers’ greenhouses with electricity, heat and CO2 for

only the Service business, but also the packaging of the highly

plant fertilization. “It is great to see that innovation is supported

efficient gas engines to power generation units based on tailored

by our customers and that we grow as our customers grow.”

engineering solutions.

Iyyanki says.

Tailored Solutions – Worldwide. Having reached a critical volume of gas engine orders in Asia, the Jenbacher team recognized the need to locate a new packaging facility in China to help ensure prompt equipment delivery and tailored customer service

It is great to see that innovation is supported by our customers and that we grow as our customers grow.

for projects throughout Asia, Iyyanki says. “We now operate three manufacturing facilities with the main location in Austria, where

Pilot customer Royal Pride Holland already operates a total of 35

we develop and produce the core engine; a container packaging

MW in Jenbacher engines and now gratefully serves as a focal

facility in Hungary; and our new operation in Hangzhou.” The

point for plant visits from all over Europe to showcase and explain

global outreach is advantageous to customers since local service

the new product. The interest in the latest innovation from Jen-

capabilities are enhanced, especially when it comes to engine

bach is high, and more development highlights are expected that

overhauls that can be done in the new locations. In addition,

will excite the global gas engine community in the future._

the business plans to build up an additional service workshop network. “We want to be where our customers are,” Iyyanki says. “A top performance in terms of innovative, highly efficient products combined with world-class service is key for a long-term successful relationship.”

We want to be where our customers are. The technological performance looks good in 2008 for GE’s gas engine business. Since late September, the first two of the new

04

coJen

product news

Full steam ahead with the first J624! It was presented to the public in June 2007. Then came a year of testing at the production location, followed by a successful evaluation. And in September 2008, it was finally ready: The latest Jenbacher flagship, the first 24-cylinder gas engine J624, went into operation with pilot customer Royal Pride Holland. Since then, the J624 has provided the Dutch greenhouse complex with reliable electricity and heat – and it also supplies CO2 as a fertilizer for faster plant growth.

T

he J624 is the most important innovation de-

Dutch gardeners as pilot customer.

veloped in recent years by GE Energy’s Jenbacher

The natural next step was to supply the first two

gas engines product team with more than 50

J624 GS in early May 2008 to the tomato green-

years of experience in gas engine technology. In

houses of Royal Pride Holland in Middenmeer, 50

the most recent issue of CoJen, the then brand

kilometers north of Amsterdam. Here, the engines

new 24-cylinder gas engine and its impressive

run under conditions similar to those that will be

performance data were described as a quantum

found at the vast majority of future customers –

leap. Its capacity is also impressive: A single J624

an important prerequisite for a pilot customer.

with an output of 4 MW can cover the power

In September 2008, the engines, which run on

needs of about 9,000 European households.

natural gas, went into operation. Since then they

The successful first run and overload test on

have been complementing the nine Jenbacher

the test bench at the Jenbacher plant not only

JMS 620 units already installed there. This brings

excited employees again, it also meant the green

the total electrical output of the complex to

light for its use by the first pilot customer.

35.2 MW.

In the greenhouse of pioneers. The fact that the energy-efficient, powerful engines from Tyrol are performing so successfully in the Netherlands is no mere coincidence. When it comes to using the trend-setting technology of combined

When it comes tousing the trend-setting technology of combined heat and power, the Netherlands are an international pioneer.

heat and power, this country is an international

05

pioneer. Dutch gardeners were also some of the

The power generated is used in part for lighting

first to use CO2 fertilization.

for the tomatoes, but most of it is fed into the

This long-term successful cooperation was a

public power grid. Since the waste heat from the

decisive factor in GE’s decision to locate its inter-

engines can be used at very low temperatures

national Center of Excellence for greenhouse

and the CO2 in its exhaust gas can also be used,

applications of Jenbacher gas engines at its

the overall level of efficiency lies at an extraordi-

Dutch branch.

nary 95%.

product news

coJen

Royal Pride Holland – an excess of tomatoes. It all started back in the 1960s, when Andre van den Ende established his own company and cultivated tomatoes and cucumbers in rotation in an area of around 4,000 square meters. With the area of 45 hectares it now cultivates, and its currently ongoing expansion to 102 hectares, Royal Pride Holland today is one of the largest operators of commercial greenhouses in the Netherlands. Flavor is written large. After growing loose tomatoes for years, in the mid 1990s the company switched to vine tomatoes, which are more flavorful because they are ripened on the vine. From “red pearl” cocktail tomatoes to “sweet pearl” cherry tomatoes, the selection of tomato varieties grown at Royal Pride Holland is primarily a question of taste.

We are setting new standards for the future with the J624 at our Dutch pilot customer. Pioneers in energy supply as well. For Mark Geleijn, too, manager of the project department at the Jenbacher gas engines division of GE Energy in the Netherlands, this commissioning was something exceptional: “I am delighted that the first J624 engines were delivered to us in the Netherlands. Apart from the special features of the engine itself – above all its modular concept with a separate, vibration-decoupled turbocharger group – this commissioning was quite exceptional simply because this is the first 24-cylinder engine in the world.” From the technical standpoint, the monitoring program, which was more extensive than usual, was a special feature of this commissioning: The J624 was thoroughly examined for an entire week. Apart from that, the commissioning was routine for the experienced Jenbacher team. “We are setting new standards for the future with the J624 at our Dutch pilot customer,” Mark Geleijn is absolutely certain of the importance of this project. What the future will bring ... ... a selective field launch of the J624. In the coming year, the engine will go into series production, initially with a limited numbers of units. The first order from Europe has already been landed. But watch upcoming editions of CoJen for more on this subject._

–> The Jenbacher J624 engines provide electricity, heat and CO2 as fertilizer for faster plant growth 06

coJen

product news

–> The first J624 engine was delivered in May 2008 to Royal Pride Holland

facts and figures J624 – a quantum leap in gas engine technology

• Compact high-speed engine with • About 11.6 meter long, 2 meter wide and 2.5 meter high • Total weight: 41 tons • Bore x stroke: 190 mm x 220 mm • Total displacement: 150 l • Fuel flexibility: natural gas or a variety of renewable or alternative gases • Electrical output: 4 MW • Electrical efficiency: approximately 46% • Allows overall plant efficiencies of up to 95% First 24-cylinder gas engine for commercial operation 1,500 rpm

07

•

•

Lean burn, turbocharged, mixture cooled gas engine

First fast-running gas engine in the 4 MW power range

product news

coJen

CoJen talks to Frank van Kleef, Royal Pride Holland:

Pilot customer with vision Frank van Kleef has been a partner in Royal Pride Holland for more than 10 years and now runs the company together with founder Andre van den Ende and his sons Bart and Koert.

CoJen: Mr. van Kleef, can you briefly tell us

What was the appeal to you in being a pilot

what your company is about?

customer for the new J624 GS?

Frank van Kleef: Royal Pride Holland stands for

We ourselves are always looking for ways to

tomatoes that not only taste superb. They are

make improvements and when possible support

grown using sustainable farming methods.

our associates with their related endeavours

The Dutch minister of agriculture, Gerda

– in this case, with the development of a gas

Verburg, named you – and company founder

engine with even better power generation

Andre van den Ende and his two sons Bart

capacity.

and Koert – “Agricultural Entrepreneurs of the

In your opinion, what are the advantages and

Year” this year. This tribute reflects less on

disadvantages of being a pilot customer?

the size and revenue of a company than on its

As a pilot customer for the J624 we are ahead

entrepreneurial vision and innovative power.

of later customers by one to two years. If

What does this award mean to you person-

unforeseen problems arise, that could be a

ally?

disadvantage. But as I know Jenbacher, I am not

It confirms that we are on the right track! Royal

particularly worried on that score.

Pride Holland is constantly investing a great

What do you see as the biggest challenges for

deal of money and energy in improvements

operators of greenhouses in the future – also

and, by doing so, demonstrates how improve-

outside the Netherlands?

ments can be achieved on the basis of forward-

Apart from high energy prices, securing supplies

looking action. The award shows that other

of food will certainly be a considerable chal-

people believe in the direction in which we have

lenge in the future. Cultivating the best, most

forged ahead.

flavorful tomatoes is just as important to Royal

What was the decisive factor in your decision

Pride Holland as it is to Jenbacher to achieve a

to use Jenbacher gas engines made by GE?

maximum of dependability and efficiency with

In our industry, Jenbacher is a name that rever-

their gas engines.

berates. The staff at Jenbacher back up their products and know exactly what the best use –>

FRANK VAN Kleef, Royal Pride Holland

for their engines is.

08

coJen

product news

A comparison to automotive engines:

Efficiency and Power Output of Large Gas Engines In addition to reliability, the power output and the efficiency of large gas engines are the most important criteria considered when purchasing such an engine. Since fuel consumption is directly linked to the emission of the greenhouse gas CO2, high efficiency is of tremendous environmental relevance as well. A story by Professor Andreas Wimmer and Professor Helmut Eichlseder, Graz University of Technology

T

he efficiency of large gas engines has improved dramatically

However, Figure 1 also clearly shows that the slope of the curve

in recent years. This is illustrated by Figure 1, which shows the

of the mechanical efficiency has decreased. In other words, the

impressive development of the mechanical efficiency of Jen-

efficiency of gas engines is approaching the limit of what is theo-

bacher’s type 6 gas engines. For many years, the efficiency of gas

retically possible. Thus it will become more and more difficult to

engines was inferior to that of diesel engines. However, this gap

achieve further increases in efficiency, requiring the latest tech-

has now largely been closed, and gas engines offer the additional

nologies, such as two-stage turbocharging, cylinder pressure-

advantage of significantly lower emissions. The levels of efficiency

based engine control, and alternative ignition systems.

achieved today are almost twice as high as those of around 26% described by Rudolf Diesel for his first self-igniting engine in the year 1897.

Figure 1: Development in the efficiency of Jenbacher gas engines

A number of measures were responsible for this remarkable increase in efficiency. However, making engines less susceptible

%

to knocking and increasing the compression ratio were the most

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achieved essentially by increasing the air to fuel ratio and by closing the intake valves either very early or very late in the combustion cycle. Using a high air to fuel ratio and Miller valve timing

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introducing the Miller valve timing, where the charge is cooled by

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has thus become a key component.

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efficiency. The difference between the theoretically achievable efficiency and the mechanical efficiency is attributable mainly to