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Once out of the digesters at the waste-to-energy plant near Rushden, UK,
the biogas is utilized in two MAN gas engines to generate renewable power,
which is then sold to the national grid. The first engine, type MAN 7L51/60 DF,
has been running successfully on biogas at the power plant since 2014, with an
output of around 6.5 MW. The second, a genset of the type MAN 20V35/44 G, was
delivered, installed and handed over in 2016, within a record eight months. It
will generate up to 10.6 MW of electrical power.
The plant is used to supply
power to the local electricity grid and now has a capacity of around 17 MW, a
total able to serve a community of around 35,000 people.
“To our knowledge,
this is the first plant that uses a 10 MW gas engine to produce green power in
the most efficient way that you can imagine,” says Hajo Hoops, Senior Sales
Manager Gas Power Plants at MAN Diesel & Turbo. “The efficiency achieved at
Wykes really is a step ahead from anything else that exists in the industry.
Their goal is 50% net efficiency,” he adds. “The company has the guts, the
knowledge and the technology to come up with a biogas that is so clean and so
controlled that you can burn it in an engine that represents the latest
Wykes is creating industrial biogas to industrial
standards. The extra work and ef-fort put in at Wykes is clearly higher than
anywhere else, Hoops believes, but it pays off because efficiency matters.
Fleetsolve, the UK’s leading manufacturer and
operator of systems for renewable biofuel and combined heat and power, also
provides sustainable solutions, but their specialty is the technology and engineering
know-how in the processing of liquid biofuels for reliable combustion in large
Keith O’Connor, Managing Director and Owner of Fleetsolve, says, “We
never use anything you have to grow for fuel, and never divert anything away
from food. Our clients have to be committed to a low-carbon environment and
must have a transparent waste management operation in a fully audited system.
Our own company is independently audited
every year, and our waste-to-energy fuel carries the International
Sustainability & Carbon Certification
(ISCC). These are accolades we want to uphold.”
Over the last ten years, Fleetsolve has often partnered with MAN Diesel
& Turbo to provide renewable energy packages. It has a tried-and-tested
system for processing waste into biofuel to run efficiently in the MAN engines.
Their clients are diverse, as are the reasons why they adopt waste-to-energy
solutions. “Today’s consumer, industrial or private, is acutely aware of the
need to have low-carbon products. Companies see waste-to-energy solutions as a
sustainable way to offset the carbon they produce in their business,” says
O’Connor. “And our solutions tie in with the increased sense of corporate and
social responsibility of many larger organizations and shareholders.”
addition, Fleetsolve has implemented data mining on a large scale. Each system
has 50 to 100 data points, which provide valuable insight for designing the
best combustion solutions according to the individual needs of their clients.
In one recent case, for a client at a rendering plant, the partnership
focused on a solution for a MAN L21/31 four-stroke medium-speed engine to
operate using a blend of waste oils and fats from the plant. Fleetsolve brought
the expertise in chemical analysis and processing, and an advanced
understanding of fluid and fluid dynamics – and was therefore able to fine-tune
the fuel-supply process to best suit the potential of the MAN engine.
“As the MAN
engines are so well engineered and manufactured, they respond particularly well
to fuels you wouldn’t normally run with engines of other companies,” O’Connor
says. “The things you would worry about with others, you don’t have to with
MAN. That’s a great benefit.” It’s also the reason why O’Connor foresees a
long-term partnership with MAN Diesel & Turbo, which would provide
solutions combining MAN engines with the company’s own fuel-processing system
to reliably and efficiently generate renewable energy.
At the rendering plant, Fleetsolve improved the external lubrication
system to provide the engine with the constant oil polishing necessary when
using organic oils, enhanced the air intake to get a cleaner burn and improved
the fueling process to optimize the burn temperature for the specific biofuel
at the plant. The MAN L21/31 engine runs for 24 hours a day, 7,884 hours a
year, and produces 1,100 kW of electrical energy and up to 1.3 MWth of thermal
energy, which achieves carbon savings for the business of over 20,000 metric
tons a year.
Although bioenergy has often been mired in controversy over
environmental risks, intensive farming and the loss of valuable farmland to
fuel crops, these two initiatives show that bioenergy can work. Crucial to
success is the ethical sourcing of waste material. Together with MAN Diesel
& Turbo, these two companies are demonstrating the truth of the proverb
“waste not, want not.” Energy generated from biomass covers more than 10% of
the world’s energy demand, but there’s plenty more waste to turn around. Hoops
is convinced of waste-to-energy initiatives, adding, “I wish that we had more
projects like these.”
We never use anything you have to grow for fuel.
of food are wasted each year in the EU,
the equivalent to 175 kg per EU citizen. The biggest culprits are
private households, which account for
53% of the total wasted
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