Decentralized Energy Generation in Gas Power Plants Close to Consumption

The eco-friendly MWM cogeneration plants enable decentralized, combined energy generation. This means that different types of gas are converted to electricity on site, and the resulting exhaust heat is used directly and is not lost. With combined power and heat production, the plants reach an overall efficiency of up to 95 percent. The generated power and heat can be used on site or fed into the public power or heat grid.

MWM’s portfolio ranges from comprehensive plant engineering to complete project rollout to turnkey plants.

Genset adopts HND-MWM engine, which is made by Henan Diesel Engine Industry Co., Ltd (HND). HND is a member of China Shipbuilding Industry Corporation(CSIC) and the research and manufacturing base of high and medium-speed, high power diesel engines in China.

HND introduced the licensed technology from DEUTZ-MWM Company, Germany in 1985 and produce MWM series diesel engine. HND-MWM engines are not only widely used in ship field such as military equipment, commercial cargo ship, passenger ship, tourist ship, working ship, fishing ship and high-speed vessel but also in other fields such as petroleum industry, coal industry, mining, nuclear power station, hydropower station, emergency/fire pump and special vehicles.

MWM’s product portfolio comprises gas engines (gas generators or gas gensets) in the output range from 400 kWe to 4,300 kWe. In this way, it is possible to set up power plants with an output of up to 100,000 kWe and more. The gas engines can be operated with various types of gas, such as natural gas, shale gas, mine gas, biogas, landfill gas, sewage gas, and syngas. They are designed for maximum electrical and thermal efficiency, low operating and service costs, and high reliability and availability. More than 4,894 gas engines (gensets) with 5,637,000 kWe have already been installed worldwide.

Gas Engines (Natural and Biogas Gas Generator Sets) by Power Class

MWM Gas Engines (Gas Gensets)

Gas Engine TCG 2016 (Biogas & Natural Gas Generator Set)

Gas engine TCG 2016 – all-out efficiency

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Gas engine TCG 2016 – Facts and Figures

• Output range from 400 to 800 kWe
• Runs on all gas types: natural gas, biogas, landfill gas, sewage gas, mine gas, etc.
• Mainly used for biogas plants and small CHP plants in Europe
• Highest electrical efficiency in the output range up to 1,000 kWe
• More than 1900 power generators with approximately 1,000,000 kWe already installed around the globe

Low Operating Costs – Gas Engine TCG 2016

Consumes up to 15 Percent Less Gas than Comparable Gensets Thanks to Its Best-of-Class Efficiency

• Special piston variants with different compression for biogas and natural gas operation
• Optimized gas exchange and camshaft, spark plugs with integrated pre-combustion chamber
• Even load balancing over the individual cylinders enables higher load level and maximum utilization of the engine reserves in terms of output and efficiency
• New closed crankcase ventilation optimizes combustion and increases efficiency by utilizing the blow-by gas
• Consistent downsizing of dead spaces improves complete combustion of the gas mixture, resulting in reduced fuel consumption and HC and CO emissions and higher efficiency

Long Service Intervals

• Longest time interval until major overhaul compared to competitors
• Use of Xchange components enables time savings of up to 75 percent during the major overhaul, resulting in reduced costs
• Turbocharger for TCG 2016C series, depending on application with water-cooled bearing housing, thus reducing maintenance costs for turbocharger
• No contamination of the turbocharger compressor thanks to improved separation of gas and liquid phase, resulting in long maintenance intervals

Very Low Lubricant Consumption

• With its lubricant consumption of only 0.2 g/kWh, TCG 2016C sets competitive standards
• Lubricant savings of up to 50 percent compared to competitors

Lower Investment Costs – Gas Engine TCG 2016

Low Installation Costs Thanks to Smaller Dimensions

• Compact genset design saves investment costs through smaller engine space and fewer plant peripherals
• Setup space up to 50 percent smaller than for comparable gensets

High Flexibility – Gas Engine TCG 2016

TEM Control Enables Use of Diverse Gas Types

• Same electrical output with natural gas and biogas
• Further information on the TEM control

Gas Engine TCG 2020 / TCG 2020 K (Biogas & Natural Gas Generator Set)

Gas engines TCG 2020 & TCG 2020 K – premium ecology and economy

Gas engine TCG 2020 / TCG 2020 K / TCG 2020 K1

Facts and Figures

• Output range from 1,200 to 2,000 kWe
• Best electrical and thermal efficiency in its output class
• Runs on all gas types: natural gas, biogas, landfill gas, sewage gas, mine gas, etc.
• TCG 2020 is mainly used for CHP plants in Europe and for biogas worldwide
• TCG 2020K was especially adapted to non-ISO conditions such as high altitudes or high intake air temperatures in the field of natural gas
• More than 2000 power generators with approximately 2,800,000 kWe already installed around the globe

Low Operating Costs – Gas Engine TCG 2020 / TCG 2020 K

TCG 2020 – High Profitability Thanks to High Efficiency

• Improvements of the intake duct and spark plug provide higher efficiency compared to predecessor model
• Miller valve control times increase genset efficiency

TCG 2020K – Optimized for Isolated Operation and Non-ISO Conditions

• Load response in only seven steps
• Fast and reliable supply in the event of grid failures or in isolated operation
• Special 1,000 kWe variant available for high altitude setup and different intake air temperatures

Higher Efficiency and Lower Pollutant Emissions

• Smaller dead spaces in combustion chamber ensure more complete combustion
• Reduced fuel consumption and CO and HC emissions
• This enables gas savings of up to 15 percent a year and increases the profitability of the plant

Higher Efficiency and Long Maintenance Intervals

• Effective crankcase ventilation increases efficiency by utilizing the returned combustible blow-by gas
• Optimized blow-by return and improved separation of the gas phase and liquid phase enable longer maintenance intervals for the turbocharger thanks to the clean intake air

K Editions: Maximum Output at Low Costs

• Improved output capacity of TCG 2020K under non-ISO conditions and excellent load response through optimum turbocharger design with broad performance map
• New turbocharger TCR 16 for TCG 2020 with water-cooled bearing housing eliminates need for separate maintenance stages for the turbocharger
• TCG 2020 K1 is a for 1000 kWe optimized version of the TCG 2020 K gas engine with a focus on high efficiency at low cost of investment

High Reliability – Gas Engine TCG 2020 / TCG 2020 K

Few Interruptions Due to Long Maintenance Intervals

• No more than two interruptions a year due to scheduled maintenance
• Longest interval until major overhaul compared to competitors
• Use of Xchange components enables time savings of up to 75 percent during the major overhaul, resulting in reduced costs

High Reliability through Mature Drive Technology in 60 Hz Range

• Engine can be operated with an optimum speed of 1500 RPM.
• Lower speed ensures stable and complete combustion, resulting in lower CO emissions and less component wear and tear

Gas Engine TCG 2032 (Biogas & Natural Gas Generator Set)

Gas engine – TCG 2032 – MWM’s largest series

Gas engine TCG 2032 – Facts and Figures

• Output range from 3,000 to 4,300 kW_el ‒ MWM’s largest series
• Runs on all gas types: natural gas, biogas, landfill gas, sewage gas, mine gas, coke oven gas, etc.
• Mainly used in large IPP projects with up to 100,000 kW_el
• Outstanding reliability and low maintenance costs
• More than 600 power generators with approximately 2,200,000 kW_el already installed around the globe

Low Operating Costs – Gas Engine TCG 2032

High Efficiency and Low Lubricant Consumption

• High fuel utilization and low operation costs thanks to optimized chamber spark plug
• Increased efficiency through new closed crankcase ventilation that enables utilization of the blow-by gas
• High availability through long maintenance intervals: first maintenance after 4,000 h, major overhaul after 80,000 h
• Up to 30 percent lower annual lubricant consumption compared to competitor products thanks to optimized tappet sealing, coke stripping rings and ring packages

Soot-Free Combustion Increases Plant Profitability

• Open combustion chamber with chamber spark plug for soot-free combustion
• Extended maintenance intervals for the exhaust gas heat exchanger
• No pre-combustion chamber with time-consuming maintenance and risk of failure
• No additional gas supply with increased gas pressure required for pre-combustion chamber

Few Interruptions Due to Long Maintenance Intervals

• No more than two interruptions a year due to scheduled maintenance
• Longest interval until major overhaul compared to competitors
• Use of Xchange components enables time savings of up to 75 percent during the major overhaul, resulting in reduced costs

High Availability – Gas Engine TCG 2032

New Turbocharger Technology Increases Genset Availability

• Improved output under non-ISO conditions
• High output of 4,300 kWe possible through use of A140 high-pressure turbocharger
• Turbocharger achieves higher compression ratio and enables operation under full load with intake air of up to 45°C
• Exhaust gas waste gate enables constant performance with different intake air temperatures and setup altitudes
• Evening out of reserve boost pressure in relation to load results in higher efficiency and improved load response

Low Installation Costs – Gas Engine TCG 2032

Compact Engine Design for Easy Transport and Installation

• Extremely lean genset with compact dimensions, low noise emissions, and smooth running guarantees minimum installation costs
• Compared to competitors, the specific output/weight ratio is up to 40 percent better
• Lighter engine components eliminate need for strong crane
• Compared to competitors, TCG 2032 V16 is up to 30 percent shorter in length
• Low weight and compact dimensions enable easy transport even to remote destinations

Short Project Period – Gas Engine TCG 2032

Short Project Period Thanks to Compact Setup

• Pre-manufactured components directly from the manufacturer ensure quick and easy assembly on site
• Identical setup of the individual modules facilitates flexible adjustment of the plant output
• Modest need for space through compact design
• Plant planning and building from one source guarantees smooth, cost-efficient project rollout

Lower Service Costs – Gas Engine TCG 2032

Up to 20 Percent Lower Service Costs

• Enhanced maintenance concept through easy access to the cylinder units
• Long service intervals and improved serviceability
• Lower maintenance costs through 50 percent reduction in number of engine parts compared to predecessor, resulting in lower maintenance overhead and reduced need for spare parts
• Lower maintenance overhead through open combustion chamber with pre-combustion chamber spark plug

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