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Reducing Operational Costs by Utilizing Bi Fuel Technology Greg Formanski Technical Sales Specialist
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Spartan Controls Confidential | Page 2 Co-firing of standard diesel fuel and natural gas (methane) Used on conventional, heavy-duty and light diesel engines No engine modifications are required GTI Bi-Fuel ® can be installed in the field or as an OEM up-fit Natural gas may be substituted for up to 70% (max) of the diesel fuel required to maintain a given speed and load What is bi-fuel?
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Spartan Controls Confidential | Page 3 Prime Power Peak Shaving Standby Power Distributed Power Generation Pumping applications Drilling Rigs Fracking Well Service Primary Applications
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Spartan Controls Confidential | Page 4 Characteristics of GTI Bi-Fuel ® System Maintains diesel-like performance and efficiency Compression ignition Vacuumed based Dedicated sensor package Auto-switching of fuel modes Non-intrusive, simple installation Easy to operate
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Spartan Controls Confidential | Page 5 Diesel vs. Bi-Fuel Response Performance 100% Diesel Block Load 70% Bi-Fuel Block Load
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Spartan Controls Confidential | Page 6 Reduced energy costs Rapid payback Extended runtime for emergency operation Reduced exhaust emissions Fuel flexibility Interruptible gas and electric rates Benefits to the User
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Spartan Controls Confidential | Page 7 Pipeline natural gas Liquid natural gas (LNG) Compressed natural gas (CNG) Wellhead gas* Bio-gas (landfill, wastewater, etc.)* Coal-bed gas* *with proper pre-treatment Fuel Gases Compatible with GTI Bi-Fuel ® System
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Spartan Controls Confidential | Page 8 Typical Static Bi-Fuel ® System Diagram Addition of kW, Engine RPM
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Spartan Controls Confidential | Page 9 Static Bi-Fuel Gas Train Low inlet pressure –.5 to 4 psi 50 micron gas filtration Zero pressure regulator DC powered, 12v or 24v dual solenoid valve Up to 6 outlets
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Spartan Controls Confidential | Page 10 Typical Dynamic STEPCON™ System Diagram
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Spartan Controls Confidential | Page 11 Main Valve ON #2 Valve ON #3 Valve ON #4 Valve ON STEPCON™ Technology STEPCON™ is designed to enhance the basic GTI Bi-Fuel system, allowing its application over a wider load range, adjusting the optimal substitution rate based on load with the capability to make substitution level adjustments in response to rapid load changes.
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Spartan Controls Confidential | Page 12 STEPCON™ installed on drilling rig
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Spartan Controls Confidential | Page 13 Typical Dynamic System Diagram
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Spartan Controls Confidential | Page 14 Dynamic GTI+ System Up to 4095 set points possible Electronic regulator Maximizes substitution in 10% load steps Ideal for rapid variable loads such as drilling rigs Anodized for corrosion resistance 3-50 psi gas supply input Compact
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Spartan Controls Confidential | Page 15 Dynamic GTI+ Technology The GTI+ system contains a single-stage, electronically-actuated, balanced poppet style, zero pressure regulator. An internal microprocessor, position sensor, and external mixer pressure sensors allow the GTI+ system to continually maximize substitution across the entire engine load range.
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Spartan Controls Confidential | Page 16 Applications and Installations - Publix Supermarkets Southeast US Over 600 units, 2007–2009 500kw CAT C15 Emergency power to avoid loss of perishable food
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Spartan Controls Confidential | Page 17 Fort Myers, FL (2) CAT 3516 Bi-Fuel systems, 2004 2,000kw each Extended runtime up to 300% for emergency standby power in critical care application Hospitals & Healthcare
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Spartan Controls Confidential | Page 18 Miami, FL (1) Mitsubishi S16R in 2003 1,600kw Extended runtime up to 300%. Emergency power for real-time supply of parts for NASA Parts Distribution
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Spartan Controls Confidential | Page 19 Toronto, Canada Cat D349 in 2005 800 kw Extended runtime up to 300%. Emergency back-up power for elevators, lights, computers, etc. High-Rise Office/Retail Buildings
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Spartan Controls Confidential | Page 20 Stennis Space Center Mississippi (2) CAT C18 500kw Emergency standby
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Spartan Controls Confidential | Page 21 Water Treatment Plant Wichita, KS (4) Cat 3516C (paralleled), 2010 2,000kw each 55% substitution Emergency standby power Extended runtime Reduced emissions
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Spartan Controls Confidential | Page 22 Irrigation Pumping Amarillo, Texas and New South Wales, Australia DDC Series 60 Cummins M11C, 2009 350kW & 300kW 70% substitution on both Prime power cost savings on diesel fuel for agriculture
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Spartan Controls Confidential | Page 23 Textile Manufacturing New Delhi, India Cummins, 2005 350kW Prime power cost savings to operate small factory Rapid payback – 16 days!
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Spartan Controls Confidential | Page 24 Oil & Gas Drilling Rigs Various locations in U.S., Canada, and China Over 500 Bi-Fuel systems installed on drilling rigs Hundreds more projected 1500kW x 3 engines per rig Huge cost savings on diesel fuel with rapid payback
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Spartan Controls Confidential | Page 25 Drilling & Fracing Rigs 40 GTI Bi-Fuel systems Running on CNG Xinjiang Province, China
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Spartan Controls Confidential | Page 26 GTI Bi-Fuel® on Drilling & Fracing Rigs 60 GTI Bi-Fuel systems Running on LNG Xinjiang Province, China
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Spartan Controls Confidential | Page 27 Fracing Trucks Western Canada and various locations in U.S. 20 units to date More companies ready to start testing on large fleets 1500–2000kW/engine @ 124 gph Each job requires 10-20 engines Huge cost savings with rapid payback Reduced truck traffic to jobsite
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Spartan Controls Confidential | Page 28 Well Servicing, Nitrogen & Foam Units Colorado 5 units 350kW Cat & DDC 65% average substitution Huge cost savings and rapid payback
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Spartan Controls Confidential | Page 29 Oil & Gas Rental Generators Williston, North Dakota Over 200 units, various sizes 200kW Cummins with 20,000+ hours on Bi-Fuel No downtime ! 55–65% average substitution Wellhead gas Temporary power to run wellhead pumps Uses flaring gas !
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Spartan Controls Confidential | Page 30 GTI Bi-Fuel® on Drilling & Fracing Rigs Total Bi-Fuel units sold: Total installed on Drilling Rigs & Frack Units: 3600 600+
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Spartan Controls Confidential | Page 31 Benefits of Bi-Fuel Cost Savings Rapid payback and huge savings on prime power applications Extended Runtime Increase runtime by 300% or more on standby power applications Reduced Emissions Typical installations reduce many toxic emissions
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Spartan Controls Confidential | Page 32 Cost Savings CAT 3512 Genset 1000 kW 55% Substitution Annual Savings @ 55% $582,286
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Spartan Controls Confidential | Page 33 Cost Savings Cummins QSK50
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Spartan Controls Confidential | Page 34 Extended Runtime 100% Diesel vs GTI Bi-Fuel ® run time on a 1000kW load
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Spartan Controls Confidential | Page 35 Emissions NOx CO 2 SOx Visible emissions PM NMHC NOx CO 2 SOx Visible emissions PM NMHC Emissions
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Spartan Controls Confidential | Page 36 GTI IS “CARB CERTIFIED”
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Spartan Controls Confidential | Page 37 Reduced NOx with GTI Bi-Fuel ® and SCR
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Spartan Controls Confidential | Page 38 Certified Emissions Test: MTU 12V1600 (600kW) Carbon Monoxide (CO) Test % Load255075 Diesel Baseline1.60.8.8 Bi-Fuel w/o Catalyst23.514.712.5 Bi-Fuel w/ Catalyst000.1 Oxides of Nitrogen (NOx) Diesel Baseline5.45.1 Bi-Fuel w/o Catalyst43.23.4 Bi-Fuel w/ Catalyst4.23.53.7 Particulate (PM) Diesel Baseline0.190.150.16 Bi-Fuel w/o Catalyst0.12.0140.07 Bi-Fuel w/ Catalyst0.090.110.05 32.7% Reduction Over 100% Reduction 56.3% Reduction 68.8% Reduction 38.2% Reduction
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Spartan Controls Confidential | Page 39 GTI Emissions Statement Based on a broad experience with the GTI Bi-Fuel System, we are confident that operation of gensets on Bi-Fuel will produce emissions reductions in the following ranges: – 1. NOx: 10% - 30% decrease – 2. HC (reactive): 20% - 80% decrease – 3. PM-10: 20% - 50% decrease – 4. Opacity: 30% - 50% decrease – 5. SOx: 50% - 70% decrease CO output will increase during Bi-Fuel operation as well as the total hydrocarbon (THC) output. If the lowest possible CO and THC output are desired, a 2-way catalysts can be used which will decrease these emissions approximately 70% - 90%, depending on load factor. The numbers and percentages listed in this document should not be used for quoting purposes or looked at as a specification. This document is for general purpose information only.
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Spartan Controls Confidential | Page 40 CARB TEST RESULTS - MAY 2014
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Spartan Controls Confidential Thank you for this opportunity! Reducing Operational Costs by Utilizing Bi Fuel Technology Greg Formanski, Technical Sales Specialist (780) 238-3862Formanksi.Greg@SpartanControls.com
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