FIAT

PROJECT
PRESENTATION

Franco Anzioso Ph. D. NIDays 09

Centro Ricerche Fiat
25/02/09
Date
 THE SCENARIO
The recently published action plan for energy efficiency underlines that the European Union
is facing a crucial challenge in the energy field:
§ Europe continues to waste at least 20% of its energy due to inefficiency
§ the perspectives for the future is that in 2050:
üis that almost ¾ of the world’s energy supply will still come from fossil fuels
üenergy demand as well as CO2 emissions will more than double

THE TARGET
Europe wants to lead the way in reducing energy inefficiency, using all available policy tools at
all different levels of government and society.

THE CHALLENGE
European Union is facing a crucial challenge in the energy field and to complement centralised
generation with distributed generation will be a winning strategy.

In this framework HEGEL will test on the field some of the most promising technologies for
distributed generation without overlooking market and competitiveness aspects.

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Date 05/09/07
 INTRODUCTION
HEGEL* IS A PROJECT AIMED AT DEVELOP DEMONSTRATE AND COMPARE HIGH EFFICIENCY
APPLICATIONS OF MICRO-POLYGENERATION

Control System
Three demonstration plants will be
Remote Maintenance constructed and tested:
Wi-Fi Control
•“ICE-Desiccant” application a tri-
generation plant that will be installed in
Torino (Italy)
•A “Combi System” application : two
integrated cogenerators powered by
different prime movers.
Such plant will be installed and test in
Turkey at Middle Technical University
•“MT-Absorption” application a
trigeneration plant that will be installed in
Spain
Building Automation HEGEL (high efficiency polygeneration
Monitoring System applications) is a project financedby European
commission in the 6th Framework Programme
under priority 6.1.

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Date 05/09/07
 THE CONSORTIUM

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Date 05/09/07
 FIAT RESEARCH CENTER
CONTINUOUS COGENERATOR

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Date 05/09/07
 CHARACTERISTIC OF THE CRF SYSTEM
Main Features: Technical features
Fuel: natural gas/ biogas
•Automotive derived natural gas engine
Feeding: multipoint injection
(stoichiometric, turbocharged, 3W catalyst)
•Power regulation at variable speed
Performance
•Plug and Play
Nominal power: ~ 120 kW
•Constant efficiency @ partial load
Thermal power: ~ 188 kW
•Telematic management
Electrical efficiency: ~ 33%
exhaust gas temperature: ~ 700°C
exhaust gas flow rate: ~ 0.13 kg/s

Function
- POWER RATE CONTROL: acting on engine RPM and fuel
injection (optimizing emissions and efficiency).
- DUAL MODE: automatically switch between island and parallel
mode.
- UPS: through the power buffer the continuity necessary before
ICE startup is assured.
- POWER QUALITY: controlled through power electronics.
- REMOTE MANAGEMENT: via a telematic system.

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Date 05/09/07
 Flexible output

A conventional cogeneration system is sized according to its nominal power capacity (best
efficiency condition)

The constant efficiency @ partial loads of the CRF system make the power output more
flexible:
à capable of more yearly equivalent hours of operation ó shorter payback
à suitable to diverse final user load profiles.

100%

Conventional
Thermal power (kW)

CHP
50% CRF innovative
CHP

0
Yearly working hours (h)
1000 2000 3000 4000 5000 6000 7000 8000 8700

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Date 05/09/07
 CRF vs Microturbine: Energy efficiency
Due to the application of advanced high efficiency engine, the CRF system shows higher
efficiency at rated power (32,5% vs 28%).
Due to its unique variable RPM power control, CRF system efficiency remains almost
constant at partial loads (30% vs nearly 17% @ 30% of rated power).

Application consequence
The higher the energy efficiency the lower the variable cost of the energy produced.
Nearly constant efficiency at partial loads provides the CRF system with a unique
capability of following variable demand load profiles in a profitable way.
EL Energy cost
Electrical efficiency Electrical efficiency
(*) Source: SRI/USEPA Report 2003
[cEuro/kWh] (*)
35%
15
35%
30% 17 30%
Electrical Efficiency

Electrical Efficiency
25% 21 25%

20% 26 20%
15%
35 15%
10% 10%
52
5% 5%

0% 0%
100% 73% 45% 18% (*) natural gas price 100% 75% 42% 32%
% of Rated Power @ 0,5 Euro/m3 % of Rated Power

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Date 05/09/07
 Emission analysis
CRF cogeneration system VS Traditional Production (boiler + centralized electric production)

Local Emission comparison* Global Emission comparison

%Nominal Thermal Power (188 kW)

%Nominal Electrical Power

100% 100%

(120kW)
74%
63%

49%
44%

0 20 40 60 80 100 120 140

0 20 40 60 80 100 120
CO2 emissions [kg/h]
NOx emissions [mg/Nm^3]
Combi System CO2 emission Traditional production CO2 emission
* Mean value
Reference value
CRF cogeneration system Italian Thermo-
Thermo-electric production
Electrical Efficiency 38% (source Piemonte standard)
CO2 specific emission 618 g/KWhe (source APAT 2004)
NOx emission test
samples 120 Standard Boiler Efficiency
confidence interval 68.3%. Thermal efficiency 90% (source Piemonte standard)
CO2 emission Stoichiometric calculation NOx specific emission (@5%O2) 100 mg/Nm3 (source Piemonte
standard)
CO2 Stoichiometric calculation

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Date 05/09/07
 THE CHP CONTROL SYSTEM

•The development of the cogeneration system with a variable rpm

UPS functionality required the integration of different systems : electrical,
mechanical, pneumatic and thermal.

•The control system has been implemented through a CompactRIO PAC

(Programmable Automation Controller) the platform used was the 9400

•A comprehensive model of the system, the monitoring and diagnosis has

been made in Matlab/Simulink and linked to the LabVIEW control layer

•The rapid prototyping saved at least 8 month of development time

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Date 05/09/07
 THE HMI REALISED IN LABVIEW

Control on
PDA

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 THE REALIZATION
BUILDING LIQUID DESSICCANT

COGENERATOR

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 ICED

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Date 05/09/07
 ICED QUICK GLANCE
THIS SUBPROJECT IS AIMED AT INTEGRATING A LIQUID DESICCANT SYSTEM WITH THE
COGENERATOR DEVELOPED AT CRF.

INSTALLATION SITE PERFORMANCE & BENEFITS (EXPECTED)

Electric 120 kW
The building, in the city of Torino – Italy,
Heating 188 kW
comprise seven University lecture halls within
Cooling* 192 kW
the Polytechnic of Turin premises.
Electrical efficiency (CHP) 33%
Total Efficiency (CHP) 85%
The building is currently heated in winter
COP expected (Cooling) 1.3
through an all-air system integrated with hot
water heaters (heat, both for AHU and heaters,
Primary Energy Savings :
is provided by district heating). No cooling is
During Winter: 31 % (heat)
present in summer.
During Summer: 28 % (cool)

CO2 Emission Savings

During Winter: 162 kg/h (heat)
During Summer: 32 kg/h (cool)

* external air @ 28.8°C 68% R.H.

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Date 05/09/07
 TAC system description

The TAC desiccant cooling system (Thermally Activated air Conditioner) is expected to
have:

• HIGH EFFICIENCY: overall expected COP exceeding 1.

• HUMIDITY CONTROL: embedded in the dessiccant control.

• HIGH AIR QUALITY: obtained trough humidity control and trough efficiency in
latent loads handling.

• HIGH FLEXIBILITY of HEAT INPUT: operation will be possible at low inlet

temperatures and even with fluctuating temperatures. A concentrated desiccants
solution storage would add further flexibility to the required heat input.

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Date 05/09/07
 THE BUILDING
FUNCTIONAL LAYOUT

The conditioned building is part of the

Polytechnic of Turin

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Date 05/09/07
 THE BUILDING AUTOMATION

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 THE HMI REALISED IN LABVIEW

HEATING SYSTEM MANAGEMENT

UTA MANAGEMENT

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 COMBY SYSTEM

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 CS QUICK GLANCE

The system will have electrical efficiency about 40% and emissions of 539 PERFORMANCE & BENEFITS
gCO2/kWhe of electrical power produced, can conveniently substitute or (EXPECTED)
complement centralised power generation, resulting in lower CO2 emissions.
In fact the average Italian energy mix (i.e. the overall efficiency of the centralised
power production) is 38%, resulting in average 618 gCO2/kWh (fuel mix includes
also “CO2 intensive” fuels such as coal) at the power station. Such value does not
account for transmission and distribution losses that on average determine
additional 7% emissions

COMBI SYSTEM CONCEPT LAYOUT

Electric ~145 kW
Heating ~ 167
167 kW
Electical efficiency ~ 40%
40%
Total Efficiency ~ 86%

Primary Energy Savings : ~ 39 %

CO2 Savings: ~ 42%
NOx Savings: ~ 73%

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Date 05/09/07
 BALANCE OF PLANT: COGENERATION
The following are the estimated Sankey diagram for Combi system

Combi System performance

Electrical efficiency: ~ 40%
Thermal efficiency: ~ 46%

Master cogenerator performance

Electrical efficiency: ~ 33%
Thermal efficiency: ~ 28%

Slave cogenerator performance*

Electrical efficiency: ~ 26%
Thermal efficiency: ~ 67%
*Calculated wrt exhaust energy

Estimated primary power saving (with respect to conventional boiler 90% + centralized
production 38% with 6.4% grid loses) ~ 227 kW

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Date 05/09/07
 SOME REALIZATIONS

BUILDING RANKINE CYCLE

COGENERATOR

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 MTA

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 MTA
MGT are excellent power generators for use in combined heat and power systems
Advantages over other competing technologies:
• Lightweight and very compact systems
• Low noise levels and vibration free
• Lower exhaust gas emissions
• Less maintenance
• Fuel flexibility (natural gas, propane, bio-gas)
A Micro Gas Turbine produces waste heat at very high temperatures that can be used to drive
absorption chillers.
The Capstone C65 :
üPower 65 kWe
üNatural gas pressure 4.5 bar
üFuel input: natural gas 224 kW
üElectrical efficiency 29 %
üMass flow 0.49 kg/s
üExhaust Temperature 309ºC
üExhaust Energy 120kW

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Date 05/09/07
 THE MTA PLANT
MTG C30 Low Pressure Natural Gas

Compressor Turbine
Generator
Electrical efficiency: ~ 22,5%

Compressor Combustion
Thermal efficiency: ~ 52%
35ºC Gas Chamber * Ambient Temperature 35ºC
Natural
1bar Gas
99 kW

Recuperator
Exhaust Gas
Absorption cycle
288 ºC Heat exchanger:
83 kW
exhaust gas 215ºC 21,6 kW Cooling
/ oil Thermal oil Hot oil driven 16 kW 7,2ºC
Robur 16 kW
212ºC 198,5ºC

Heat exchanger: Costumer

80ºC 5080 l/h Heating
exhaust gas /
Hot water
Exhaust water 80ºC
Gas 75ºC
30 kW
108ºC Electric Load
22,2 kWe

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Date 05/09/07
 Absorption system

ROBUR
has modified the ACF 60-00 in order to be fed by diathermic oil.
The ACF 60-00 TK Power Liquid is a reversible machine suitable to satisfy the energy request in
heating and cooling.
Rectifier
ROBUR ACF 60-00 TK Power Liquid
specifications:
Cooling capacity 16 kW
Chilled water temperature 7.2ºC Outlet
Evaporator

Condenser
Pipe in pipe

COP 0.7
Absorber

Heating Medium input 21,6 kW

Hot oil 220ºC

Heating Medium Inlet temp. 215 ºC

Heating Medium Oil Flow 2 m 3/h
Absorber
Heat medium Thermal oil
Air cooled
Solution
pump
Refrigerant Ammonia
Absorbent Water
Weak solution Strong solution Refrigerant vapour Refrigerant liquid Cold water
* Ambient temperature 35ºC

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 MTA PLANT

Exhaust gas
circuit
Heat exchanger
Boiler
Exhaust gas
60 kW
Absorption Chiller – termal oil
Microturbine
ACF 60-00
Capstone C30
Indirect fired unit
ROBUR

Thermal oil circuit

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Date 05/09/07
 Thank You
For further information: franco.anzioso@crf.it

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be used, duplicated nor communicated by any means to any third part, in whole or in party, except with the prior written cons ent CRF
Date 05/09/07