For many years, the world has equated Dresser-Rand with reliable machinery for applications in oil, gas, chemical, petrochemical, process, and defense industries. More and more, however, our products and services are being applied in the broader energy infrastructure markets, including the environmental solutions markets.
Environmental initiatives such as clean fuel legislation, flaring regulations and stricter emissions controls are driving demand for our products. Furthermore, the interest in and government support for renewable energy sources, as well as environmentally focused solutions such as combined heat and power (CHP), waste heat recovery (WHR), biomass and compressed air energy storage (CAES) are driving this business forward.
We acquired Grupo Guascor a few years ago, extending our addressable market to include channels into environmental solutions. In addition, we added Synchrony’s oil-free, environmentally friendly active magnetic bearings to our product portfolio.
Last year, approximately 98% of our revenues were generated from energy infrastructure – oil, gas and environmental solutions. In fact, more than a quarter of our 2013 bookings (26%) were in the environmental solutions arena, second only to downstream bookings at 32% (upstream constituted 26% and midstream 15%).
Our oil and gas and power generation clients need to reduce their CO2 emissions, allowing us to interact with them on a new level. Over the life cycle of our equipment, the more efficient the equipment and the process or plant, the less energy it consumes to operate. Therefore, less CO2 and other emissions are produced as a result.
Furthermore, we are establishing relationships with new clients, such as independent power producers (IPPs) and co-generators. IPPs own and / or operate facilities to generate electric power for sale to a utility, central government buyer, and end users. They generate electric power for on-site use and may also feed excess energy into the distribution or transmission grid system. Today, Dresser-Rand provides products to sugar mills, steel mills, glass manufacturers, tomato paste makers, dairies, and numerous other industries that are producing electricity from waste heat and waste by-products.
Combined Heat and Power (CHP), or Cogeneration
Based on the total energy generated, cogeneration plants typically cut NOx and CO2 emissions by almost 50% compared to thermal power plant/boiler systems, while complying with strict emissions regulations.
As a partner to commercial, industrial and municipal energy users we have delivered energy savings through cost-effective energy efficiency investments with predesigned, factory tested, fully packaged CHP systems to hundreds of clients around the world.
Governments of most developed countries recognize that cogeneration is an efficient way to extract as much of a fuel’s energy as possible. For example, we supplied two Guascor® engine gen-sets for power and heat generation in a Mexican water treatment plant. The electricity sector is federally owned, so the Federal Electricity Commission (Comisión Federal de Electricidad or CFE) controls the sector. Taking into account agricultural and forest waste, and solid urban waste from 10 main cities in Mexico, the country has an estimated power potential capacity of 803 MW and could generate 4,507 MWh per year.
The biogas generated from the water treatment plant feeds two of our Guascor containerized generator sets, each with 796 ekW output. The thermal energy obtained from the exhaust gases, as well as from the cooling system is used to heat water from 104 to 176 °F (40 to 80 °C) for reuse.
The benefits include production of renewable energy from waste, reduced carbon emissions, and cost effective, on-site electrical power.
Waste Heat Recovery
There are multiple applications in which the energy is being lost to the atmosphere. Power generation plants (based on engines and gas turbines) working in open cycle and industrial clients (cement, glass, steel, etc.) with different heat sources in the manufacturing process are demanding energy efficient solutions that reduce their power consumption and improve their generation mix.
Depending on client needs, we can offer a steam-based WHR solution or a supercritical CO2 solution depending on operating needs. An Echogen® waste heat recovery system drives value for a client through its unique combination of a lower cost per unit of electricity produced, compact footprint, higher energy recovery from the waste heat stream, and ability to generate power from a wider range of heat sources than competing technologies. Since the technology recaptures heat that was previously released into the atmosphere, the cost per unit of electricity decreases.
In September, we welcomed more than 50 clients, industry experts and other guests to Olean, N.Y. for “Echogen Technology Day” to introduce our new Multi-MW EPS100 waste heat recovery unit. During the event, and coinciding with the successful system shop testing qualification, we took attendees on tours of Dresser-Rand’s Olean manufacturing and testing facility. They also saw demonstrations and heard presentations on the technical aspects of the new Multi-MW EPS100 waste heat recovery unit.
Our KG2-3G gas turbine is designed to meet demanding emission regulations. It is ideally suited for continuous power generation on- and offshore, emergency and stand-by power supply, and as an indirectly-fired option for CO2-neutral biomass plants. Because of its simple, low-maintenance design, high reliability, and operational experience, the KG2 turbine generator package is a preferred solution for these types of applications. The wide fuel range also enables operation on extremely low heating value fuels, landfill gas and associated gas from crude oil production.
Our steam turbine generators play a major role in biomass power generation initiatives as manufacturers, institutions and municipalities search for ways to produce green power from renewable waste resources. We manufacture steam turbines from 500 kW to 100 MW for a variety of steam conditions, including pressure regulation of intermediate and low pressures.
Compressed Air Energy Storage
The ability to extract energy from renewables when they are being curtailed, store it and use it when it is needed is a growing need in the power industry. Our SMARTCAES™ solutions lower overall energy costs, maximize use of indigenous renewable energy resources, offer greater electrical grid security through reduced reliance on fossil fuels, and deliver a significant reduction in the carbon footprint of power systems through more responsive, sustainable energy generation and management.
Last year, we received a project award from Apex Compressed Air Energy Storage for a CAES facility in Texas, and we entered into a strategic alliance with renewable energy group Gaelectric to develop CAES projects in Europe.
It has been 23 years since Dresser-Rand manufactured equipment for the McIntosh, Alabama facility in the U.S.; however, growing interest in wind and solar power is bringing attention back to CAES technology in order to compensate for the variability of those two power sources. We are well positioned to meet these demands.
LNG on the Go
Our modularized, compact, redeployable, distributed natural gas liquefaction LNGo™ plant is capable of producing 6,000 to 8,000 gallons of LNG per day. This self-powered system requires no external utilities and eliminates environmental concerns because no flaring is required, which makes permitting easier. The system combines our MOS™ compressor, a Guascor® generator set, and Enginuity® controls to offer a new liquefaction process that can be installed and operating within months. It complies with numerous safety and design standards including NFPA 59A standards for small scale LNG facilities.
We successfully tested our first LNGo unit late last year. LNGo plants can help clients monetize valuable natural gas from stranded wells and capture and capitalize on flared gas. Their short delivery time and the ability to redeploy them make them an offer unmatched in the industry.
A Paradigm-Shift in Air Turbine Technology for Marine Energy Applications
Our HydroAir™ variable radius turbine (VRT) represents a major paradigm shift in air-turbine technology for oscillating water columns (OWC) in respect to its high efficiency over a broad range of flow rates. This is particularly important given the variable nature of ocean waves.
We are leveraging our long history of experience in developing rotating equipment to design, build and test a full-scale 500 kW HydroAir radial Power Take Off (PTO) turbine (see page 16). The pre-commercial turbine will also apply our experience gained from the 10 kW prototype HydroAir axial turbine we installed in Port Kembla, Australia during 2010.
The PTO system to be built and tested consists of the HydroAir radial turbine assembly (rotor, rotor blades, guide vanes, shut-off valve, and ductwork), the generator, instrumentation, electrical storage, marinized structure housing the turbine, generator, instrumentation, and electrical storage equipment. We are pursuing several applications for this full- scale design to improve its reliability, availability and efficiency.
The project is being carried out under the U.S. Department of Energy – Marine Hydro- Kinetic (MHK) program; Funding Opportunity Announcement (FOA) Number DE-FOA-0000848, ‘’Marine and Hydrokinetic System Performance Advancement.’’ This program has a number of specific areas and the project is under Topic Area 2: Next-Gen Power Take-Off (PTO) System, Award Number DE-EE0006609.
Dresser-Rand’s Enginuity® Control, Monitoring and Safety Systems
With our long history in rotating equipment, we understand the challenges of our clients’ operating environments. Gone are the days when designs were focused on start-stop sequencing, basic operations and multitudes of manual controls.
In 2008, we acquired the assets of Enginuity LLC, a private, U.S.-based company that specialized in combustion and catalytic emissions technology solutions, controls and automation, and aftermarket services for reciprocating gas engines used in the gas transmission market.
Today, our Gas Engine Technology Center (GETC) in Fort Collins, CO, offers these unique solutions to Dresser-Rand clients worldwide through its Enguity® equipment, and aftermarket services. These technological solutions lower carbon emissions by enabling gas-fired engines to run smoother and more efficiently on less fuel.
Today’s controls and automation systems perform a variety of tasks that were unheard of just a few years ago. Parametric emissions monitoring (PEMS), reporting, combustion monitoring, and integrated start stop-malfunction-procedures require state-of-the-art controllers capable of simultaneously handling a multitude of tasks in real time.
Increasingly, our clients express their interest in having us manage their entire project, including the long-term maintenance. We offer preliminary assessment, and engineering, procurement and construction (EPC) services for a number of our energy projects. Our EPC services are based upon recovery systems; they may be in combination with renewable energy (solar photovoltaic and hybrids systems), and are focused on distributed energy, sustainability, energy efficiency, CO2 footprint reduction, and alternative energy use.
The shockwave compression technology we invested in from Ramgen Power Systems, LLC is expected to represent a significant advancement. The principal advantage of shockwave compression is that it can achieve high compression efficiency at very high single-stage compression ratios. The result is a product that lowers costs and reduces footprint.
We successfully tested a 9.0:1 pressure ratio, 10,700 HP (8 MW) CO2 unit this past year with a 1,620 PSIA (111 bar) discharge.
The unit was tested on a dedicated closed loop CO2 test facility at our Olean Operation. We validated aerodynamic performance, as well as operating characteristics and mechanical integrity. Development testing of the final geometrical iteration is expected to commence in January 2015.
Thereafter, the team will develop a family of supersonic compressors to serve the CO2 market. The high-pressure ratio-per-stage capability of this technology is the key enabler. The end goal is a compression system that is a rugged and robust machine. Higher efficiency means lower energy costs and lower emissions.
The Energy Infrastructure Market
While our offerings remain in-line with our core rotating equipment expertise, we continue to expand outside the oil and gas space to serve the needs of the broader energy markets.
The move toward more environmentally friendly solutions – even in traditional oil and gas markets– is very real. And we will remain a key player as new mandates and regulations, such as air emission requirements, fuel the drive toward more efficient and environmentally friendly alternative energy solutions.