Tag Archives: Rolls-Royce Power Systems

Rolls-Royce to step up hydrogen content in mtu power generators

Environmental, Power supply for mines, Sustainable mining, , , , , , ,

Rolls-Royce says it is further developing its mtu gas engine portfolio for power generation and cogeneration to run on hydrogen as a fuel and, thus, enable a climate-neutral energy supply.

Generation sets powered by mtu Series 500 and Series 4000 gas engines can, today, be operated with a gas blending of 10% hydrogen, but, beginning in 2022, operation with a hydrogen content of 25% will be possible, the company said.

Perry Kuiper, President Sustainable Power Solutions at Rolls-Royce Power Systems, said intensive tests on test benches and pilot installations at customer sites in 2022 will lead to Rolls-Royce continuously marketing new mtu Series 500 and Series 4000 gas engines beginning in 2023 for use with up to 100% hydrogen, and, on a design to order basis, conversion kits to allow already installed gas engines in the field to run on 100% hydrogen.

Last month, Rolls-Royce and FLANDERS signed an MoU to develop hybrid mining truck retrofit kits for hybridising mining trucks with mtu engines, batteries and hybrid control systems.

Andreas Görtz, Vice President Power Generation at Rolls-Royce Power Systems, said: “The decarbonisation of power generation requires reliable, flexible, but also climate-neutral, power plants to supplement the fluctuating generation from wind and sun. We assume that natural gas will initially be the primary fuel in the development of the hydrogen ecosystem, but we see hydrogen as technically and economically possible. That is why we continue to develop our gas engines for use with green hydrogen – whether as a 10 or 25% admixture or for 100%.”

Rolls-Royce says fuel cells powered by 100% green hydrogen can also play an important role in future energy supply in combination with renewable energies.

At its Friedrichshafen headquarters, Rolls-Royce’s Power Systems division has installed a 250 kW fuel cell demonstrator, which will be used to test and present future CO2-free energy systems to customers. The entire hydrogen ecosystem, including the infrastructure for supply, conversion, test benches and future production, is also being mapped in the company’s own plants, thus building up expertise, it said.

Rolls-Royce’s Power Systems division, through its climate protection program, “Net Zero at Power Systems”, has set itself the target of saving 35% of greenhouse gas emissions by 2030 compared with a 2019 baseline using new technologies.

This near-term target plays an important role in the Rolls-Royce Group’s ambition to achieve carbon neutrality by 2050 at the latest, it said.

In addition to new technologies, a key element in achieving these targets is the certification of key mtu engine products to run on sustainable EN 15940 fuels such as e-diesel and second-generation biofuels as early as 2023, the company added.

Rolls-Royce mtu Aiken facility to offer engine remanufacturing capabilities

Environmental, Mining consumables, Mining equipment, Mining services, Power supply for mines, , , ,

Rolls-Royce has announced a $17.4 million investment at its mtu Aiken manufacturing facility in Graniteville, South Carolina, USA, for the addition of a new Remanufacturing and Overhaul Regional Center.

The planned 109,000-sq.ft (10,126 sq.m) expansion project will provide dedicated and streamlined remanufacturing and overhaul operations to support growth based on customer demand, it said. It will also result in the addition of about 20 new jobs.

To be built next to the mtu Aiken plant’s existing engine manufacturing operations, the new centre will bring currently outsourced workshop and warehouse operations in-house and expand them to provide remanufacturing of mtu Series 2000 and 4000 engines and components, the overhaul of mtu brand and customer-owned engines, plus internal and external rework services to help customers and distributors fine-tune maintenance and performance metrics, the company said.

Construction of the new centre is scheduled to begin later this year, with operations expected to begin in early 2023.

“Remanufacturing offers a wise lifecycle investment for customers, returning equipment to like-new condition and resulting in lower acquisition, maintenance and operation costs,” Rolls-Royce said. “Already performed at select global plant locations, the Rolls-Royce remanufacturing and overhaul process is designed to ensure optimal performance and durability, where used engines and assemblies are fully disassembled, cleaned and inspected, and then reworked and reassembled using all new parts to replace any outdated, worn, or damaged components.”

Dr Otto Preiss, Chief Operating Officer at Rolls-Royce Power Systems, said: “Investing in a remanufacturing and overhaul centre in the US is the next milestone in implementing our global strategy to optimise the value of our installed base, with regional centres and supporting workshops offering the best support for our customers.”

Marc Goldschmidt, Global Vice President Remanufacturing and Overhaul, added: “The new centre will fulfill regional and local customer needs using the global network and processes, following the remanufacturing and overhaul Lead Plant located in Magdeburg, Germany.”

The facility at Aiken will feature distinct work areas to carry out the remanufacturing and overhaul process: core management; cleaning and disassembly; measuring and inspection; rework; reassembly; test; and painting and packaging. Upon start-up, the centre will remanufacture all applications of mtu Series 2000, Series 4000, and Detroit Diesel 2-Cycle engines. The future aim is to add capabilities to support the company’s sustainable solutions such as battery containers, along with natural gas engines and systems.

Steve Blaszczak, Senior Manager, Remanufacturing and Overhaul – US, said: “Our investment in remanufacturing and overhaul solutions is also in line with our initiatives toward more environmentally-friendly solutions. By remanufacturing and overhauling engines, we are able to extend their useful life while also bringing them to the latest emissions standards. This benefits our customers as well as the environment.”

Since its opening in the fall of 2010, the mtu Aiken Plant has continued to innovate, invest and expand, the company said.

“What began with the production of Series 2000 and Series 4000 engines, has grown to include the assembly of military engines, the machining of parts and even the production of energy through its solar field and microgrid,” it said. “With an on-site research and development centre and now a new Remanufacturing and Overhaul Center, the mtu Aiken Plant covers the full circle of life for an mtu engine – from concept to second life (ie overhaul).”