16-cylinder engine delivers high efficiency and low emissions

Clive Nickolay outlines the benefits of what is claimed to be the most efficient 16-cylinder engine in its class.

Many of within the power industry are facing a severe energy crisis. Local grids are not able to support the growing demand, and businesses are often times responsible for their own energy production. As such a single generator set package that produces more than 14MW of power can alleviate power shortfalls.

Caterpillar Power Generation Systems (CPGS) offers the 16CM43, the most efficient 16-cylinder engine in its class. Generating up to 14.4MW of power, the 16CM43 features an advanced design that results in a long operating life, simplified maintenance, high efficiency and low emissions. With increased power density and high reliability, the fuel-flexible 16CM43 is ideal for prime, standby, distributed generation and peaking.

Integrated subsystems that reduce sealing surfaces enhance ease of maintenance, and the 16CM43 features a long-stroke design that operates at lower engine speeds, resulting in increased component life and decreased maintenance costs. The 16CM43's low operational costs are also kept low with the lowest brake-specific fuel consumption (BSFC) through reduced lube-oil consumption and greater time between overhaul (TBO).

The 16CM43 is designed for reliable operation with intensive cooling of key components enabled by exhaust valve seats, injector cooling integrated into the lube oil system, and a high-efficiency turbocharger. This engine is capable of operation up to 700cSt/50°C fuel quality according to CIMAC H55/K55.

The 16CM43 is manufactured with the highest-quality engine parts, made from state-of-the-art materials and highlighted by semi-dry wear-resistant liners with calibration inserts, pistons equipped with forged steel crowns and aluminum skirts, inlet/outlet valves outfitted with armored seats, and a high-efficiency turbocharger. The engine's one-piece dry engine block is made from high-strength nodular cast iron and operates free from cooling water with an under-slung crankshaft.

A recent application of the 16CM43 generator set is a mining operation in South America. In recent years, demand for raw material from the mine has grown, chiefly copper. As a result of longer work hours and increased production, more power is needed at the site. Caterpillar is providing a finished plant designed for safe, reliable, efficient, long-term operation.

Caterpillar will provide the total plant, including engineering, procurement, construction, startup, testing, project management, warranties and operator training. The buildings on the site will include a power house with a control room, a maintenance shop and warehouse, a fuel treatment building and an administration building with offices.

Projected to be fully operational by March 2010, the plant will be completed in two phases with two Cat 16CM43 Series reciprocating engine generator sets operating alongside two existing CM series generator sets. The new plant will provide 44eMW and over 20thMW of combined heat and power. All produced power, net of internal loads, will be delivered at medium voltage to the customer-supplied substation.

The plant is designed for continuous operation at constant load, with all engines running at full output, although the customer may choose to operate at reduced output by shutting down one or more engines. In the event of complete loss of load, the plant will be designed to automatically reduce output and continue to supply its own internal power needs without tripping or interruption.

Illustrating the 16CM43's flexibility, the generator sets will run primarily on heavy fuel oil (HFO), with distillate fuel oil (DFO), commonly called diesel, used as a secondary fuel for maintenance and auxiliary services. The HFO and DFO will require bulk storage tanks and delivery systems, along with other pump and filter equipment that have been factored into the site design. Supplied secondary equipment will include matching electric generators, radiators for engine cooling, intake air filters, exhaust silencers and stacks, and a control system.

The plant's heat recovery system, developed to support the thermal needs of the copper refining process, will include exhaust heat recovery units for heating thermal oil, a thermal oil circulating system, an auxiliary boiler and dumping coolers. Heat exchangers will be plate type for Ht circuit heat recovery, and shell and tube heat exchangers will handle thermal oil and hot water.

In addition to the plant's generator set and power plant control system, a substation is planned that will include a step up transformer and load centers. A low voltage system and motor control centers for plant auxiliary loads as well as a convenience voltage system for lighting and convenience outlets will also be included to complement the standard medium voltage generator bus and breakers.

Like all Cat engines, the 16CM43 is designed with reliability and ease of maintenance at the forefront. Modular design and integral construction reduce the number of components by 40 per cent over conventional designs. The 16CM43 employs easily removable cylinder heads and fluid connections, as well as split connecting rods that allow the removal of pistons without disturbing the big end bearing.