Category Archives: #Energyreality

#Energyreality, economic prosperity and energy, Education, Energy and Electricity Fundamentals, Energy, Politics and Economic Prosperity

The Magnificent and Indispensable Heat-Engine on Which Civil Society Depends, Part III, Internal Combustion Engines up to 110,000 Horsepower

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This is Part III of a three part series. Part I covered the basics of the three major Heat-Engines that provide about 75% of our electricity in the U.S. Part II covered the propulsion systems for ocean shipping. This article will explain the basics of smaller Heat-Engines used for electricity generation, farming, food production, food distribution, automobiles, trucks, trains, aircraft, small engines for landscape, construction, mining, military defense machines and more. Internal Combustion Engines (ICE’s) powered by fossil fuels are used widely in all sectors of our economy.

Conventional Energy=Life as We Know It

Let’s start with the largest Internal Combustion Engine ever built. The Wartsilla Marine Engine is credited to be the largest reciprocating Diesel engine in the world. These have been tested at up to 114,000 Hp.

State of the art design Marine Propulsion Prime Movers Have Been Adapted for Use as Stationary Power Generation for a Long Time.

Electric Power generation technology progressed from ship and aircraft propulsion systems over the years. Many central station power plant systems have their roots in marine and aircraft propulsion. Consider these milestones for land, sea and aircraft:(14)

  • Robert Fulton Steamboat Clermont-1807
  • Otto invents the 4-Cycle Gas engine-1867
  • Charles Parsons, invents Steam Turbine-1884
  • Charles Parsons Steam Turbine drive on Turbinia-1894, Fastest Ship in the world
  • Rudolf Diesel invents Compression Ignition Diesel engine-1895
  • First large Diesel engines for Maritime use are in German Submarines during WWI
  • Dr. Hans von Ohain (Germany) and Sir Frank Whittle (UK) are both recognized as being the co-inventors of the jet engine, later adapted to electric power generation-1933
  • U.S. Nuclear submarine Nautilus launched 1954 powered by a PWR
  • Nuclear powered Merchant Ship NS Savannah, launched 1959
  • Largest Diesel Engine ever built-Wartsilla RTA96-C 107,000 HP-2006

Internal Combustion Engines for Electricity Generation

Large natural gas and Diesel powered generators are commonly used for Dispatchable backup power for areas served by large capacity of wind and solar generation. When the wind stops and sun is not shining, the Grid must be stabilized with adequate generation that is needed quickly. Internal combustion engines serve this need very well. The picture below is from a facility near Marquette, Michigan. This picture below is a 17 MW (24,000 Hp) gas engine. Multiple engines can be installed for total power capacity of over 225 MW as in the Denton, TX plant.

Photo credit Stephen Storm, Wartsilla Project info: https://www.powermag.com/new-gas-fired-plants-come-online-in-michigan/

The advantages of the gas engines are: They have black start capability, fast load response, VAR (Volt Ampere Reactive) support, most importantly they can run 24/7 under any weather conditions and they are Dispatchable. The adaption from marine propulsion systems makes the features of black start and load responsiveness intrinsic in the design. These are referred to as “RICE”, an acronym for Reciprocating Internal Combustion Engines.

Aeroderivative Gas Turbines

The aeroderivative gas turbines also serve as tremendously reliable, Dispatchable and powerful prime movers for generators. The name aeroderivative is descriptive as these heat-engines have a long history of development and advancements in materials and design for reliable aircraft propulsion. Therefore, reliability is an intrinsic priority. One of the most common and proven designs is the G-E LM-2500 shown below.

From G-E Gas Turbine Power website: https://www.gevernova.com/content/dam/gepower-new/global/en_US/downloads/gas-new-site/resources/reference/ger-4250-ge-lm2500-g4-aero-gas-turbine-marine-industrial-applications.pdf

In Part I of this series I described the larger G-E Gas Turbines used with Combined Steam Cycles (GTCC) of the 600-700 MW capacity range. Like the internal combustion reciprocating engines, the gas turbine prime mover has the advantages of fast starts, Dispatchability, VARs support, 24/7 operation, rapid load response and quick shutdown. Truly flexible generation.

Heat-Engines in our Everyday Lives

The most common Internal Combustion Engines (ICE’s) of course are used in transportation. Automobiles, trucks, tractors, farm equipment, construction equipment, aircraft, ships and trains. According to the U.S. Department of Energy, about 37% of the total Primary Energy used in the U.S. during 2023 was for transportation. About 28 Quadrillion BTUs to be exact.

These are the forms of energy that power our lives each day. The ICE is a large part of our lives whether it is in powering our computer, providing illumination, powering industrial production, construction, farming and providing jobs. Also, very importantly for our freedom of travel…..providing the fuel for transportation of our families and friends.

Fertilizer, Farming, Food Production and Food Distribution

Perhaps farming and food distribution should be at the top of the list as it is one of the most basic human needs. Food production begins with fertilizer production which is off topic for this article, but fertilizer production represents a significant portion of total primary energy consumption. It is said by Vaclav Smil and other experts that synthetic fertilizer production is important to feed about 50% of the world’s population. Then, once fertilizer is produced; planting/harvesting/processing/Distribution of food progresses from farm to table. Energy is important every step along the way.(9)

The enormous productivity benefit of a Diesel tractor is obvious. The importance of energy in producing fertilizer, food processing, refrigeration and trucking distribution is not so obvious. However, much of food production farm to table, involves heat-engines and fossil fuels. In fact, the cost component of energy; farm to table is about 50% energy.

The IEA has analyzed the cost component of energy for common foods and documented that about 50% of food cost is from energy.(10)

Conclusions

Conventional forms of energy are important and it takes a lot of natural gas, petroleum, coal and nuclear to power and sustain our high quality of life. Those that believe wind and solar can replace conventional forms of energy during the next twenty years are delusionally misguided and indoctrinated with misinformation. Professor Vaclav Smil has documented this quite well, (He has written dozens of books on the subject and is, in fact one of the sharpest world energy experts)

Four components of our lives cannot be replaced by renewable power. Those four pillars of society are Fertilizer, Steel, Concrete and Plastics.(11, 15)

The “Heat-Engines” that Civil Society Depends on will remain important for a long time and so will fossil fuels. This three part series was intended to provide an overview of these magnificent machines.

Yours truly,

Dick Storm, August 10, 2024

References and Information for further reading and research

  1. Interesting Engineering: https://interestingengineering.com/lists/15-of-the-largest-engines-in-the-world
  2. History of Large Gas Engines, Newcomen Society: https://fredstarr.com/wp-content/uploads/14.-Large-Gas-Engines-Lawton.pdf
  3. Denton Energy Center, 225 MW Wartsilla Natural Gas Engine Power Plant:
    https://www.cityofdenton.com/335/Denton-Energy-Center-DEC
  4. Wartsilla Marine Engines and Generators:
    https://www.wartsila.com/marine/products/engines-and-generating-sets
  5. Power Magazine, Article on Marquette Energy Center, Michigan: https://www.powermag.com/new-gas-fired-plants-come-online-in-michigan/
  6. Wartsilla article on Marquette Power Plant:
    https://www.wartsila.com/energy/learn-more/references/utilities/marquette-energy-center-usa
  7. G-E Aeroderivative LM2500 Gas Turbines: https://www.gevernova.com/content/dam/gepower-new/global/en_US/downloads/gas-new-site/resources/reference/ger-4250-ge-lm2500-g4-aero-gas-turbine-marine-industrial-applications.pdf
  8. Largest Diesel Engine in the World, Wartsilla 2006: https://en.wikipedia.org/wiki/Wärtsilä-Sulzer_RTA96-C
  9. Energy used in Agriculture, Vaclav Smil article: https://www.vaclavsmil.com/wp-content/uploads/docs/smil-article-worldagriculture.pdf
  10. IEA Report on How the Cost of Energy is Exacerbating the Cost of Food, 2022: https://www.iea.org/commentaries/how-the-energy-crisis-is-exacerbating-the-food-crisis
  11. Time Magazine, with Vaclav Smil on the four Materials our Society Needs from Fossil Fuels, Ammonia, Steel, Plastics and Cement: https://time.com/6175734/reliance-on-fossil-fuels/
  12. Part I of this series: https://dickstormprobizblog.org/2024/07/30/the-magnificent-and-indispensable-heat-engine-on-which-civil-society-depends-part-1-heat-engines-1-3-million-horsepower/ 
  13. Part II of this series: https://dickstormprobizblog.org/2024/08/07/the-magnificent-and-indispensable-heat-engine-on-which-civil-society-depends-part-ii-focus-on-fossil-fuels-for-ocean-shipping/
  14. A Short History of Power Generation, 1850-1955, Part I: https://dickstormprobizblog.org/2022/01/14/a-short-history-of-energy-electricity-and-how-our-high-quality-of-living-came-to-be-high-human-development-index-part-1-1850-1955/
  15. Four Pillars of Civilization, Ammonia, Cement, Steel and Plastics:  https://dickstormprobizblog.org/2022/07/25/pillars-of-modern-civilization-all-dependent-on-energy/

#Energyreality, China, Coal Power, economic prosperity and energy, Nuclear, Regulations

The Rise, Fall and Rise Again of Nations and the Realities of Energy

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Introduction

The University of South Carolina provides OLLI programs (Osher Lifelong Learning Institute) which include Geopolitics, Science and many other courses. I am an instructor on energy and electricity. Two other instructors that I respect and have enjoyed their courses are retired senior military officers. General Craig Whelden served in the Pacific and has taught several courses on the “Rise of China”. I took notes from his courses and combined his information with my experiences in the relationship of energy & electricity generation. These thoughts are posted here. Retired Navy Captain, Greg Blackburn has taught several courses on Economics and the “Fate of Nations, Their Rise and Fall and Rise Again”. I took notes on Captain Blackburn’s and General Whelden’s courses and posted my thoughts as of January 2021 here.

As I read a LinkedIn post by CS Krishnedev earlier this week, these three OLLI courses came to mind. (Rise of China, Fate of Nations and Energy & Electricity) Mr. Krishnadev’s post is here. In his post, Krishnadev discusses how China is far ahead of the west in the design, construction and deployment of nuclear power plants.

Photo from Krishnadev, CS Post on LinkedIn, August 13, 2023

Leaders in Heavy Manufacturing of Nuclear Power Plant Reactors and Steam Generators

America invented nuclear power and held the lead for many years in the design, manufacturing, construction and operation of nuclear power plants. The Combustion-Engineering Chattanooga facility comes to mind as one of the most capable and advanced nuclear and fossil manufacturing facilities in the world. That was then.

America invented nuclear power for electric power generation. Thanks to Admiral Rickover and President Eisenhower's "Atoms for Peace" initiative of the 1950's. Once the leader in heavy manufacturing, we have now ceded this leadership to Asian countries. Here is my take on the realities of nuclear power in the U.S.A.

Of course, the magnificent C-E Facilities are gone now. So are the thousands of talented and experienced engineers, technicians and craftsmen. Westinghouse is a fine American name but was sold off long ago. Babcock & Wilcox is still based in the U.S. and involved, but the company is downsized from the 35,000 or so employees that worked there in the 1960’s and 1970’s. I started my power generation career with B&W in 1966, so it is with personal knowledge and experiences that I remember this. The photo below is a Reactor vessel being loaded onto a barge from the Mt. Vernon Indiana manufacturing facility.

From “B&W Steam, It’s Generation and Use”. 39th edition

Specialized manufacturing tools, such as the Gun Drill shown below is used to drill approximately 16,000 precise holes through a 24″ tube sheet to manufacture a steam generator, such as the one below for the B&W Once Through Steam Generator.

From B&W “Steam, It’s Generation and Use” 39th Edition, 1978

The highly successful B&W Once Through Steam Generator as used at Oconee, Three Mile Island, Crystal River and other Nuclear Steam Systems is shown below.

Nuclear Steam Generator from B&W Steam, It’s Generation and Use” 39th edition

View inside the Containment building showing the Reactor and Once Through Steam Generators. To provide a reference of the size of these, the nozzle at the top of the steam generator in the upper left of the photo below is 36″ diameter.

B&W “Steam, It’s Generation and Use” 39th edition

These pressure vessels were built using the most advanced manufacturing, welding and non-destructive testing techniques in the world. However, after the 1979 Three Mile Island incident, very few new NSS’s were manufactured in the U.S.A. Eventually the Combustion-Engineering manufacturing facility in Chattanooga was shut down and B&W downsized. The Westinghouse Electric Corporation which was the pioneer designer and manufacturer of nuclear power plants (starting with the U.S. Navy Nautilus and Eisenhower’s “Atoms for Peace” Initiative) was broken down into numerous business units and sold off. The nuclear power business unit was sold in 1999.

The World Nuclear Association lists the current major manufacturers of heavy pressure vessels. This list is shown below. Much of the heavy manufacturing equipment such as Electroslag Welding, 15,000 ton presses, precision gun drills and other heavy manufacturing equipment once available in Chattanooga and other locations in the U.S. has been lost.

Here are the Heavy Pressure Vessel Manufacturers listed by the World Nuclear Association that are capable of fabricating nuclear reactor pressure vessels, today.

The enormous presses, rolls, welding, machining and forging apparatus that the U.S. once was a leader in are now gone and will take a huge government policy commitment and large capital investments to replace. A new workforce of tens of thousands of engineers, technicians and craftsmen will have to be trained as well. In other words, the entire Supply-Chain, including education will have to be rebuilt. This, if accomplished would be on a scale of President John F. Kennedy’s “Moon Shot” commitment of 1960.

Summary & Conclusions

If the U.S. was really committed to “Electrifying Everything”, that is, everything possible. Then the most practical and proven fuel to provide carbon free electricity is nuclear. An excellent OpEd was published in the TN Star Tribune newspaper a couple years ago on this. I copied it, along with my thoughts, onto my blog, here.

The Net-Zero Carbon path if continued, will further weaken the U.S.A. and strengthen the CCP. I do not have anything against the Chinese people and the many millions that have been lifted from poverty by China’s Development of many coal, nuclear, hydroelectric and renewable power production power plants. However, I am frustrated that the current U.S. leaders, have put the U.S. on a path of decline in manufacturing and economic strength. Also, a decline in influence in the world and a decline in military capability. Much of the decline is due to energy policies that are at a literal “War on conventional forms of energy”. The “Green New Deal” (aka Inflation reduction Act) incentivizes the myth of renewable power in an impossible to achieve replacement of fossil and nuclear fuels.

I have been a supporter of “All Fuels are Important” and that the U.S. should be utilizing all fuels that are available within our borders. Including coal, oil, gas and uranium. It is a myth to believe that wind and solar can replace coal, oil, gas and nuclear fuels. One of my blog articles on the impossibility of reaching Net-Zero Carbon is here. The government’s policies which penalize conventional fuels and incentivize renewables, if continued, will weaken the United States.

The course taught by my friend Greg Blackburn, “The Fate of Nations”, comes to mind. A screen shot of one of the slides he used is copied below. The current U.S. Climate Policies are contributing to the Rise of China and the Decline of America. It is my hope that the voters will elect members of Congress and a new President that will wake up and stop the madness.

The Bureaucratic Agencies of the Biden Administration since Biden’s inauguration have created ever worsening Regulations that are weakening our country and literally forcing the economic decline of our nation. It is as if the Biden policies are being dictated by Xi Jinping and Vladimir Putin. The Biden policies are weakening America, day by day from within. I have used the term, “Self-Sabotage”.

Yours very truly and respectfully,

Dick Storm