When operated in a combined cycle with a steam turbine, the new gas turbine has a world-record efficiency rating of 60 per cent. This represents a huge leap in efficiency in the US, where the average efficiency rating of fossil-fired power plants is barely 30 per cent, with even that of combined-cycle power plants below 40 per cent. If all of the combined-cycle power plants were to use the high-efficiency Siemens turbine, they would generate nearly 350 more terawatt-hours per year with no increase in CO2 emissions. That is the amount of electricity consumed by 25 million Americans, and at the current US price for one kilowatt hour, has a value of $40 billion.

The environment turbine from Siemens and the Siemens gas turbine (top)

Another advantage of the new gas turbine is that it can be started quickly. This is important when a power plant needs to offset fluctuating electrical input into the grid, such as is the case with the increased use of wind and solar energy. The use of the new turbines will therefore help bring about the energy change advocated by US President Barack Obama, whose administration plans to have renewable energy sources cover a quarter of the country’s electricity requirements by 2025.

Siemens has been working for nearly ten years on the new gas turbine, which recently completed a two-year field trial in E.on’s Irsching power plant. The turbine for the US market is somewhat smaller because the country has a different electrical frequency than Germany.

The greater number of revolutions per minute requires a reduction in the turbine’s dimensions due to the greater centrifugal forces. Output is 275 megawatts (MW) instead of the 370 MW generated by the European version. In combined-cycle mode, the power plant will generate roughly 400 MW.

More than 800 employees were involved in the development of this masterpiece of German engineering. A turbine is made up of more than 7,000 individual parts. Temperatures inside the combustion chamber can reach as high as 1,500 deg C.

The first rows of blades feature a high-tech ceramic coating to keep them from melting. When the turbine is in operation, the gap between the blades and the housing is about as wide as a human hair, or roughly one-tenth of a millimetre. The design must allow for the thermal expansion of the turbine.

Technology from Siemens has twice been honored at the inaugural Innovation Award for Climate Protection and the Environment. Divided into five categories, together worth €125,000 in prize money, the award was presented by Federal Minister for the Environment Norbert Röttgen and Werner Schnappauf, Director General of the Federation of German Industries (BDI), at a ceremony held in Berlin on Thursday.

The world’s most efficient gas turbine, developed by Siemens Energy, secured the prize in the category for environmentally friendly products and services. A new dishwasher from BSH Bosch und Siemens Household Appliances, which uses special minerals to accelerate the drying process, was also awarded one of the prizes.

The new gas turbine is the centrepiece of the combined-cycle power plant operated by E.on in Irsching, near Ingolstadt in Bavaria. This spectacular piece of engineering is over 13 metres in length, five metres high, and 444 metric tons in weight – heavier than the Airbus A 380. On its own, it generates 375 megawatts of power.

When it is paired with a steam turbine in combined-cycle mode, the plant’s total output rises to around 570 MW. That corresponds to the power requirements of around 3.4 million people, that is the population of a city about the size of Berlin. In the process, the plant achieves a world-record efficiency of over 60 per cent, which benefits both the environment and the climate.

On the basis of the world wide emissions for power generation, each new combined-cycle power plant fitted with this turbine would reduce carbon dioxide emissions by some 700,000 metric tons a year. That corresponds to the amount of C02 produced by approximately 350,000 passenger cars, each driving 15,000 kilometres a year.

The gas turbine was built in the Siemens plants in Mülheim an der Ruhr and Berlin. All in all, the company has invested around €500 million in the development and construction of the gas turbine facility and its testing in Irsching.

The Innovation Award for Climate Protection and the Environment is presented by the Federal Ministry for Environment, Nature Conservation and Nuclear Safety (BMU) and the Federation of German Industries (BDI). The jury is chaired by former Federal Minister for the Environment Klaus Töpfer.

With its Environmental Portfolio, which generated sales of around €23 billion in 2009, Siemens is the world’s largest supplier of green products and solutions. By means of such products and solutions, customers of Siemens reduced carbon dioxide emissions by 210 million metric tonnes over the same period. That is the equivalent of the combined total of CO2 emitted annually by the cities of New York, Tokyo, London, and Berlin.

Siemens researchers collaborating with the Russian oil company Rosneft have developed a process for boosting extraction of oil from wells. At present it is possible to extract only roughly between 30 and 40 per cent of the oil in a well, on average; the rest remains in the deposit.

Oil producers around the globe are working to improve this yield. The new process from Siemens uses an acid-bearing foam to clean oil wells very efficiently.

This frees the reservoir rock from substances that block the movement of oil, which can then flow more readily to the borehole. Rosneft was able to significantly increase the flow at several wells using the method.

The earth does not give up its black gold willingly: On average, only about ten per cent of the oil bubbles up on its own out of the three to six kilometre-deep boreholes.

Several tricks can be used to increase the yield. Injected water, gas, or steam increases the pressure in the well. Hot steam and gases such as carbon dioxide also lower the viscosity of the oil.

The new method is based on a long-used means of cleaning oil wells that involves use of an acid solution to dissolve unwanted impurities including calcium, gypsum, and barium sulfates in the oil-bearing sediments. These impurities block the flow of the oil to the borehole. This treatment is generally performed every two to five years. A large share of the solution seeps into the porous rock, however.

Last year, researchers from Siemens Corporate Technology in Russia began their efforts to gain higher yields by analysing the oil wells in computer simulations and developing a model for a new foam-acid treatment.

Rosneft provided a wealth of data on the individual wells, including borehole depth, permeability, pressure ratios, and flow rates, thus enabling the researchers to assess the treatment’s effect.

Rosneft is now using the method to increase extraction. The chemical foam seals porous areas in the rock, and the acid mixture subsequently introduced into the well flows to points where obstructions are waiting to be dissolved. Rosneft tested the procedure at 27 oil wells and succeeded in increasing the flow by an average of 17 tonnes per day.

Without the foam, the wells produced only 8.6 additional tonnes. Use of the sealant also reduces the amounts of chemicals required for the cleaning process. This saves money and lessens the impact on the environment. Siemens now wants to work with Rosneft on projects for the extraction of oil from oil shale. A corresponding feasibility study is now in progress..

The ZoneAir XATS 1020 is typically found on offshore platforms and vessels for painting and sandblasting, gas flaring, well testing and enhanced oil recovery. As a long-term investment, the ZoneAir XATS 1020 offers low cost of ownership with simplified maintenance and a 665-litres (175-gallon) stainless steel fuel tank for eight hours of operation at full load, which results in increased uptime.

As a rental option, the ZoneAir XATS 1020 is ideal for seasonal or temporary oil and gas applications. Its containerised housing and forklift slots make it easier to transport and stack for flexibility and versatility on site. Rental customers benefit from the latest Zone 2 (Class 1, Div 2) compressor technology and reduced downtime with optional 24/7 service support from Atlas Copco’s Specialty Rental division.

The ZoneAir XATS 1020 is driven by a Cummins QSM 11 Tier 3 compliant engine and includes the new C190 screw element from Atlas Copco. The engine features flameproof Pyroban components such as an inlet shutdown valve, inlet flame trap, Exd alternator and battery system, water-cooled exhaust gas cooler, spark arrestor and engine safety control system. The ZoneAir XATS 1020 also includes Pyroban’s 3GP gas detection system. The 3GP system is a reliable and proactive gas detection system that guarantees safe operation in a hazardous area. It eliminates the need for exhaust flame arrestors and the related daily maintenance, which increases uptime.

The ZoneAir XATS 1020 is housed in a 15-foot DNV container and is fully ATEX 94/9/EC certified for Zone 2 (Class 1, Div 2) hazardous area operation. There is a single service side for easy accessibility. Routine maintenance is simplified with heavy duty air filters, a fuel pre-filter with water separator, easily accessible genuine oil filters and central drains to remove liquids.

Other features include an air starter with air reservoirs; external fuel filling and manual fuel cut-off valve; two emergency stops on the opposite sides of the container; a platform shutdown system; and a user-friendly control panel protected by a lockable stainless steel cover.

Atlas Copco offers Zone 2 (Class 1, Div 2) compressors and boosters with different capacities and pressures to meet any customer’s needs.

Portable Air is a division within Atlas Copco’s Compressor Technique business area. It develops, manufactures and markets portable compressors, natural gas boosters, and generators for prime or standby power worldwide. Products are offered to the construction, rental and general industries under several brands. The divisional headquarters and main production center are located in Antwerp, Belgium.

Atlas Copco is an industrial group with world-leading positions in compressors, construction and mining equipment, power tools and assembly systems. The Group delivers sustainable solutions for increased customer productivity through innovative products and services. Founded 1873, the company is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2009, Atlas Copco had about 30 000 employees and revenues of BSEK 64 (BEUR 6.0). Driven by a future generation element and using the most advanced development techniques,Atlas Copco has redesigned its smallest oil-injected screw compressor range GA 5-11/GA 5-15 kW Variable Speed Drive (VSD). By delivering more performance, more flexibility and more reliability, this new range sets a new industry standard in the 5 to 15 kW compressor range. An 8 per cent increase of air delivery, noise levels as low as 60dB(A), new VSD voltage variants, an extended operating range, a new Elektronikon® controller and an additional tank-mounted GA 15 VSD model, boost the possibilities of this new range.

This GA 5-15 (VSD) range is used in a variety of applications as general assembly and manufacturing and in a broad range of industries including, automotive, water treatment, air segmentation, construction and many others.

Since energy costs account to up to 70 per cent of the compressor’s lifecycle cost (LCC), it is Atlas Copco’s commitment to reduce this cost drastically with every new compressor generation. Atlas Copco’s engineers have succeeded in lowering SER (Specific Energy Requirements) by up to 8 per cent by integrating the new screw compressor element in an enhanced packaging. At the same time, FAD (Free Air Delivery) is increased with up to 8 per cent, resulting in remarkable savings on your annual electricity bill.

When the compressed air demand is fluctuating, the advanced control algorithms of Atlas Copco’s VSD (Variable Speed Drive) create average energy savings of 35 per cent. The entire GA 5-15 VSD range has been equipped with new saver cycles on both fan and dryer, increasing the average energy savings even further.

Installation flexibility is characteristic for this GA 5-11/GA 5-15 VSD Premium-range. The GA Workplace Concept is reinforced with noise levels starting from 60 dB(A). This GA-range is the most silent in the complete Atlas Copco GA-portfolio, allowing for installation close to the point of use. Installation cost is further minimised by extending the standard operating range to up to 46 deg C, making a dedicated compressor room unnecessary.

More VSD models, including a tank-mounted GA 15 VSD and new standard Voltage 200/575 variants, reduce installation costs even more, extending the VSD offer towards its customers.

The newly developed element has been optimised and built to last. Reliability is further increased by the improved belt-driven drive train, developed in accordance with the highest industry standards.

The introduction of the Elektronikon in the GA 5-15 (VSD) allows for remote online monitoring through a simple ethernet connection. This internet-based compressor visualisation increases both reliability and efficiency by offering a great variety of control and monitoring features. The graphical controller (a standard feature for the VSD unit) even enables the control of up to 6 compressors. Reliability is finally improved by introducing a new integrated dryer range. By guaranteeing excellence in air quality, downstream equipment is protected from corrosion; even in the most tropical conditions.

With the GA 5-11/GA 5-15 VSD range, Atlas Copco reinforces and extends its premium offer in the smaller kW range. Atlas Copco’s drive for innovation allows for continuous improvements, setting a standard in the field of oil-injected air.

The new oil-free scroll compressor SF 17-22 kW is the result of Atlas Copco’s striving for continuous innovation. This revolutionary range opens a new world of possibilities for the most sensitive applications. Increased customer flexibility, reduced operating costs and improved ease of use are the most significant achievements.

The SF 17-22 was specifically designed for applications in industries such as hospitals, laboratories, breweries, universities or pharmaceuticals. The oil-free multi-scroll compressors SF 17 and 22 consist of up to four new 5.5 kW compressor element modules, making it possible to adapt the compressor to the required customer air demand with increased customer flexibility in comparison with the previous 3.7 kW element and the SF 11 to 15 kW. The new element modules can be combined in 2 different ways: the SF multi-core and the SF multi-duplex.

The SF multi-core enables you to pay for the air that you use by combining several 5.5 kW elements in one canopy. One or more modules can be stopped when there is fluctuation in air demand. This flexible use of the compressor saves energy. If there is an increase in plant demand in the future, the SF 17 can be upgraded to a SF 22 kW with simple kit. This makes the SF 17-22 a very cost efficient source of oil-free air at a low initial investment for current and possible future requirements.

The SF multi-duplex consists of 1 or 2 elements, backed up respectively by 1 or 2 additional elements, integrated in a sound insulated enclosure. This SF multi-duplex design is compliant with all the stringent redundancy standards within the medical sector.

Atlas Copco’s 100 per cent oil-free scroll compressor technology protects both the production process and the end product quality while fulfilling the most stringent requirements for pure and clean oil-free air.

By optimising cooling flow design, pressure drop and lower inlet air temperature, Atlas Copco has increased reliability and performance level. This results in a free air delivery (FAD) up to 51 per cent higher and specific energy requirements (SER) down 6 per cent for the new SF 17-22 range when comparing to the previous multi-scroll range.

The integrated Energy Saver System (ESi) monitors and controls the running hours of each element module, allowing for equal wear so service visits can be combined, optimising your production process and minimising downtime. Convenient access to each element module renders for minimum maintenance time.