24/7 +380675180487

Molodizhne, Odessa region, Ukraine



24/7 +380675180487

Molodizhne, Odessa region, Ukraine




January 31, 2022 | 1 min read


Rolls-Royce and its distributor partner Knopf & Wallisch (K&W) has supplied 3 mtu customized and containerized combined cooling, heat and power plant (CCHP) trigeneration units to Romanian cloud service provider ClusterPower. They will be used for the efficient and sustainable energy supply at its new technology campus near the southern Romanian city of Craiova, where the IT company will open the largest data center in Romania.
More information -



November 09, 2021 | 8 min read


The consequences of global warming have been keenly felt around the world in recent years. The transition to a carbon-free society is therefore coming to the fore. 123 countries and regions, including Japan, have already declared their goal of reducing greenhouse gas (GHG) emissions to almost zero by 2050. Various sources of 'clean energy' are being considered for its realisation, including hydrogen.
Countries in Europe and the US in particular are making concerted efforts to reduce NOx emissions in urban areas, environmentally protected areas and major ports. And IMO adopted a strategy for reducing greenhouse gas emissions from international shipping back in 2018, which prescribes a reduction in emissions per unit of transport of more than 40% by 2030.

In 2015, Japan's Ministry of Land, Infrastructure, Transport and Tourism commissioned Yanmar to research innovative projects to develop safety guidelines for hydrogen fuel cell ships and develop a roadmap for the expansion of hydrogen fuel cell ships. Using the accumulated information, the company's experts began developing a shipboard hydrogen fuel cell system based on Toyota parts and MIRAI fuel cells in 2019.

Hydrogen has great potential as a next-generation energy source:
- high specific weight on Earth
- can be obtained by decomposing water from renewable energy sources (solar, wind, geothermal, etc.)
- Does not emit CO2 during use

Yanmar predicts that decarbonisation requirements will eventually apply to business. The development of hydrogen fuel cell systems is therefore a strategic step towards Yanmar customers' business continuity, preserving their reputation as environmentally responsible companies and creating a sustainable society.

The prototype of such a system makes it possible to identify possible problems in advance during the design and construction of such facilities. For example, the electrification of the powertrain is known to be important for decarbonisation. But lithium-ion batteries, which are used in cars, are not suitable for ships due to insufficient energy density and charging time. Ships require more power continuously over long periods of time.
This is why hydrogen is becoming an excellent alternative to batteries. It has a higher energy density with a shorter filling time. In addition, because hydrogen generates electricity electrochemically, it has no noise, vibration and odour from the exhaust of conventional engines.

For the practical application of the hydrogen fuel cell ship system, Yanmar is working with the Japanese government and other companies to build a demonstration test boat. Yanmar has also taken it upon itself to develop safety regulations for hydrogen fuel cell ships. Since there has been no precedent so far, it has had to move gropingly. For example, answering the questions "what happens if a hydrogen fuel cell is submerged in seawater?", "what to do if there is a hydrogen leak" and many others.

Once the safety regulations have been formulated, Yanmar has embarked on a full-scale development of shipboard hydrogen fuel cell systems. The safety guidelines define not only the design of the hydrogen fuel cell, but also the requirements for installation on board the boat. And there are many components that need to be developed, so companies such as Toyota Motor Corporation, Iwatani Corporation, Toyota Tsusho and many others were involved in the construction of the demonstration boat.

The first thing the designers encountered was a completely different output device for moving the boat. Conventional diesel engines have a standardised design method. And the demonstration test boat is powered by the ship's hydrogen fuel cell system, so a lot of details such as inverters, switchboards for voltage control, large batteries and hydrogen tanks had to be installed.

A lot of time was also spent on the placement of the 8 hydrogen tanks. COVID-19 also intervened, as the various components of the boat were manufactured in different cities in Japan and there were problems with specialist travel. The development team rose to the challenge and a full-scale verification test of the demonstration boat was carried out in March 2021.

The company said: "The performance of a 38-foot heavy-duty vessel with an electric motor capable of 20 knots or more is breathtaking! Naturally, there's no smell of oil or smoke. It's also quiet. What's more, the electric motor has better acceleration characteristics than the ship's engine. As the number of test riders increases in the future, ride comfort will be appreciated more and more. 

The tests started with the configuration of the software for the electric powertrain control. Then the operation of the hydrogen fuel cell system was tested under real navigational conditions. Then, in September, the boat was moved to Osaka Bay. There, a mobile hydrogen station was used to fill the world's first vessel with hydrogen at a high pressure of 70MPa.
The tests were then carried out on a route connecting tourist sites. Yanmar wants to use the results of its work for commercial hydrogen fuel cell systems and marine hydrogen infrastructure research.

Moreover, thanks to the test coverage by Japanese media, the developers managed to get feedback from customers, local and foreign public organizations, which is really valuable.
During the tests, nuances were revealed that the designers did not think of when building ships with conventional engines. For example, since the demonstration boat is electric, there is little vibration and noise, so more attention should be paid to the vibration and noise characteristics of the parts. The possibility of reducing hull weight to improve manoeuvring and maintenance performance of the vessel is also being considered.

To realise a carbon-free society, various technological developments are underway around the world. In the field of powertrains, the electrification of cars, railways and ships is an important topic. In addition, the hydrogen fuel cell propulsion system developed by Yanmar can be used not only on ships, but also on land.

Yanmar plans to bring the hydrogen fuel cell system to market (300 kW) by 2023 and introduce it at major exhibitions in Japan in 2025.
Yanmar sees its mission as creating a hydrogen fuel cell system, hydrogen engine and transmission for distribution not only in Japan but also around the world. It is also important to develop the infrastructure for hydrogen supply and charging stations.



● From 2022 mtu Series 500 and Series 4000 ready for 25% hydrogen● From 2023 mtu engines and conversion kits available for 100% hydrogen

October 29, 2021 | 8 min read


Rolls-Royce 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. Already today, gensets powered by mtu Series 500 and Series 4000 gas engines can be operated with a gas blending of 10 percent hydrogen. Beginning in 2022, operation with a hydrogen content of 25 percent will be possible. “After intensive tests on test benches and pilot installations at customers in 2022, Rolls-Royce will continuously market new mtu Series 500 and Series 4000 gas engines beginning in 2023 for use with up to 100 percent hydrogen, and on a design to order basis
conversion kits to allow already installed gas engines in the field to run on 100% hydrogen,” said Perry Kuiper, President Sustainable Power Solutions at Rolls-Royce Power Systems.

Power plants with hydrogen engines support energy transition
“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 percent admixture or for 100 percent," explains Andreas Görtz, Vice President Power Generation at Rolls-Royce Power Systems.

Rolls-Royce builds expertise for H2 ecosystem
In addition, fuel cells powered by 100% green hydrogen can 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-kilowatt 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.

Rolls-Royce focuses its climate protection programme Net Zero at Power Systems on new technologies and fuels
With its climate protection programme "Net Zero at Power Systems", Rolls-Royce's Power Systems division has set itself the target of saving 35 per cent of greenhouse gas emissions by 2030 compared to 2019 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. 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.

How Russian Mine reached 40,000 engine hours before overhaul 


° Why expert 24/7 service support was a must-have for Jubilejny.
° How Rolls-Royce helped Jubilejny extend mtu engine life in harsh conditions.
° About the benefits of Rolls-Royce’s state-of-the-art engine analysis.

September 16, 2021 | 10 min read


The Jubilejny open-cast mine mine must be one of the loneliest places on earth. It maybe fairly close to the Siberian town of Aichal with its 13,000 inhabitants, but beyond that it’s a long way to anywhere. The nearest town is 500 km distant, and you’re just 60 km from the Arctic Circle. Over 10 million carats of diamonds are mined in Jubilejny each year with the help of mtu-powered haul trucks. The climate is extremely harsh – for man and machine alike. Permafrost, dust and mud prove no obstacle to the hardy engines from Friedrichshafen.
Belaz haul trucks with payloads of 136 t rumble their way towards the open cast mine.The Aichal Diamond Combine, owned by Alrosa, has 55 such dump trucks, of which 45 are equipped with 12-cylinder mtu Series 4000 engines. Michail and Yefgeni, two driverstaking a break from their diffi cult jobs, say their experience of the engine is very positive. They reckon it runs more quietly and with less vibration than other models,whilst being economical and not susceptible to breakdowns.

The sun shines in a cloudless sky. The hilly landscape has a covering of snow. Quarry stone has been scattered on the snow-covered gravel road to prevent the six-meter-high dump trucks from slipping. The thermometer is showing -21°C at the end of February, in fact temperatures here can drop as far as -46°C during December.
The mtu engines are specially prepared for the chilly conditions in Siberia. Because the polar diesel used in this area has a kerosene content of 60%, making it much thinner than normal winter diesel, mtu has designed the injectors to be able to cope with the thinner fuel. Louvers in front of the radiator prevent the engine from cooling down. These are always closed when idling during really cold spells.The engine control unit automatically adjusts fuel quantity and injection timing in line with the air temperature. In addition,depending on ambient temperature, pre-injection is used alongside main injection during start-up.

Spectrometric analysis of engine oil for improved maintenance
The first four 136-t haul trucks with mtu engines were delivered to Aichal in 2005. “At the time, we sent five people to a coal mine in South Yakutia for training, where mtu engines were in use,” reported chief engineer Andrey Kayukov. At 38, he is one of the younger members of the workforce.
The acquisition of an expensive spectometric oil analysis laboratory was a major step forward in engine maintenance, he says. Spectrometric analysis of engine oil is now used to detect metallic particles caused by engine wear. This allows conclusions to be drawn about specific damage to the engine.

The chief engineer reports that spectrometric analysis has postponed the general overhaul of the engines by a considerable length of time.A general overhaul of the engine is recommended after 25,000 operating hours. But they now have one mtu engine with 40,000 engine hours, and eleven mtu engines with 33,000 to 38,000 engine hours, which have had only minor repairs, but no general overhaul. Two of the mtu engines obtained in 2005 are still in use. “As soon as we find any metal particles in the engine oil, we have an indication of where the fault could be,” said chief engineer Andrey Kayukov.

In order not to leave engine evaluation to the mechanics alone, a video endoscope is also used: “In a twelve-cylinder engine, we could see metal abrasion in one cylinder. We have decided to install two new cylinder sleeves. Without diagnostics, we would have replaced the entire engine.” “If we run out of ideas, we send the engine inspection files to Friedrichshafen,” he continued. “However, that doesn’t happen more than once a year.” He says it is ‘not very convenient’ to contact mtu because of the eight-hour time difference between Friedrichshafen and Aichal.

In service 24/7
The haul trucks are in operation 24 hours a day, seven days a week. The haul truck drivers work 12-hour days, after which they have two days off. The haul trucks only stand still when their drivers are taking a break.
In winter, the engines are not switched off during breaks because it is difficult to restart them in the cold. If they do get turned off, an electrically operated heat source is placed near the engine.
“Electricity is cheaper here than diesel,” explained the chief engineer. They order spare parts every three months from mtu’s spare parts warehouse in Chimki near Moscow, according to Sergei Lapygin, head of the vehicle fleet. The spare parts are then flown from Moscow to Polarnoye, a town one and a half hours north of Aichal, by the company’s own Alrosa airline. That said, cargo planes from Moscow only take off if they are carrying aggregate loads of at least five tons.

Engines checked every 20 days
How are the engines repaired? Chief engineer Kajukov explained: “Every 20 days we conduct a technical inspection. The engine data is checked, and the oil and filters changed.” Mechanic Wenjamin Metelski is working in one of the repair workshops. Together with a colleague, he is currently overhauling an mtu engine. The 52-year-old Metelski proudly explains that he has been doing this job since 2005, when the first haul trucks with mtu engines came to Aichal. “In 2008, for the first overhaul, experts came from Germany and showed us slides to demonstrate how repairs are done.”

The engine the two workers are currently overhauling has run wellover 60,000 hours, he told us. They have installed a new diesel pump, a new turbo compressor and new high-pressure lines. There are only experienced mechanics working in the repair shop. Sometimes they are assisted by the haul truck drivers. The workshop looks very neat and tidy. Safety regulations are very strict. A cable or tool carelessly left behind can have disastrous consequences, given the size of the components the men have to deal with. Helmets are mandatory, and of course alcohol is prohibited in the workplace. At least it’s nice and warm in the workshop. When you leave the bay, there’s a cold wind and crunching snow – and the mtu-powered Belaz trucks are constantly going up and down with their valuable rocky cargo.

mtu gas engine - construction and applications


The new mtu gas engines power the first ferries and are delivered for harbor tugs and for a research project

June 03 2021 | 10 min read


CHP authomation


What is CHP authomation and its role

May 21 2021 | 25 min read


Successful operation of CHP is more than installation a properly selected CHP unit and connecting it. To ensure safe and reliable operation, every piece of equipment must work seamlessly - from CHP and mechanical systems to HVAC systems, electrical systems and utilities. Automation systems make this possible. More details -

What is cogeneration?


CHP is a confident step towards energy independence for business

May 13 2021 | 17 min read


Rising electricity prices are always upsetting news for businesses. One of the ways to reduce the electricity tariff for enterprises is cogeneration plants or CHP - cogeneration heat and power.

As the name implies, such an installation can provide a facility with both electricity and thermal energy, if necessity. In more detail, what is gas-piston mini-CHP, the principles of their operation and the advantages of installation at enterprises -

Reliable off-grid power supply


Self-sufficient energy supply: Granjas Carroll pork processing plant has a state-of-the-art independent power plant

May 06 2021 | 17 min read


The Granjas Carroll pork processing plant is located 2400 m above sea level, surrounded by wilderness, far from the stable traditional power supply centers. The plant can handle up to 1.5 million pigs per year. Therefore, it is critically important for him to have reliable, constant energy without fluctuations in voltage or frequency. This is necessary for stable power supply and refrigeration.
The local provider cannot fully meet the plant's energy needs. Therefore, the company was faced with the task of building its own power plant that could operate in a completely autonomous mode and cover all the energy needs of the plant.

Then the Granjas Carroll team turned to the local expert on distributed energy systems Electriz, S.A. de C.V. After analyzing the situation, Electriz experts recommended installing 4 MTU Series 4000 gas generators and 1 MTU Series 4000 diesel generator set. All of them work under one common control system.

Built in just a few months, the facility was commissioned at the end of 2018 and has been operating without interruption since then. In the future, it is planned to use the heat of exhaust gases, oil cooler and mixture cooler for efficient production of steam and hot water. They will come in handy in production processes.

What is a stand-alone power plant for a pork grower?
The four gas units used in the plant are 4000 series 20-cylinder natural gas systems that produce a total of 7.7 MW of electricity.
One 4000 series 16-cylinder diesel generator system with 2 MW electrical output to ensure long-term stability of the unit. The diesel unit will operate continuously at up to 10 percent load to minimize fuel consumption, allowing natural gas units to generate more power. The mtu MCS main control panel integrates unit control and remote control. All systems operate in isolation from the mains, providing a reliable, stable and efficient power supply to the entire facility.

A stand-alone power plant perspective
With flexible MTU systems, the plant will be able to double its capacity in the future - even by connecting the power plant to the grid to provide additional power for the surrounding population.
At a later stage, there are also plans to use biogas from animal waste as another source of fuel to operate the plant. “There are many good companies, but when you have a problem and the company proves to be reliable, responsive quickly and thoroughly, you don't want to do business with anyone else,” said Daniel Salazar, CEO of Electriz, S.A. de C.V. “Efficiency and affordability are key to the energy business, and MTU solutions offer both.”

How to reduce utility bills in a large hotels? 


The energy needs of hotels that operate all year round are usually more or less constant. Therefore, it is hotels that are ideal objects for the installation of CHP

April 20 | 20 min read


Energy needs of hotels that operate all year round are usually constant. Therefore, it is hotels that are ideal objects for the installation of CHP - cogeneration heat and power.
These units operate on the basis of gas piston engines that use natural gas as fuel. They are capable of producing electricity and heat at the same time. Or cold, if additionally equipped with absorption refrigeration systems. This provides the hotel not only with financial savings, but also independence from traditional power grids.
They can be used to supply electricity and heat / cold to rooms, swimming pools, spas, and ancillary facilities such as laundry and storage facilities.
More details on how it works -

Raising energy efficiency


Cogeneration is the production of heat and electricity from a single source, usually natural gas. Today it is possible with the help of gas engines with efficiency 90%.

April 12 | 20 min read


Cogeneration is the production of heat and electricity from a single source, usually natural gas. Today it is possible with the help of gas engines with efficiency 90%.Initially, cogeneration plants (CHP) were intended only for large objects - greenhouses in several acres or entire residential neighborhoods, now smaller objects - hospitals, hotels, office buildings and factories - can benefit from CHP.
For example, MTU offers cogeneration modules with an electrical power from 120kW to 2,150kW and from 730,000 BTU / hour to 7.790,000 BTA / hour.It is advisable to install a cogeneration installation on your object? Module which power to pick up? How to calculate the return of investments?Read more:



Combined heat and electricity production with CHP is new posibilities for food production

March 24 | 20 min read


Most food productions need both in electrical and thermal energy. Cogeneration installation, which aims to combine heat and electricity production, can partially cover high demand technological lines for heat and electricity.
For example, ice cream producer Langnese generates heat for the production process using the Rolls-Royce cogeneration plant. It is equipped with a 16-cylinder engine MTU16V4000 type L62, which works on natural gas generates 1,719 kW of thermal energy and provides the efficiency of 87.1% by optimizing the use of heat.
A malt plant DURST MALZ uses 2 cogeneration plants from Rolls-Royce on its ownProduction facilities since July 2011. They provide a plant at the same time and warm and electricity. CO generational installations GC 357 N5 produce about 1 MW heat, which is used for dryingmalt. Approximately 700 kW of electrical energy, which the installations are generated in addition to heat, enters the overall power grid of the plant. Thus, the installation efficiency is about 90%.



In general MTU cogeneration plant can achieve overall efficiency up to 96%. But for this it is necessary to take into account several factors when installing it

March 11 | 5 min read


Generation of thermal and electrical energy from a single fuel source, for example, natural gas or biogas - this is a mass of advantages:
● Improving the energy efficiency of the object by reducing fuel consumption
● Reducing greenhouse gas emissions
● Increased energy degree from traditional network

In general, the MTU cogeneration plant can achieve overall efficiency up to 96%. But for this it is necessary to take into account several factors when installing it. Some of the most important are:
● Methods of fuel used
● The height of the area above the sea level on which the object is located
● Environmental temperature
● Humidity

Read more -

Categories of equipment for backup energy


Reserve diesel generators are necessary on those objects where continuous power supply with a stable voltage is important.

March 11 | 5 min read


Reserve diesel generators are needed on those objects where continuous power supply with a stable voltage is important.
They can be divided into 2 large groups:
• Standby Power (backup)
• Mission Critical Power (emergency)

Standby Power

In case of disconnection of the power grid or voltage drop, this DGU class increases power in a few seconds to restore the flow of electricity to consumers. Reserve DSU must ensure maximum reliability, high load capacity and rapid response. In addition, they must satisfy various power needs if necessary.
Suitable for residential complexes, industrial facilities and even whole areas of cities.

Mission Critical Power
Emergency diesel generators are needed at facilities where power supply interruptions can lead to large financial losses or threaten the lives of people. They must have the most accessible capacity and high medium load factor. For example, MTU solutions have the best medium load coefficient (more than 85%)
Suitable for airports, hospitals, telecom operators, Internet providers and data centers.

Categories of PowerGen equipment


As of 2020, the deterioration of power grids in Ukraine was about 80%, and in some areas - up to 100%. This data is provided by civil society organizations that unite operators of the electricity distribution system.

March 04 | 10 min read


As of 2020, the deterioration of power grids in Ukraine was about 80%, and in some areas - up to 100%. This data is provided by civil society organizations that unite operators of the electricity distribution system.
For end consumers this is fraught with:
• interruptions in the supply of electricity due to emergency situations
• increase in tariffs, because constant repairs are expensive for operators

And, if for the population this is only an annoying inconvenience, then industrial enterprises suffer colossal losses because of this. This is why there is a growing interest in power generation equipment.
In general, it can be divided into 3 groups:
• Continuous Power
• Prime Power
• Grid Stability

Continuous Power
The equipment of this group works as part of the traditional power grid. Such installations have a constant load and generate additional electricity. A variety of installations - CHP (cogeneration heat and power) - produce both electricity and heat energy at the same time.

The Continuous Power category is suitable for facilities that need complex energy supply. For example, airports, residential complexes and even entire villages

Prime power
If access to the traditional power grid is not available or it is significantly difficult, then you will need installations of the Prime Power category. They are under variable load and are suitable for the objects that are being built. For example, new metro stations or residential developments on the outskirts of cities

Grid Stability
Renewable energy sources significantly reduce CO2 emissions into the atmosphere. But the strength of the wind and the light of the sun are fickle and unpredictable. Therefore, the compensation of fluctuations in the power grid and its stability is the main task of the equipment of the Grid Stability category. Such installations are able to quickly and repeatedly turn on, therefore they are in demand by producers of "green" energy.

But for some businesses it is economically unprofitable to generate all the energy they consume on their own. In this case, you can reduce the risk of blackouts by using equipment for backup power supply of Standby Power and Mission Critical Power categories, which we will talk about in the near future.

The Rolls-Royce Power Systems Division is expanding the portfolio of its product and solution brand mtu to include uninterruptible power supply systems


From 1st February, the flywheel energy storage power supply systems have been marketed as mtu Kinetic PowerPacks. The manufacturer Kinolt taken over in july 2020 has been incorporated in Rolls-Royce Power Systems and is now the competence centre for dynamic uninterruptible power supplies.

January 21 | 10 min read


● After takeover in July 2020 uninterruptible power supplies extend choice of mtu products● Highly efficient UPS systems protect micro power grids and safeguard the energy supply for safety-critical installations● Belgian subsidiary to trade as Rolls-Royce Solutions Liege S.A. in future
The Rolls-Royce Power Systems Division is expanding the portfolio of its product and solution brand mtu to include uninterruptible power supply systems. From 1st February, the flywheel energy storage power supply systems have been marketed as mtu Kinetic PowerPacks. The manufacturer Kinolt taken over in july 2020 has been incorporated in Rolls-Royce Power Systems and is now the competence centre for dynamic uninterruptible power supplies.
For especially critical installations such as data centres, hospitals or industrial plants with sensitive production processes, the mtu Kinetic PowerPacks provide continually high energy quality and eliminate parasitic effects on the power grid. In the event of failure of the (usually public) power grid, the systems reliably safeguard the energy supply without loss of power or voltage in the microgrid.
mtu Kinetic PowerPacks combine the function of an uninterruptible power supply with an emergency power supply using flywheel energy storage and modern diesel engines. The technology offers high quality supply to the consumer grid combined with compact dimensions.
"As compact UPS systems, the mtu Kinetic PowerPacks represent a substantial addition to our range of practice-proven emergency power gensets. We can now offer our customers complete energy security solutions for their safety-critical installations that are extremely economical in terms of both acquisition and operating costs. The sales and service organisation will gradually be incorporated in the Rolls-Royce Power Systems service organisation. As a result, customers will have access to an even closer network," says Andreas Görtz, Vice President Power Generation at Rolls-Royce Power Systems.
Integration into the mtu product range had already been announced in July 2020 when Rolls-Royce took over the Liège (Belgium) based manufacturer Kinolt. Established in 1984 as Euro-Diesel, the company is among the market leaders in uninterruptible, dynamic power supplies. Along with incorporation of its products in the mtu portfolio, the new subsidiary has been given a new name. The business formerly known as Kinolt S.A. has been trading as Rolls-Royce Solutions Liège SA since February 1st, thus following the new brand concept of the Rolls-Royce Power Systems Division. 
About Rolls-Royce Holdings plcRolls-Royce pioneers cutting-edge technologies that deliver clean, safe and competitive solutions to meet our planet’s vital power needs.Rolls-Royce Power Systems is headquartered in Friedrichshafen in southern Germany and employs around 10,000 people. The product portfolio includes mtu-brand high-speed engines and propulsion systems for ships, power generation, heavy land, rail and defence vehicles and for the oil and gas industry as well as diesel and gas systems and battery containers for mission critical, standby and continuous power, combined generation of heat and power, and microgrids.Rolls-Royce has customers in more than 150 countries, comprising more than 400 airlines and leasing customers, 160 armed forces, 70 navies, and more than 5,000 power and nuclear customers.Annual underlying revenue was £15.45 billion in 2019, around half of which came from the provision of aftermarket services.In 2019, Rolls-Royce invested £1.46 billion on research and development. We also support a global network of 29 University Technology Centres, which position Rolls-Royce engineers at the forefront of scientific research.



Rolls-Royce is supplying two mtu 16V 4000 M55RN gas engines to Sembcorp Marine Integrated Yard for the construction of the world’s first liquefied natural gas (LNG)-hybrid powered tug. 

January 21 | 10 min read


Sembcorp Marine installs two mtu 16V 4000 M55RN gas engines in harbour tug
Jurong Marine Services will operate the eco-friendly tug in Singapore from end 2021
LNG Hybrid tug first of 12 tugs for more sustainable harbour operations
Rolls-Royce is supplying two mtu 16V 4000 M55RN gas engines to Sembcorp Marine Integrated Yard for the construction of the world’s first liquefied natural gas (LNG)-hybrid powered tug. The harbour tug will be operated in Singapore by Jurong Marine Services, a wholly owned subsidiary of Sembcorp Marine. The new LNG-hybrid tug is the first of 12 tugs that Sembcorp Marine plans to design and build to replace the existing diesel-powered ones between now and 2025.

“We are very happy to be part of Sembcorp Marine’s efforts in environmental protection and adopt new green technologies in their operations. The mtu marine gas engines are part of Rolls-Royce's Green and High-Tech programme. Without exhaust gas aftertreatment they emit no sulfur oxides only very small quantities of nitrogen oxide and particulate mass is below the verification limit”, says Chew Xiang Yu, Head of Rolls-Royce Power Systems' commercial marine business in Asia.

This is the first LNG-hybrid tug to be powered by mtu gas engines worldwide. Designed by LMG Marin (Norway), part of the Sembcorp Marine group, to deliver 65T Bollard Pull (BP) with ABS Class, the LNG-hybrid tug is estimated to be completed in the later part of 2021. The main propulsion system of the tug comprises twin 16-cyclinder mtu Series 4000 gas units which will provide a combined total power of 2984 kilowatts at 1600 RPM (revolutions per minute). The new gas engines are able to deliver performance comparable to a high-speed diesel engine. Equipped with multipoint fuel injection, dynamic engine control and enhanced turbocharging, the engines cater for dynamic acceleration capabilities, high power output and reduced emissions considerably below the current IMO III limits without the need for exhaust aftertreatment. The LNG-hybrid propulsion system will be able to provide flexibility to cater for various operational modes and is able to switch between low emission liquefied natural gas (LNG) engines and zero-emission battery power.

The new mtu gas engines are already powering ferries operated by the Dutch shipping company Doeksen in the specially protected Wadden Sea. A Lake Constance ferry operated by Stadtwerke Konstanz will also start operating in 2021 with the new mtu gas engines.

The Rolls-Royce Power Systems Division is expanding the portfolio of its product and solution brand mtu to include uninterruptible power supply systems


From 1st February, the flywheel energy storage power supply systems have been marketed as mtu Kinetic PowerPacks. The manufacturer Kinolt taken over in july 2020 has been incorporated in Rolls-Royce Power Systems and is now the competence centre for dynamic uninterruptible power supplies.

February 02 | 6 min read


Rolls-Royce introduces new MTU gas engine Series 500 for Power Generation


Rolls-Royce is launching a new MTU Series 500 for power generation. With a power range of 250 to 550 kilowatts and peak efficiencies of up to 42.6 percent in this power class, the gas gensets offer a climate-friendly and economical solution for the industrial and utility sector in addition to other applications

December 15 | 10 min read


Moving towards climate neutrality - fuel cell technology for future energy and propulsion systems


Since 2015, Rolls-Royce Power Systems has been investing specifically in environmentally friendly future solutions for less CO2 and pollutant emissions and lower consumption of energy and raw materials with its Green and High-Tech Program.

December 07 | 20 min read


The future propulsion and energy systems are intended to help meet the social challenges of climate change, increased energy requirements and the mobility and energy demands of a growing world population. It is therefore important to expand renewable energies and Power-to-X technologies, make alternative fuels available, prepare internal combustion engines for alternative fuels and develop alternative energy and drive systems. With this in mind, it is only logical for Rolls-Royce Power Systems to expand its portfolio to include fuel cells and to extend its development activities step by step to various areas of application. Because the potential of fuel cell technology is convincing!

Turning waste to green electricity


How Rolls-Royce (MTU Onsite Energy GmbH) gensets сonvert landfill gas to electricity in Shenzhen, China

November 30 | 3 min read


The city of Shenzen is also called the Silicon Valley of China. From 30,000 inhabitants in the early 1970s, the southern Chinese city has grown to more than ten million, with glittering skyscrapers, a modern transportation system and world-class shops. New factories and start-ups open almost daily, driving the boom. But this growth also brings problems with it : energy demand is rising and the environment is being polluted. Power generators from Rolls-Royce now help to solve these problems. Landfill gas is produced at the many waste disposal sites and thus gensets produce electricity.

The challenge of landfill gas
The big challenge: Landfill gas is a waste product that is relatively easy to obtain. Bacteria decompose the organic part of the waste and thereby produce landfill gas. It contains the flammable methane that gas engines run on. However, depending on the type of waste that decomposes, the composition of landfill gas is different and so is the methane content. On average, between 35 and 60 percent of landfill gas consists of methane, the rest is carbon dioxide. And the amount of methane has a great influence on the performance of the engine. If the methane number of the gas is too low, the engines begin to knock: then parts of the compressed gas-air mixture explode even before it has been fully ignited by the spark of the spark plug and the engine's performance drops. 

Using landfill gas produced there during the decomposition of waste, three MTU 20V 4000 L32FB gensets generate almost 6,000 kilowatts of electrical power.
"So far, our gensets have been running very stably at a methane content of about 50 to 55 percent," explains Darren Ding, who supports MTU gas customers in China. 

So far, MTU's gensets have proven themselves under very difficult conditions. The units operate in the most humid and hot environment in China, and the site ventilation conditions are very poor - Xuming, Head of the New Energy department at Micropower, the operator of the plant
Using landfill gas that is generated anyway
The client is Shenzhen Shengshi Energy Co, Ltd. based in Longgang District, Shenzhen City. In recent years, the company has had twelve landfill biogas power plants with a total capacity of 120 megawatts built, and six more are currently under construction. The company feeds the electricity into the public grid. This is because landfill gas is still a large market in China - unlike in large parts of Europe. It is true that the Chinese government is also increasingly focusing on separating and recycling waste. But 70 percent of municipal waste in China is still being disposed of in landfills. "Making use of these gases, which are in any case produced during the fermentation of this waste, is a great benefit for China," says Darren Ding. It's a win in two respects: in addition to the economic gain, the environment also benefits by not letting the landfill gas escape uncontrolled or being flared. And so Darren Ding and his colleagues are working to ensure that more landfill gas power plants in China are equipped with MTU cogeneration units.

By the way: How landfill gas is produced
During degradation processes, gaseous metabolic products are excreted in landfills. Microorganisms that decompose the waste release methane and carbon dioxide under certain oxygen and temperature conditions. At the end of the biochemical degradation process, a water-saturated gas mixture is produced, which is called landfill gas.



Pull over, fill up, drive on – without losing time. What drivers of petrol-powered automobiles have long taken for granted will, over time, become the new norm for E-drivers too. Many utility grids tend to reach overload when having to cope with several E-vehicles being charged at the same time, or with super-chargers that are demanding high power delivery quickly. Now SYNERG-E, an EU-funded tech project, is helping E-vehicle service stations overcome these challenges at several locations in Austria. How? With stationary battery storage systems carrying the Rolls-Royce brand MTU.

November 26 | 8 min read


E-mobility is one of industry's most transformative trends and today the focus not only of untiring development work and state subsidizing, but also endless debate. The reasons why E-drives have become a talking point are manifold: increasingly aware of the benefits, more and more people are choosing to swap their petrol-powered automobiles for vehicles with an electric drive. The advantages speak for themselves: energy-efficiency, no local carbon emissions, low running and maintenance costs, and virtually silent operation.

But there is one big sticking point: the infrastructure for public charging stations, which attracts criticism for its lack of charging points and excessively slow and complicated charging. Many local utility grids indeed tend to reach overload when several E-vehicles are being charged simultaneously in one place, or when high power is being drawn off by supercharger stations within a short space of time – as frequently happens in busy places such as motorway service areas, shopping centers, and petrol stations. Furthermore, in the long-term, the growing number of supercharger stations is set to create stability problems in Europe's power network.

E-fast charging stations equipped with mtu-battery storage. The overall system of the fast charging stations consists of the mains connection, the battery, the charging stations and a microgrid management system.
Full storage capacity The battery containers in the SYNERG-E project are around six meters long, almost three meters high and weigh up to 14 tons.

MTU battery storage systems shave peak loads induced by E-vehicle super-charging
The SYNERG-E project is to provide the solution to both these challenges: operators of super-charger stations can be sure of a reliable power supply, while transmission system operators benefit from extra electrical power. With that end in mind, Austrian electricity company Verbund Solutions and E-mobility providers Smatrics and Allego have joined forces as project partners. Between 2018 and 2019, they set up supercharger stations at three locations in Austria – in Innsbruck, Bergkirchen and Feldkirchen near Graz. Each is equipped with four charging points able to power up an E-vehicle in just a few minutes. Three further locations are planned.

The key role in the project is played by MTU-brand stationary storage batteries from Rolls-Royce which provide the much-needed buffer between the charging stations and the utility grid. “The MTU-brand EnergyPacks QM each deliver 500 kVA/ 550 kWh for performing peak shaving at times of high demand,” explained Alexander Flunk, project manager at Rolls-Royce Solutions Berlin (formally the Qinous company). “They help to avoid the high network charges that arise during peak hours and render the charging stations invulnerable to overload situations occurring on the local power grid.” MTU battery storage is central to the highly cost-effective microgrid solutions being offered by Rolls-Royce. MTU storage batteries make a positive contribution to energy sustainability and secure a reliable power supply that meets the needs of individual customers.

Surplus power for the operating reserve market
“The system as a whole basically comprises the grid connection, battery, charging points and microgrid management system. As operators, we gain from the two core functions that our super-reliable MTU-brand storage batteries perform in our project,” explained Karl Potz, head of Power Solutions at VERBUND Energy4Business GmbH. “Not only do they smooth out the fluctuations in the local power demand caused by supercharger stations, they also provide additional grid services for transmission system operators.” The surplus energy stored in the batteries is marketed by VERBUND Energy4Business as operating reserve, thereby helping to counteract stability problems in the public utility grid.

Ultra-fast charging stations for electric vehicles: pull over, fill up briefly, drive on fast - with the SYNERG-E project's fast charging stations this is everyday life for electric car drivers.
Ultra-fast charging stations for electric vehicles: pull over, fill up briefly, drive on fast - with the SYNERG-E project's fast charging stations this is everyday life for electric car drivers.
MTU EnergyPacks provide a scalable, all-in-one solution
MTU EnergyPacks are based on lithium-ion cells that have high cycle efficiency, thereby enabling an average service life of around 15 years. Their job is to store energy from the local power grid and make it available to the supercharger stations as and when required. The battery containers in the SYNERG-E project are some 6m long and 3m high and can weigh up to 14 tons. MTU EnergyPacks are generally available as scalable all-in-one solutions that boast fast power delivery and charging and a low maintenance requirement.

“With MTU EnergyPacks, simultaneous charging of up to four E-vehicles with 150 kW or two vehicles with 350 kW is now possible at our service locations without overloading the local utility grid,” explained Karl Potz from Verbund Energy4Business GmbH. A central monitoring system controls overall operation of the supercharger stations by optimizing power generation and deployment in accordance with their particular needs.

Energy and transport synergies for the whole of Europe
60% of the SYNERG-E project is financed by the 'Connecting Europe Facility', a funding instrument of the European Commission. The total project volume is 8.7 million euros. The aim of the project is to demonstrate the performance capabilities, reliability and interplay of individual components at work in the energy and transport segments. The technology and related business model are then to be implemented at a later date at other locations spread throughout Europe. “Our supercharging stations have been in continual service for over a year now and we're seeing very positive results,” reported Karl Potz from Verbund Energy4Business GmbH. “With this concept, E-vehicle drivers can look to the future with confidence.”

Pull up, tank up, and drive on – without losing time. That'll soon be the new norm for E-vehicle drivers too. 

New 16V 4000 L64FNER gas generator set 


The set has new extended Time Between Overhaul (TBO) from 63,000 upto 84,000 operating hours

June 24 | 5 min read


MTU Onsite Energy is excited to introduce the new 16V 4000 L64FNER gas generator set which is another further great step in the continuous improvement and development of the existing portfolio.The Series 4000 L64FNER is tailored for worldwide use fitting perfectly to the needs and challenges of themodern power plant industry. The natural gas-powered generator set was developed to serve customer needswith outstanding performance for combined heat and power (CHP) projects in various applications such asindustrial and commercial facilities, hospitals, data centers, manufacturing plants, peak shaving plants, andmany more. The generator set is delivering 2028 kWe net power output with a very compact design ensuringthe lowest footprint and highest power density in its class.
Compared to the existing version of L32, the L64FNER realizes a power increase of 30% and an increase ofthe electric efficiency by 0.7% together with its remaining highly robust and outstanding behavior againstderating (ambient temperature/humidity/altitude/methane number). Achieving more than 2MW with only 16cylinders instead of 20 not only reduces the overall installation costs but also lowers operating andmaintenance costs significantly. Good serviceability has always been a top priority in the development of thisproduct. Attractive maintenance intervals and a very low oil consumption result in reduced lifecycle costs forthe customer, e.g. cylinder heads achieving up to TBO lifetime. In addition, the systems are digitallyconnected and equipped with a data logger providing access to digital solutions from MTU, including remotemonitoring, a fast and reliable service support and -coming soon- further functionalities like predictive failureprevention and operational optimization.
The penetration of renewables is changing the worldwide energy market demanding flexible, robust and highefficiency solutions. The 16V 4000 L64FNER gas system offers the option to start from 0 to 100% full poweroutput easily in less than 120 seconds. Quick ramp-up and ramp-down rates as well as optimized part loadoperation make this product ideal for grid stabilization, peak shaving applications and hybrid solutions, such as microgrids.
Low Emissions - 250 mg/Nm, 500mg/Nm³ (0.5 g/hp-h, 1 g/hp-h) NOx are realized without after treatment,even meeting the new expected German unburned THC emissions legislation (<5%40gm0031%O2).MTU has delivered more than 5,500 stationary gas generator sets worldwide. All of this experience has beenconsidered in developing this next generation. In the attached presentation you are able to find additionaldetails.

Rolls-Royce ships its first B36:45V20 gas generator sets 


B36:45V20 gas generator sets was shipped to C-Energy in the Czech Republic

Aug 7 | 5 min read


Rolls-Royce ships its first B36:45V20 gas generator sets to C-Energy in the Czech RepublicRolls-Royce has completed manufacturing of the first of the new medium speed B36:45V20 gas engines at the Bergen Engines facilities in Norway. Two generator sets have now been shipped to its new home in the Czech Republic, for the independent power provider C-Energy.
The B36:45V20 engine is 14 metres long and 5 metres high, has a weight of 170 tonnes, and is the largest and most powerful medium speed engine that has been developed and manufactured by Rolls-Royce. It set a new standard in power and efficiency with exceptionally low fuel consumption and emissions of NOx, CO2, SOx and particulates.
At 600 KW per cylinder the two 20-cylinder engines will extend C-Energy’s existing power plant with further 23 MWe. The extension of the gas fired plant is considered as an additional step towards a green future for the region and country where electricity and heat are still predominantly generated by coal-fired plants.
Libor Dolezal, CEO of C-Energy said: “We decided to install the new type of Rolls-Royce’s largest engines to enhance the plant’s thermal capacity as part of our overall strategy to reduce heat and electricity production from coal and also to expand the energy business. Given our very good experience with four engines B35:40V20, we decided to install new types providing us both higher output and efficiency in cogeneration production. It is quite exciting being the very first customer of this new type of engine, the largest one in the Rolls-Royce portfolio of medium speed engines.”
The existing 37 MWe power plant of C-Energy, located in the in Planá nad Lužnicí roughly 100 kilometers southeast of the capital Prague, was reconstructed in the beginning of 2015 with four B35:40V20 gas engines from Rolls-Royce. At this time, this was the first natural gas power plant based on medium-speed gas engines in the South Bohemian Region of the Czech Republic.
With the extension, the gas engines of the power plant will, from the end of 2019, deliver a total of 60 MWe electricity and heat for companies and homes in the nearby town of Tabor/Sezimovo Ústí. Rolls-Royce and C-energy has an agreement for a new service contract.
For further information, please contact:
Merethe FjeldstadBergen Engines AS, Rolls-Royce Power SystemsTel: +47 913 72 128Email: moc.ecyor-sllor.sp%40datsdlejf.ehterem
The content of the press releases reflects the status as of the respective date of publication. They are not updated. Further developments are therefore not taken into account.

Rolls-Royce Power Systems business unit to restructure its brands


- current MTU companies will now include Rolls-Royce in their names
- MTU will remain brand name for products and solutions

Aug 7 | 5 min read


The Rolls-Royce Power Systems business unit, with its core brand MTU, will present itself more clearly in future as an integral part of the British Rolls-Royce engineering group. A new brand architecture is currently evolving, which will be visibly implemented as of autumn with the launch of the new MTU website. The new, clear brand structure will support the PS 2030 strategy of the Power Systems business unit and the global growth path. Rolls-Royce will be the corporate brand and the employer brand. Consequently, the companies within the business unit that include MTU in their names will be given a new designation. MTU, as the brand name customers are familiar with, will continue to be used to identify the company’s products and solutions. The current MTU Onsite Energy brand for decentralised power supply systems will be integrated into MTU.

One of the first visible steps to be taken will be the renaming of four operating companies, which manufacture products and solutions: MTU Friedrichshafen GmbH will thus become Rolls-Royce Solutions GmbH in autumn 2019. This will be followed by MTU America Inc., which in future will operate as Rolls-Royce Solutions America Inc. Today’s MTU Onsite Energy GmbH in Augsburg will become Rolls-Royce Solutions Augsburg GmbH and MTU Onsite Energy Systems GmbH in Ruhstorf will be renamed Rolls-Royce Solutions Ruhstorf GmbH. The remaining subsidiaries will successively be given new designations based on the above examples. The products of Bergen Engines will also be part of the new brand architecture.

“The new brand architecture will provide clarity and improve the recognition of our company and its products,” said Andreas Schell, CEO Rolls-Royce Power Systems. “Our new profile is a clear commitment to Rolls-Royce, as its second largest business unit. By the same token, Rolls-Royce is committed to our MTU brand, which is something we are proud of,” Schell added.

The new brand profile will be visible with the launch of the MTU brand’s new website in autumn of this year. Additionally, company employees will be given e-mail addresses with the domain suffix, plus new working clothes that will emphasise the affiliation of the MTU brand with Rolls-Royce.

author picture

AUGUST 06, 20194 min reading

Almost ready to roll: 8-cylinder gas engine on the test stand

The new 8-cylinder MTU gas engine for marine applications has been humming away on Test Stand no. 146 in the new development test facility at MTU Plant 1 in Friedrichshafen since the beginning of June 2019

It is being put through its paces before the Constance Municipal Works (Stadtwerke Konstanz GmbH) will take delivery of it and a second example of these new engines at the end of the year. From 2020, the engines will be propelling a new ferry operated by Bodensee-Reederei which runs passenger services on Lake Constance. 

  • Engine technical characteristics

    The “little brother” of MTU’s already series production-ready 16V 4000 gas engine will be available with a power rating of between 750 and 1,000 kW. Starting in 2020, Rolls-Royce Power Systems and the Constance Municipal Works will be trialing two 746 kW engines in a new ferry set to ply the route between Constance and Meersburg. This will make it one of the first inland passenger vessels in Europe to be powered by high-speed pure gas engines. The fuel used is liquefied natural gas (LNG). 

    article image
    From 2020, the engines will be propelling a new ferry operated by Bodensee-Reederei which runs passenger services on Lake Constance

    “We are very much looking forward to using the MTU gas engines from our long-standing partner Rolls-Royce Power Systems in this new addition to our fleet,” said Dr. Norbert Reuter, CEO of Stadtwerke Konstanz GmbH.

    Even without exhaust gas aftertreatment, the MTU mobile gas engine is already well below the thresholds stipulated by current emission guidelines (IMO III) – indeed, particulate mass is below the verification limit, and nitrogen oxide emissions are very low. 

  • Implementation experience

    MTU unveiled its mobile gas engines for marine propulsion back in September 2016, and meanwhile prototypes have successfully racked up well in excess of more than 8,000 hours on the test stand. 

    article image
    The “little brother” of MTU’s already series production-ready 16V 4000 gas engine will be available with a power rating of between 750 and 1,000 kW.

    The first pre-production 16-cylinder engines were delivered at the end of 2017 to shipyard Strategic Marine in Vietnam which installed the engines in catamarans being built for Dutch shipping company Doeksen. 

Follow us:

author picture

JULY 12, 201910 minutes reading

Rolls-Royce showcases forward-looking MTU Onsite Energy technologies for the reliable and sustainable power supply of the future

The future of a sustainable and reliable energy supply in times of climate change, decarbonisation and the energy transition was the main focus of the 3rd Power Generation Symposium, which has been arranged by the Rolls-Royce MTU Onsite Energy brand and will be held on 2 and 3 July in Friedrichshafen. 

Around 600 experts from the energy sector, including 400 MTU Onsite Energy customers, discussed strategies for handling growing energy demands in view of the urgent need for environmentally sound and climate-friendly solutions. Rolls-Royce is moving forward as a pioneer in sustainable power generation and, with its MTU Onsite Energy brand, offers forward-looking energy solutions, such as microgrids, CHP plants and emergency standby systems, that will safeguard the energy transition and secure an uninterruptible power supply. There were few live demonstrations of these solutions during the symposium.

  • Power generation sector

    The power generation sector is one of the most important markets for Rolls-Royce and in 2018 accounted for roughly 30 per cent of the total sales generated by the Power Systems business unit (Rolls-Royce Power Systems total revenue: 3,900 million euros). Under the MTU Onsite Energy brand, Rolls-Royce supplies cost-effective, reliable and environmentally friendly system solutions for the supply of energy covering a very wide range of applications. These include systems for emergency standby, baseload and peak load applications to high-performance cogeneration plants and microgrids.

    article image
    Over past few years, symposium has become a key industry event and annually gathers recognized experts to discuss trends and challenges in global energy markets.

    The product portfolio also includes diesel gensets with outputs of up to 4,000 kVA, gas gensets delivering up to 2,500 kW of power and battery containers. This range of products is supplemented by medium-speed engines and generators for power generation to 11,600 kW. With gensets from MTU Onsite Energy, Rolls-Royce is one of the most important system partners for operators of data centres. The majority of the major Internet companies and collocation providers put their trust in MTU Online Energy emergency standby gensets to safeguard their data centres.

  • Main topics

    The main topics were environmentally sustainable, reliable and economical generator sets based on natural gas, biogas and diesel fuel with a unit capacity of more than 3 MW. High-capacity backup power systems that can cover the demand for industrial-scale loads, including data centers and microgrids, have become a separate important focus of Symposium.

    article image
    Power Generation Symposiums have a long tradition at Rolls-Royce Power Systems: in the United States, the symposiums have been held every year since 2009, and in the course of the last 10 years around 4,000 energy experts have attended. In the Near East, similar events have already been held and an event is scheduled to take place in Asia in the year 2020. 

    MADEK specialists are always ready to advise how to provide installation and transfer of enterprise to energy sources running on natural gas or biogas, which will not only significantly save material resources, but also take care of the future environment.

Follow us:

author picture

June 06, 20197 minutes reading

MTU Africa gives mining trucks a new lease on life

MTU Africa, a subsidiary of Rolls-Royce Power Systems, has already successfully retrofitted multiple mining trucks with MTU engines and has recently added another eight projects to the list, converting three Komatsu 960-2KT and five Hitachi EH3500-AC2 mining vehicles.

These were first-time retrofits on both types of vehicle. Last December and March of this year, staff from South Africa and Zambia worked on First Quantum Minerals’ Sentinel Mine in Zambia to repower the first of three 960-2KT Komatsu trucks. In the rebuild, a competitor engine that had reached the end of its service life was replaced by a new 20-cylinder Series 4000 engine. The third project is to follow in May. 

  • Results of pilot project

    The results of the first project once again confirm the classic virtues of MTU products: “all truck operators at the mine now prefer to drive the repowered truck”, which boasts outstandingly fast response characteristics at lower engine revolutions per minute. Other quintessential MTU strengths now gained by the repowering project are greater reliability and robustness, longer maintenance intervals and lower fuel consumption. The truck fleet used at the Sentinel mine includes not only the Komatsu trucks but eight Liebherr T284 mining trucks, also powered by MTU’s 20-cylinder Series 4000 units, and two LeTourneau front-end loaders. MTU Africa has excellent credentials in mine-truck repowering, especially on Komatsu vehicles, and has in the past retrofitted Komatsu 730E, 860E-1K and 930E-4 trucks with MTU Series 4000 engines. 

    article image
    Repowering of a 960-2KT mining truck with a 20-cylinder Series 4000 engine. Each project confirms the outstanding strengths of this series, in particular in terms of excellent fuel consumption, performance, reliability and uptime, long maintenance cycles and customer service quality – all superb customer benefits.

    MTU Africa personnel were furthermore engaged by operator First Quantum in Zambia at its Kansanshi mine to replace the competitors engine of a Hitachi EH3500-AC2 mining truck with a MTU 12-cylinder Series 4000. The Kansanshi mine is the largest copper mine in Africa, and five trucks in total are to be repowered there over the next few months. The tried-and-trusted MTU 12-cylinder Series 4000 is already powering two of the Hitachi EH3500-AC3 trucks at the same mine

  • Over 800 Series 4000 retrofits worldwide

    It is always a compliment to MTU engines when they are retrofitted to mining trucks – especially when they replace other manufacturers' engines. Since the launch of the Series 2000 and Series 4000, they have been fitted to over 800 mine trucks as well as excavators, front-end loaders and surface blast hole drilling rigs worldwide, with the Series 4000 accounting for the lion's share. Each project confirms the outstanding strengths of this series, in particular in terms of excellent fuel consumption, performance, reliability and uptime, long maintenance cycles and customer service quality – all superb customer benefits. The engines used are always bang-up-to-date versions. One major driver of lower total cost of ownership is the excellent fuel consumption. “As consumption accounts for around 80 to 85% of TCO, this is a key purchasing criterion for many customers,” emphasized Robert Wagner, Senior Manager Mining /Oil & Gas in Europe, the Middle East, Africa and Russia. 

    article image
    Since the launch of the Series 2000 and Series 4000, they have been fitted to over 800 mine trucks as well as excavators, front-end loaders and surface blast hole drilling rigs worldwide, with the Series 4000 accounting for the lion's share. Last December and March of this year, MTU Africa staff repowered 960-2KT Komatsu trucks.

    Mine trucks usually need new engines after three to five years. Rolls-Royce Power Systems supplies what it calls Repower Kits for this purpose. These are pre-assembled drive modules consisting of an engine, a generator and a radiator all mounted on a base frame. They also come with an electronic engine management and monitoring system. MTU engineers are happy and skilled to the task to tailor-made technical adjustments where necessary.

    Across the world, the most potential for repowering with the Series 4000 can be found in Russia, the US, Australia, Chile, Peru, Africa and China. As one of the latest developments in Europe, the company is currently opening up markets in Bulgaria and Serbia.

    MTU’s extensive experience in equipping dump trucks and exceptionally high qualification of the company's engineers are trusted all over the world. The largest dump truck in the world with a carrying capacity of 450 tons - the BelAZ-75710 - is equipped with two 16-cylinder diesel generators MTU DD 16V4000. This engine model has proven itself so well that BelAZ plans expansion of foreign markets in this particular configuration. Also companies are negotiating the development and implementation of innovative solutions, for example, the use of gas piston engines on BelAZ dump trucks. These trucks will be very beneficial to use in areas rich in natural gas.

Follow me:

Picture about the post

Sustainable energy supply in the mining industry - Rolls-Royce Power Systems offers microgrid solutions from MTU Onsite Energy


May 07, 2019

5 min read

Rolls-Royce Power Systems is expanding its portfolio of energy systems with the addition of microgrid solutions for mines from MTU Onsite Energy. This means that mine operators will now be offered a sustainable energy supply system that can be operated in remote regions independently of public power grids. The solutions combine renewable energy sources with a battery storage system and both diesel and gas generator sets, in addition to a central controller to ensure that the mine’s entire demand for electricity is made available in a reliable and efficient manner, and one that is friendly to the environment.
Besides diesel and gas generator sets from MTU Onsite Energy, the solutions offered by Rolls-Royce Power Systems also include battery containers combined with photovoltaic and wind power plants in microgrids. The modular designed 40-feet MTUEnergyPack is entirely new on the market. It stores electricity from any source – ready to deliver at the flick of a switch. Peak Power: 2,515 kW (DC)/ 2,475 kVA (AC); Nominal Capacity Range: 700 - 1,260 kWh 
“For mine operators, energy costs, which account on average for 15 % of the overall operating costs of mine, are a key factor,” Lars Kräft, Vice President Industrial Business at Rolls-Royce Power Systems, explains. “And with a demand for electric power of 50 to 100 MW per mine, sustainability, efficiency and the reliability of the energy supply are now becoming increasingly important in the industry. We have identified our customers’ needs and, with our microgrid systems, are now offering them a solution tailored to their specific requirements,” he adds.

Besides diesel and gas generator sets from MTU Onsite Energy, the solutions offered by Rolls-Royce Power Systems also include battery containers combined with photovoltaic and wind power plants in autonomous power grids. All the components are connected to each other via a smart energy management system, which optimises the way in which the energy is used both technically and commercially. Any excess renewable energy can be stored in the batteries and then made available whenever it is needed. At the same time, fluctuations in power generated from renewable energy sources due to weather conditions and the time of day are compensated for with reliable diesel and gas generator sets, in addition to battery storage systems. The system is thus designed to provide a stable power supply at all times – even when the demand for electric power is high and when systems are required to operate around the clock.

Using renewable energies and the associated benefits of carbonisation means that mine operators can make considerable progress in achieving a significantly more sustainable energy supply, which also benefits their stakeholders, such as investors or communities located close to the mine. Due to the integration of renewable energies and the smart networking of all components, there is a significant cost benefit to mine operators. Fuel costs can be reduced for example, in addition to the saving of costs required for connecting mines to the power grids. 

author picture

March 27, 201910 min reading

What will be in tomorrow’s tanks?

Hydrogen, methane, methanol, DME, OME, synthetic diesel – when it comes to combustible fuels we are spoilt for choice. But which of them offers the best prospects for the future? R&D specialists at MTU are currently working on a range of projects to establish which fuels are most economical and efficient and what the best engines for them will be.

The latest report from the Intergovernmental Panel on Climate Change (IPCC) reads like a final warning: This late in the day, climate targets agreed upon internationally are going to prove very difficult to achieve and they will only be achievable at all if we act with unswerving determination. And those determined efforts must include the decision to say goodbye to fossil fuels like coal, oil and natural gas because burning these resources has been a major factor in the increase of greenhouse gases in our atmosphere.

  • A future fueled by hydrogen and methane? 

    The future lies with synthetically produced fuels that offer clean and climate-neutral combustion overall. One such fuel is hydrogen that can be produced from renewable energy sources using electricity. It can either be used directly or synthesized into methane using carbon dioxide. The big advantage of hydrogen and of synthetic methane is that they produce no, or at least significantly less, polluting emissions during combustion. In addition, they can also be produced using electricity generated by wind power and photovoltaic installations. However, if not used immediately, this power has so far proved difficult to store. This explains why, on especially sunny or windy days, there is often more power available than consumers need. An alternative way of storing that energy is to use it to produce fuel – that means transforming electrical energy into energy for powering engines.

    How does electric power become fuel?
    Engine specialists have taken this line of thought a step further because methanol can be derived from methane and, as a liquid fuel, it is much easier to store. The benefits of methanol are especially obvious for marine applications. “Until now, LNG (liquefied natural gas) has been seen as a possible future fuel for ships. But LNG can only be transported and stored in high-pressure tanks or at temperatures of minus 164°. It is difficult to maintain such temperatures over longer periods of time,” explained Dr Peter Riegger, MTU Director Research & Technology. Methanol could provide an alternative because, unlike LNG, it does not require complex infrastructural storage facilities and can therefore be integrated much more easily in marine vessels.

    But methanol is not the ultimate step in the ongoing fuel development process. Methanol can be used to produce diesel alternatives such as DME and OME. These are synthetic fuels that could also be used in slightly modified diesel engines. In this context, Fischer-Tropsch synthesis processes can also be used to synthetically produce diesel fuel that fully conforms to standards.

    The main question currently facing MTU specialists is which fuel is most likely to prove most economic and most energy-efficient in the future. “If we use hydrogen to produce methane or methanol, then we lose energy in the process,” said Riegger. “Despite that, methanol could still prove to be the fuel of the future, particularly in marine applications because it is relatively simple to store and handle,” he added. However, the situation looks rather different when it comes to stationary engines for generating electricity. Here, infrastructure is by no means as important because existing natural gas grids can be extended. Consequently, for this scenario, hydrogen presents a more promising alternative.

    “I believe that we will rely on a range of different fuels in future. Sole reliance on a single fuel is not a likely option,” said Riegger. 

  • MTU projects to develop environmental friendly gas engines

    Headed jointly by MTU and the DVGW (German Technical and Scientific Association for Gas & Water) Research Unit at the Engler-Bunte Institute of the Karlsruhe Institute for Technology, the ‘MethQuest Project’ currently involves 27 partners who are working on methods of generating fuels from renewable energy sources for use in engines. One area of their activities involves MTU researchers looking at two new engine concepts for marine applications. “We are working on two different projects. One focuses on an Otto engine concept and the other involves a flexible-fuel engine concept with direct injection,” explained project leader, Dr Manuel Boog. 

    Fuel development chain
    Otto engines have been around for a long time because it is easy to burn gas in Otto engines. The problem with this concept is that the gas is never entirely combusted and uncombusted methane can escape. The phenomenon is called ‘methane slip’. “Methane is more damaging to the atmosphere than CO2. Consequently, the potential of gas engines to achieve substantial reductions in greenhouse gases is not exploited,” said Boog. One of the aims of the MethQuest Project is to develop a ‘methane oxicat’ (catalytic converter) to neutralize the negative effects of methane. The problem is that methane requires high temperatures for oxidation in the exhaust gas tract. In the engine, such temperatures are only present upstream of the turbocharger turbine. The catalytic converter therefore needs to be located here. However, this has a seriously negative influence on engine dynamics and MTU engineers are therefore working on an electrically assisted turbocharging concept that will counteract these disadvantages. 

    Gas engine with no methane slip
    The second gas-engine concept under investigation for marine applications, the flexible-fuel, direct-injection concept, involves the development of a completely new combustion process. “Here, just like in a diesel engine, the air is first compressed in the combustion chamber. The main source of energy, gas, is then introduced and a small quantity of diesel is injected at the same time to ignite the gas,” explained Boog. The advantage of this process is that the gas is almost entirely combusted and the unwanted occurrence of methane slip remains negligible. “We have already demonstrated that this combustion process works in a different, publicly sponsored project called ‘FlexDi’,” added Boog. The concept has the additional benefit that the combustion process involved also means that methanol can be used to power engines without complications. One of the challenges remaining to be solved here is the development of a suitable high-pressure gas system as the injection concept means the gas needs to be highly compressed and heated for injection.

    “We will run trials with both concepts and the pressurized gas supply system and will then decide which is the most promising for further development in the context of the drive system overall,” said Boog. Both concepts aim to produce engines that deliver comparable power and performance to diesels but with a significant reduction in environmentally negative emissions.

    Hydrogen and the combustion engine
    In the context of the ‘MethPower’ research project, MTU is also working on the development of engine concepts for stationary gas engines. “We want to establish which engine will allow us to generate electricity most efficiently,” said Project Leader Dr Michael Thoma. This project also involves the development of two engine concepts that will ultimately be compared with each other. One is a hydrogen-powered engine. “Hydrogen can be produced from superfluous electric power by electrolysis. It therefore makes sense to use it in our engines,” explained Thoma. Just as with the natural gas engine, the MethPower Project employs the combustion of hydrogen using the Otto process. A spark plug is used to ignite the hydrogen/air mixture. However, hydrogen burns much faster than natural gas. “That is a challenge we will deal with over the coming months,” declared Thoma.

    Together with its other aims, the MethPower Project is working on the continued development of an engine that will run on natural gas and/or methane. “The MTU portfolio has included these engines for quite some time. What we are now seeking is to incorporate the engine in a system based on fuel generation and exhaust gas utilization,” said Thoma. The CO2 generated during combustion could be extracted directly from the engine exhaust and this CO2 could be used to produce new methane. “The idea is particularly interesting in the context of microgrids,” said Thoma. In this configuration, the gas engine is integrated in a network of power generators and storage devices. The network could be extended by including a ‘power-to-gas’ installation that would reduce the battery requirement. “The power-to-gas installation would work in conjunction with a gas storage vessel, like a large battery. It would use renewable electrical energy to produce methane that could be converted back to electricity if required whenever no sun or no wind is available,” explained Thoma.

    At the end of the process, R&D specialists will have to decide which concept will provide the best balance between energy generation and energy consumption and thus deliver the greatest efficiency.

    Solutions for the future
    Synthetic fuels and new engine concepts all have one thing in common – they all make a major contribution to minimizing CO2 emissions and promoting moves toward the more responsible use of energy. “That is our aim and our duty as a responsible company. We aim to develop drive solutions for the future and we commit to playing an active role in that process,” said Dr Peter Riegger in summary.

Follow MTU:

Picture about the post

How do gas engines differ from diesel engines?


March 15, 2019

7 min reading

Gas engines are increasingly taking the place of diesels in a range of areas including off-highway applications. Both types of engine deliver similar performance but gas engines emit less CO2 during the combustion process. 
So, what precisely are the differences between the two?
TURBOCHARGERSThe turbochargers used on diesel engines and mobile gas engines are virtually identical. They both feed the engine with the air (and, therefore, oxygen) it needs for combustion. On stationary gas units, the turbocharger has to process both the air and the entire volume of the gas/air mixture and in stationary genset applications, turbochargers are optimized to match full-load conditions because these engines generally operate at full-load.
MIXTURE COOLINGDiesel engines have charge-air coolers that cool the air heated in the compressor before it enters the combustion chamber. On gas engines, this function is performed by the mixture cooler. Depending on the application in question, the gas/air mixture is cooled in two stages to around 50 to 60°С before passing on to the combustion chamber. The thermal energy extracted during the cooling process can be decoupled from the system and fed into a heating system, for example.
FUEL MIXTUREIn diesel engines, air is sucked into the combustion chamber where it is compressed to levels that raise its temperature as high as 700°С. Injectors then introduce diesel fuel that ignites in the hot air. In stationary gas engines, the air is mixed with fuel gas before it passes through the turbocharger and mixture cooler to the combustion chamber. Mobile gas engines utilize multi-point injection systems. Here, air is routed to the cylinder and gas is introduced just before it enters the combustion chamber. This means that the volume of gas can be flexibly regulated dependidng on the power required.
IGNITIONThe most obvious difference between diesel and gas engines can be found in the ignition systems. Diesels are self-igniting engines in which high levels of compression cause the diesel/air mixture to ignite spontaneously. Like gasoline-fueled engines, gas engines use a spark generated by a spark plug to ignite the gas/air mixture (the illustration shows the spark plug connectors and cables leading to the cylinder head cover). Diesel injection systems and extraneous ignition systems on gas engines both need suitable control concepts that determine factors such as, for example, injection timing and duration (diesels) or inginition point and energy (gas).
KNOCK CONTROLDiesel fuels adhere to precise specifications and deliver highly consistent levels of quality for efficient engine set-up. However, the constituents in gaseous fuels vary and this affects combustion. For example, different gases have different methane numbers (similar to octane ratings for gasoline) that indicate the proportional mixture of an equivalent fuel consisting of methane and hydrogen. If the methane number is too low, inefficient spark ignition and other uncontrolled combustion processes can occur in the combustion chamber. These generate `engine knock` and gas engines need to be controlled to deal with the phenomenon. Stationary gas engines use vibration sensors to identify knock whilst pressure sensors do the same on mobile gas engines. Consequently, ignition timing is adjusted as an initial reaction and engine power can be reduced as a second step. In extrem cases, the engine can be shut down to prevent damage.
TROTTLE FLAPSOn both diesels and mobile gas units the formation of the fuel mixture is controlled flexibly for each ignition sequence in order to influence engine power. Stationary gas engines use a premixed gas/air mixture that remains constant and engine power is influenced by using throttle flaps to regulate the flow of the mixture. Mobile gas engines also have throttle flaps but these regulate the pressure of the mixture entering the cylinder.