Seeking to quickly boost cement production capacity to support the Sochi 2014 Winter Olympics and other construction projects in Russia, the Verhnebakanskiy Cement Plant in Novorossiysk is expanding its 44.3-megawatt (MW) on-site natural gas power plant by installing a 12 th Jenbacher J624 gas engine from GE (NYSE:GE).
The cement factory is located in the southwestern city of Novorossiysk, the country's main port on the Black Sea. The factory was upgraded with a new 2.3 million tons-per-year production line that opened in 2011, making it the largest cement facility in Russia in terms of capacity.
To generate reliable on-site power, the factory’s owner originally installed 11 of GE’s 4-MW Jenbacher J624 units in 2011—marking the first containerized J624 generator set project in the world for industrial on-site power. With an electrical efficiency of 45.6 percent, GE’s distributed power solution is helping the operator minimize energy costs by reducing natural gas consumption to generate electricity.
“In order to increase production capacity, we chose GE’s technology since we already have had a successful operating experience with the J624 gas engines. The use of GE’s gas engines has allowed us to improve the economic performance of our facility,” said Anatoly Ziskel, managing director of the JSC Verhnebakanskiy Cement Plant.At the time, the project marked the largest single order of Jenbacher gas engines in Russia and also represents GE’s largest J624 power plant project worldwide. As with the first 11 qualified J624 units, one of GE’s authorized Jenbacher engine distributors in Russia—Max Motors LLC of Sochi—will supply the latest J624 unit for the power plant, which Max Motors designed, built and maintains. The on-site power station uses natural gas provided by a local pipeline. “When the original on-site power plant began operating in 2011, the project was an important industrial milestone for GE’s J624 gas engine technology,” said Karl Wetzlmayer, general manager—gas engines for GE Power & Water. “By selecting a 12 th J624 unit to help boost production capacity, this expansion represents an important showcase for the long-term reliability and flexibility of our gas engine technology for industrial customers throughout the Russian Federation and around the world.” GE’s J624 Jenbacher gas engine was introduced in June 2007 as the world’s first 24-cylinder unit. Customer benefits include high power density, low installation and operating costs, low specific fuel consumption and high heat recovery rate. A single J624 unit has the potential to meet the power needs of about 9,000 European households.