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Views: 0 Author: Site Editor Publish Time: 2025-07-30 Origin: Site
At the energy hub of a large integrated farm in Johor, Malaysia, four King Power-branded 200kW biogas generator sets operate in synchronized harmony. This distributed energy system, jointly developed by Chinese and Malaysian technical teams, converts agricultural waste into clean electricity through intelligent paralleling technology, offering an innovative benchmark for energy self-sufficiency in tropical agricultural settings. The system's power core features biogas-specific engines licensed from Germany's industrial benchmark—Deutz AG.
Spanning 200 hectares, the farm integrates pig farming, tropical fruit cultivation, and organic fertilizer production, generating approximately 80 tons of livestock manure and agricultural waste daily. Traditional open-air composting not only emits significant methane (25 times more potent than CO₂ as a greenhouse gas) but also risks groundwater contamination from leachate during monsoon seasons. In 2024, the farm introduced King Power's biogas power generation system, establishing a closed-loop "waste-biogas-electricity-heat" industrial chain. This initiative achieves annual CO₂ emission reductions of 12,000 tons while cutting external electricity costs by 65%.
The project employs four King Power KP-200G biogas generator sets, powered by Deutz technology biogas-specific engines with these key features:
Thermal Management: Dual-stage turbocharging with intercooling maintains intake air temperature ≤55°C despite Malaysia's 32°C average annual temperature, improving volumetric efficiency by 12%.
Wear Resistance: DLC (Diamond-Like Carbon)-coated cylinder liners and piston rings reduce friction by 40%, enabling reliable operation under 95% humidity conditions with frequent start-stop cycles.
Cooling Optimization: Reinforced water jacket design with variable-speed electronic water pumps keeps engine oil temperature within the 90-95°C optimal range.
Gas Mixing: Deutz's patented gas mixer enables dynamic adjustment of air-biogas ratios, supporting stable combustion across methane concentrations of 55%-70%.
Ignition System: Pre-chamber ignition with 80mJ energy output ensures efficient combustion of low-calorific biogas (≥4.8kWh/m³).
Knock Control: Integrated knock sensors and closed-loop control adjust ignition timing within 0.1 seconds during biogas composition fluctuations.
The King Power intelligent paralleling cabinet integrates synchronization controllers, load sharing modules, and protection units. CAN bus communication enables real-time coordination among units, achieving power redistribution within 0.5 seconds during load changes while maintaining voltage stability within ±1% and frequency stability ≤0.1Hz.
The "3+1" operational strategy (three primary units + one standby) perfectly matches the farm's diurnal load variations:
All four units operate at full capacity (280kW) to meet peak demands from irrigation systems (120kW), cold storage (80kW), and feed processing (60kW). Engine load factors reach 93% with 38.5% thermal efficiency.
Two units maintain base load (150kW) while waste heat recovery via plate heat exchangers provides pigsty heating. The combined heat and power (CHP) system achieves 82% overall efficiency, reducing fuel costs for oil-fired boilers by 30%.
During unit maintenance, remaining units automatically compensate for power deficits. The paralleling cabinet's reverse power protection prevents unplanned islanding operations, ensuring grid safety.
Annual processing of 29,000 tons of agricultural waste, reducing open composting area by 4,000m².
75% methane recovery rate equivalent to the carbon sequestration capacity of 180,000 cold-hardy pine trees annually.
Treated biogas slurry returned as liquid fertilizer reduces chemical fertilizer use by 40%.
Annual electricity cost savings of MYR 480,000 through self-generation.
MYR 120,000 annual fuel cost savings from waste heat utilization.
MYR 80,000 additional income from CDM carbon trading.
Total project investment of MYR 800,000 with a 4.2-year payback period.
Creation of 15 technical jobs, with three Malaysian engineers certified through King Power-Deutz joint training.
Designation as a "Green Energy Demonstration Base" by Malaysia's Energy Commission.
Inspiration for five neighboring farms to initiate biogas power projects, forming a regional green energy cluster.
Targeted innovations address Malaysia's tropical climate challenges:
Salt Fog Resistance: 316L stainless steel paralleling cabinets with conformal-coated electrical components pass 1,000-hour salt spray tests.
Flood Protection: Generator sets mounted on 1.2m-high foundations with automatic drainage pumps and water level sensors.
Intelligent Ventilation: Variable-speed cooling fans maintain engine oil temperature ≤95°C in 40°C ambient conditions.
Insect Control: 304 stainless steel filters with 0.5mm apertures prevent insect ingress into engine air intakes.
The project validates the feasibility of biogas power generation for small-to-medium farms, establishing standardized technical packages:
200kW units suit farms generating 800-1,200m³/day of biogas.
IEC 60034-30-compliant synchronization control ensures multi-unit grid stability.
AR-based remote assistance enables Malaysian technicians to receive real-time guidance from Chinese experts via smart glasses.
Blockchain-integrated carbon footprint tracking ensures traceable greenhouse gas emission reductions.
This 200kW biogas generator paralleling system, powered by Deutz-licensed technology, demonstrates flexible scalability through modular design and resolves distributed energy integration challenges with intelligent control. As Malaysia implements its Renewable Energy Roadmap, such "agri-PV complementary" projects are becoming pivotal to rural energy revolutions, offering a Sino-German technological collaboration model for sustainable tropical agriculture.
