Energy for dry spells – a tour around the most modern diesel power plant in the world
Hydropower covers 80 percent of Costa Rica’s energy needs. During its dry season, the country relies on diesel as an additional energy source. The most modern and efficient power plant in the world has been built in the North West of Costa Rica in a project led by MAN Diesel & Turbo. A tour.
We are making rapid progress along the Panamericana highway. Our route takes us from Puntarenas, the lively Pacific port on the Gulf of Nicoya in Costa Rica, into a gently rolling hilly landscape. Far and wide, there is nothing but luscious green and rampantly overgrown nature. It is hard to believe that here, right in the heart of the jungle, should be the location of Costa Rica’s largest power plant.
Strict environmental rules: Pure hightech hidden in the jungle
“Remaining inconspicuous was part of the project specifications,” explains Wolfgang Frank in retrospect. As Project Manager at MAN Diesel & Turbo in Augsburg, Frank played a significant role in the construction process of “Termoeléctrica Garabito,” one of the world’s most advanced and efficient diesel power stations. “Costa Rica is a very ecology-minded country, with strict emission standards for industrial facilities, which apply both to noise and exhaust gases,” says Frank.
Following a construction period of about 18 months, Wolfgang Frank’s project team of 12 handed over a complete power generation facility with 11 four-stroke generator sets and a total output of 200 megawatts to the Grupo Instituto Costarricense de Electricidad (ICE) and its partners. “Due to the optimized combustion of heavy oil and diesel, we have succeeded in lowering fuel consumption, which in turn results in fewer nitric oxide emissions and less CO2,” explains Frank.
Hightech in the middle of the primeval forest: As Costa Rica’s largest power station, Termoeléctrica Garabita could cover around 10 percent of the entire country’s power needs alone. It is the world’s most modern and efficient diesel power station.
Hydropower currently supplies around 80 percent of the country’s electricity. While the always humid Caribbean side of the country receives regular precipitation, the wet-dry Pacific side must rely on additional power sources during its dry season, which lasts from December to May. For this reason, “Termoeléctrica Garabito” is at full throttle in spring. Considering the massive scale of this power plant complex, the prevailing quiet at this site is utterly astonishing. At best, only a subdued hum would suggest that 11 heavy diesel generator sets are on duty here.
The challenge: transporting the engines
The 11 MAN machines are not only built on an impressive scale, but are heavy too. just one of the engines weighs about 320 tons, which made transporting the heavy equipment one of the biggest challenges for Wolfgang Frank and his team. It took 11 semitrailer trucks with a shipment height of 8, a length of 45 and a width of 6.5 meters to transport the generator sets first assembled at the premises of MAN Diesel & Turbo Costa Rica in San José to the primeval forest. “And all this while moving at a walking pace, and having to contend with river crossings as well.”
Assembly of the filter system was also something of an adventure, as it took the form of a component kit weighing 1,500 tons and the parts had to get to the construction site in the right sequence. It took months to get the 25-meter-high filter in place. Utilizing electrostatic charging, the filter installation separates particles out of the engine exhausts, thus playing a key role in the reduction of emissions, which helps to meet the strict emission standards in Costa Rica.
A tour around the power station
Perfect infrastructure
Short transport routes from the port, as well as the presence of an electricity infrastructure, were decisive factors when choosing a site for the Costa Rican power station. The power plant is 20 kilometers away from Puntarenas, the lively Pacific port on the Gulf of Nicoya in Costa Rica.
Plant manager Verny Rojas Vásquez is delighted to welcome visitors from Germany. He has visited MAN Diesel & Turbo in Augsburg himself and likes to be able to show off the most efficient power plant in the world.
Teamwork in Costa Rica
Verny Rojas Vásquez takes us to the office buildings first. He likes to introduce the members of his team. They all wear jeans and the same yellow ICE shirt.
At the heart of the power plant
On we go now to the control room of the plant. A security code opens the door. The staff are calmly monitoring the power plant. “We ensure that the plant is running smoothly from here,” explains Rojas Vásquez.
Remote control
“The control system is actually operated via remote from the ICE headquarters 100 kilometers away in the capital of San José,” summarizes Rojas Vásquez. “Either directly via an interface or over the telephone with our control center.”
MAN power in the machine room
An expansive glass door offers a look at the 11 mighty 18V48/60 diesel engines: “When going full throttle, the plant needs around 900 tons of heavy oil and diesel every day—the equivalent of roughly 60 truck loads,” explains the plant manager.
Operated using diesel and heavy oil
“We need diesel to start up the system while it is still cold. Only when we reach an operating temperature of 70 to 80 degrees will the heavy oil reach sufficiently elastic properties to flow through the pipes.”
The key to cutting emissions
The two mighty towers of the filter system reach for the skies akin to silver fingers. With the help of electrostatic charging, particles are separated out of the engine exhausts which cuts emissions.
Fuel for 18 months of operation
Around 45,000 cubic meters of fuel is the capacity of the heavy oil and diesel tanks on the plant grounds. When a tanker docks, it takes around 800 truckloads to carry 20,000 cubic meters of heavy oil and diesel to Garabito. Trucks come and go from the pumping stations without a break.
Practicing for emergencies
Back at the administrative offices, there is a sudden burst of activity. One employee is being carried on a stretcher and shouting is heard across the grounds. Since Costa Rica sits on a seismological hot spot of the planet and earthquakes are not uncommon, the staff regularly have drills. On the site itself, highly advanced technology such as shock-resistant pipeline fasteners are used to protect against earthquakes.
Perfect infrastructure
Short transport routes from the port, as well as the presence of an electricity infrastructure, were decisive factors when choosing a site for the Costa Rican power station. The power plant is 20 kilometers away from Puntarenas, the lively Pacific port on the Gulf of Nicoya in Costa Rica.
Plant manager Verny Rojas Vásquez is delighted to welcome visitors from Germany. He has visited MAN Diesel & Turbo in Augsburg himself and likes to be able to show off the most efficient power plant in the world.
