COMBINED HEAT AND POWER 2 COMBINED BENEFITS OF DISTRIBUTED COGENERATION Increasing demand for energy and long transmission distances from power plant to end user affect the reliability of the electricity supply, and also put pressure on the price of electrical and thermal energy. The power and energy market has been deregulated and liberalized, pushing power generation towards a decentralized model. More and more power and heat is being produced close to the point of consumption. At the same time, the world is calling for more efficient use of fuels to protect the environment for future generations. Wärtsilä addresses these demands with its Combined Heat and Power (CHP) solutions for utilities, IPPs, industry and municipalities. Typical plant sizes range from 4 to100 MWe, in single or multi-engine configurations. The combination of high efficiency and low emissions offered by Wärtsilä CHP plants is unequalled in the market. Wärtsilä engines as such comply with various national and local environmental requirements and with World Bank guidelines for power plants. Cogeneration is a closed process that requires no auxiliary cooling of the engines since the heat from the process is taken into profitable use. CHP plants, with their unbeatable electrical efficiency and high total efficiency throughout the load range, have very low CO2 emissions, so they easily comply with the most stringent environmental and CHP regulations. Wärtsilä CHP plants can run on various grades of natural gas and liquid fuel, while still maintaining low emissions and high efficiency. The plants include thermal heat recovery for hot water, steam, direct-fire hot air, or chilled water – raising an already efficient power plant, 43-45% in terms of net electricity, to a total efficiency of 90% or above. More efficient use of fuel also translates into lower emissions per unit of fuel. Typical specific CO2 emissions by different power plant types WÄRTSILÄ CHP – WIN-WIN CONCEPT CO2 emissions in g/kWh 800 750 600 670 600 450 340 1) Coal fired steam boiler Gas turbine natural gas single cycle Gas turbine fuel oil single cycle Diesel engine fuel oil single cycle 2) Gas engine natural gas CHP Diesel engine Gas engine emulsified fuel natural gas single cycle single cycle 1) 7 bar (g) saturated steam production. 2) Hot water production (45°C in/85°C out). Single cycle: g/kWhe. CHP-mode: g/kWhtot (heat + electricity). 240 ++ Extremely efficient utilization of primary fuels ++ Decentralized energy production (DE) enables individual CHP solutions that are economical and efficient ++ Optimized plant size with step-by-step investment thanks to multi-unit design. Gives lower investment risk in a changing market ++ Maximized plant availability in all operating situations ++ Flexible operation for changes in power and heat demands ++ Electrical output and efficiency are unaffected by the rate of heat production ++ Lower power transmission costs ++ On-site maintenance without production down-time == Low capital and operational costs per output unit. High profitability! 3 PISTICCI, ITALY Type of customer ..........................Industry - IPP Engine type............. 4 x Wärtsilä 18V34SG (Gas) 3 x Wärtsilä 18V32 (LBF) Total electrical output............... 22 MW + 24MW Total heat output ................. 17.3 MW + 2.1 MW Total efficiency........................................... 59% Fuel .......................................Gas/Liquid biofuel PLANT CONCEPT Wärtsilä+CHP+plants+powered+by+reciprocating+ engines+offer+fl+exibility+and+uncompromising+ performance+wherever+power+and+heat+are+ required. Wärtsilä’s+gas+and+diesel+engines+have+by+ far+the+highest+electrical+effi+ciency+for+prime+ movers+in+the+market.+The+exhaust+gases+and+ cooling+water+from+the+engine+can+fl+exibly+ be+utilized+for+numerous+applications+–+as+ low-pressure+steam+for+industrial+entities,+as+ district+heating+and/or+chilled+water+for+cities,+ offi+ce+complexes+and+municipalities;+or+the+ exhaust+gases+can+be+used+directly+for+drying,+ etc.+Depending+on+customer+needs,+the+CHP+ plant’s+total+effi+ciency+can+even+exceed+90+%. Typical+heat+recovery+systems,+between+the+ prime+mover+and+the+customer’s+equipment,+ are+of+“hang-on”+type+and+ensure+both+ optimized+heat+production+and+effective+engine+ cooling+and+operation.+Wärtsilä’s+heat+recovery+ design+takes+into+account+all+the+customer’s+ seasonal,+monthly,+weekly+and+daily+variations+ in+running+and+operational+heat+production+ conditions.+Heat+production+does+not+affect+the+ electrical+output+or+the+electrical+effi+ciency+of+ the+prime+mover. The+modular+design+of+Wärtsilä+CHP+plants+ enables+rapid+delivery+anywhere+in+the+world.+ Prefabricated,+functionally+pre-tested+modules+ guarantee+consistent+quality+and+performance+ 4 and+make+on-site+installation+a+matter+of+ assembling+and+connecting+the+modules.+ Wärtsilä+has+the+resources+and+capabilities+ to+carry+out+deliveries+ranging+from+the+supply+ of+equipment+and+engineering+to+complete+ turnkey+projects+including+engineering,+ procurement+and+construction.+A+globally+ experienced+project+organization+guarantees+ successfully+executed+deliveries+around+the+ world. One+of+the+benefi+ts+of+Wärtsilä’s+modular+ plant+concept+is+the+unique+fl+exibility+of+ operation+enabled+by+the+cascading+multiengine+structure+of+the+plants.+Multi-unit+ installations+provide+load+fl+exibility:+extra+ generating+sets+can+be+turned+off,+while+the+ plant+continues+to+run+at+peak+effi+ciency+with+ as+many+units+as+required. As+needs+change,+the+design+of+the+plants+ makes+it+possible+to+increase+the+plant+size+in+ stages+by+adding+new+engines.+This+also+allows+ for+a+smaller+initial+investment+with+the+option+ to+expand+later+as+required. CHP module Wärtsilä 20V34SG Engine auxiliary module (EAM) MONOPOLI, ITALY Engines ............................... 6 x Wärtsilä 18V46 + Steam turbine Output ................................ 100 MWe (engines) + 11 MWe (turbine) Fuel ..............................................Liquid biofuel Emission control ................ SCR NOX abatement Pre-engineered and pretested modules minimizes construction time and maximize reliability. Exhaust gas silencer +10,950 FIELD CONCEPT EXAMPLE CHPmodule Exhaust gas boiler Enginegenerator set Where the building site is ample and not situated in the midst of a densely populated area, the single floor plant layout with an overall lower plant profile is used. The main heat recovery system is situated outside the main engine hall, either under a separate roof or as weatherproof equipment. 21,250 Radiator TOWN CONCEPT EXAMPLE +15,500 When the plant is situated in the middle of a city or an industrial plant site, the layout is more compact and the protective shielding is stronger. The two floor plant lay-out allows a small and compact footprint. The exterior of the plant and possible architectural design of the power house has also to be suited to its surroundings. The emission levels have to be kept very low with effective emission reduction systems and heavyduty silencers have to be installed to eliminate any noice problems. Combined SCR/OXI-CAT (option) CHP-module Engine-generator set 22,500 5 industrial process steam or even chilled water, Wärtsilä provides a design that ensures maximum efficiency and the best possible overall solution. The automation system not only controls all the internal processes in the Wärtsilä CHP plant but is also carefully integrated with all necessary signals and connections to existing systems to guarantee a fully compatible plant. capacity or temperature in the industrial process or the district heating network. Such a plant is very suitable when all the heat and power it produces can be used for either heat or processing purposes. To optimize the balance between thermal and electrical energy production, each plant is customized to suit the needs of the end user. Whether it is hot water for district heating, LOW-PRESSURE STEAM GENERATION FOR INDUSTRIAL APPLICATIONS POWERFUL CHOICES The high efficiency of Wärtsilä’s CHP plants translates into considerable savings in fuel costs compared to other technologies. For optimized balance and profitability, the plants are customized to the customer’s specific needs. A decentralized combined heat and power plant increases the reliability of energy supply in the neighbourhood. Total energy production is local and close to the point of consumption. Local heat generation ensures a quick response to changes in Steam consumer Electricity Steam generator Lube oil cooler Hot water consumer (optional) CAC 1 and 2 COGEN FOR MAXIMUM STEAM GENERATION Steam consumer Electricity Burner CAC 1 and 2 6 UJPALOTA, HUNGARY Type of customer...........................................IPP Engine type....................... 3 x Wärtsilä 20V34SG Total electrical output............................ 20 MWe Total heat output................................ 19.2 MWth Total efficiency......................................... 84.6% Fuel..............................................................Gas 7 °C TRIGENERATION Typical trigeneration solution for airports 95-105 °C 1-stage absorption chiller Chilled water or district cooling 12 °C Electricity 80-90 °C Boiler 70-105 °C CAC1/ jacket water Hot water or district heating Lube oil cooler 45-55 °C Circulation pump HOT WATER GENERATION FOR DISTRICT HEATING APPLICATIONS 7 RINGKØBING, DENMARK: Type of customer ......................................Utility Engine type...................... 1 x Wärtsilä 20V34SG Total electrical output............................ 7.9 MW Total heat output ................................... 9.7 MW Total efficiency........................................... 96% Fuel .............................................................Gas 8 Liquid fuel Gas fuel Gas fuel Gas Liquid fuel Liquid fuel Gas SG operation Dual-fuel operation GD operation Diesel operation ENGINE WORKING PRINCIPLES 1.05 Derating due to cooling water temperature. (Derating due to inlet air temperature starts at 45°C) Derating factor 1 Wärtsilä 20V34SG (radiator cooling) 0.95 Aeroderivate gas turbine 0.9 Industrial gas turbine 0.85 0.8 Source: GE Ger-3567 Ger-3695; Wärtsilä perf 15 20 25 30 35 40 45 Ambient temperature (°C) Wärtsilä reciprocating gas engines offer stable output and high performance in hot and dry conditions. No water consumed for plant cooling = remote area suitability! ENGINE TECHNOLOGY A+reciprocating+engine+is+the+most+effi+cient+ means+of+converting+liquid+or+gaseous+fuels+ into+energy. The+Wärtsilä+CHP+plant+can+run+on+most+ natural+gas+types,+heavy+and+light+fuel+oils,+and+ emulsifi+ed+fuels.+Dual-fuel+engines+give+added+ reliability+to+the+CHP+plant,+since+they+can+use+ whichever+fuel+is+available+at+the+lowest+cost. The+heart+of+Wärtsilä’s+generating+sets+is+ Wärtsilä’s+reliable+engine+technology,+the+result+ of+long+experience+of+demanding+marine+and+ power+plant+applications.+All+Wärtsilä+engines+ have+a+simple+and+straightforward+modern+ design+with+facilities+for+easy+and+rapid+on-site+ maintenance. The Wärtsilä 20V34SG engine features the latest design in gas technology. 9 Typical interior and design of a control room in Wärtsilä power plants. CUSTOMER CARE Wärtsilä’s aim is to ensure that customers obtain the best possible performance from their power plant investment throughout its lifecycle. After all, who could be better at this than the people who designed and built the plant? Wärtsilä provides a comprehensive range of services built on the concept of enhancing the customer’s profitability by optimizing all aspects of the power plant operation. The services range from rapid spare parts delivery to a complete operation and maintenance partnership, allowing the customer to focus on their core business. 10 Wärtsilä Operations & Maintenance currently runs more than 130 plants around the world, making it the world’s leading power plant O&M contractor. If customers choose to operate the plant themselves, they can still rest assured that they have the best possible support available as and when needed – from training and on-line support to service packages or plant modernization and upgrading. Wärtsilä’s global network is always ready to make sure the power plant performs flawlessly, free of breakdowns and unwanted downtime throughout its lifetime. COMBINED CYCLE SOLUTIONS Wärtsilä’s combined cycle solutions with reciprocating engines reach plant efficiencies far above 50%. This is achieved by recovering energy from the otherwise wasted heat produced in thermal power plants, either by using a conventional steam bottoming cycle recovering hot exhaust gases or an organic rankine cycle recovering heat from sources with lower temperatures. Photo courtesy of Jung Bu City Gas and JB Enertek Co., Ltd CHEONG SOO, KOREA The purpose of Cheong Soo plant is to provide District heating and electricity (CHP) to a newly established and build town with about 6400 house holds including public buildings. The CHP plant generates electricity in parallell with the electrical grid and supplies the district heating to the network for the town. During summer the plant provides also district cooling. Type of customer ............................................................................ IPP Engine type..........................................................2 x Wärtsilä 20V34SG Total electricity output............................................................. 16.9 MW Total heat output..................................................................... 14.2 MW Total efficiency............................................................................ 85.1% Fuel.................................................................................... Natural gas 11 THE SINGLE-SOURCE SUPPLIER THAT STAYS WITH YOU Wärtsilä has the resources and capabilities to carry out deliveries ranging from the supply of equipment and basic engineering to complete turnkey projects including financing, engineering, procurement, construction, operation and maintenance. BARAJAS AIRPORT, SPAIN In 2003, AENA, the Spanish Airport Authority, called for bids to supply thermal and electrical energy to the major Barajas airport in Madrid under a twenty-year power purchase agreement. The trigeneration plant, generating a net electric power of 33 MW, is connected to the airport’s internal grid and to the public grid. The plant provides electricity continuously, as well as heating during the winter and cooling during the summer. Engines................................................................6 x Wärtsilä 18V32DF Total electrical output............................................................. 33.6 MWe Total heat output...................................................................... 24 MWth Total absorption cooling output.................................................. 18 MWc Total efficiency............................................................................... 74% Fuel............................................................................. Natural gas/LFO LINATE AIRPORT, MILAN, ITALY Type:........................................... Industrial self generation, Trigeneration Engines................................................................3 x Wärtsilä 20V34SG Total electrical output................................................................ 24 MWe Total heat output................................................................... 17.5 MWth Total efficiency........................................................................... 80.2 % Fuel.................................................................................... Natural gas 12 THIS IS NOT THE FUTURE. THIS IS TODAY. THE+WÄRTSILÄ+TOWN+CONCEPT+is+a+ Combined+Heat+and+Power+plant+designed+for+ decentralized+energy+production+in+built-up+ areas+close+to+consumers.+These+facilities+ have+a+high+level+of+performance,+comply+with+ all+environmental+regulations+–+particularly+ noise+emissions+–+and+are+designed+to+ blend+smoothly+into+the+surrounding+urban+ architecture.+As+the+heat+recovery+system+ and+other+auxiliaries+are+built+into+functional+ modules+surrounding+the+engine,+Town+ Concept+plants+have+a+small+footprint. Town+Concept+CHP+plants+can+also+easily+ be+expanded+as+the+demand+for+power+and+ heat+grows. Exhaust stacks Cooling radiators Exhaust gas boiler Transformer Control room Lubrication oil tank Engine air intake filters Engine generator set Engine exhaust outlet Module for hot water generation District heating pump Feed and return for district 13 POWER PLANT OUTPUT RANGE Gas engines MW 1 5 10 50 100 300 Wärtsilä 34SG Dual-fuel engines (gaseous fuel/liquid fuel) Wärtsilä 32GD Wärtsilä 34DF Wärtsilä 50DF Liquid fuel (LFO, HFO, CRO, emulsified, LBF) Wärtsilä 20 Wärtsilä 32 Wärtsilä 46 LFO = light fuel oil HFO = heavy fuel oil CRO = crude oil LBF = liquid biofuel Boiler and absorption chillers at Madrid’s Barajas airport, Spain. 14 500 Performance data as guidelines for CHP calculations – Wärtsilä gas fuelled generating sets at 50 and 60 Hz Performance data Wärtsilä gas engines at frequency 50 Hz Wärtsilä gas engines at frequency 60 Hz Engine 9L34SG 16V34SG 20V34SG 20V34DF 18V50DF 9L34SG 16V34SG 20V34SG 20V34DF 18V50DF Liquid + Liquid Liquid + Gas + Gas + Gas + fuel+ fuel + fuel+ mode mode mode mode mode mode 1460–2000* (LFO)+ 1460–2000* (LFO)+ mg/Nm3 95–190* 95–190* 95–190* 190–380* 190–380* 2000* 95–190* 95–190* 95–190* 190–380* 190–380* 1600–2000 (HFO) 1600–2000 (HFO) Gas + mode Engine optimization: + NOX (dry @ 15 vol-% O2) Liquid + fuel+ mode 2000* Electric power kW 3888 6970 8730 8730 8730 16621 16621 3758 6737 8439 8439 8439 17076 17076 Heat rate 1) kJ/kWh 7817 7753 7737 8036 8127 7616 8185 7817 7753 7737 8036 8127 7616 8186 Efficiency 1) % 46.1 46.4 46.5 44.8 44.3 47.3 44.0 46.1 46.4 46.5 44.8 44.3 47.3 44.0 Cooling circuit inlet/outlet 2) °C 36/59 36/66 36/67 36/69 36/77 36/68 42/83 36/58 36/65 36/66 36/68 36/75 36/68 42/85 –– HTCAC temperature inlet/outlet °C 42/52 45/57 46/58 47/59 49/65 45/59 54/72 42/52 45/56 45/57 46/58 48/64 45/59 55/73 –– Cylinder temperature inlet/outlet °C 84/91 82/91 82/91 81/91 83/91 80/85 79/85 84/91 83/91 82/91 81/91 83/91 80/85 78/85 –– Lubrication oil circuit inlet/outlet °C 63/74 63/76 63/77 63/78 63/80 63/74 63/78 63/74 63/76 63/76 63/78 63/79 63/74 63/78 –– LTCAC temperature inlet/outlet °C 36/37 36/38 36/39 36/39 36/41 36/38 42/46 36/37 36/38 36/38 36/39 36/40 36/38 42/46 Charge air flow ± 5% kg/s 6.2 11.1 13.8 14.1 17.5 26.2 32.5 6.0 10.7 13.4 13.5 16.7 26.1 32.5 Exhaust gas flow ± 5% kg/s 6.4 11.4 14.2 14.5 17.9 27.0 33.5 6.2 11.0 13.8 13.9 17.2 26.6 33.5 Exhaust gas temp. ± 15 °C 400 400 400 380 335 400 377 400 400 400 380 335 401 369 Exhaust gas energy ± 10% kW 2657 4733 5924 5714 5975 11016 12705 2567 4572 5722 5486 5718 11379 12415 Cooling circuit-energy ± 10% kW 1929 3436 4294 4595 5631 7403 9504 1868 3322 4147 4432 5404 7409 9991 –– HTCAC energy ± 10% kW 840 1405 1723 1710 2238 3237 4129 817 1369 1680 1659 2168 3219 4117 –– Cylinder cooling energy ± 10% kW 560 1005 1254 1404 1587 2101 2514 540 965 1214 1354 1517 2238 2925 –– Lubrication oil energy ± 10% kW 424 761 961 1065 1149 1528 1967 414 741 920 1035 1108 1538 2048 –– LTCAC energy ± 10% kW 105 265 357 416 662 542 884 97 247 333 384 611 539 901 Heat losses by radiation ± 20% kW 130 230 290 350 350 630 670 120 220 280 340 340 640 670 Note: Heat and mass balances are dependent on ambient conditions and plant application, above given figures are for guidance only and calculated at ISO 3046 reference conditions; 25°C ambient temperature, 100m above sea level and 30% relative humidity. 1) Heat rate and electrical efficiency at generator terminals, including engine-driven pumps, ISO 3046 conditions and LHV. Tolerance 5%. Power factor 0.8. Gas Methane Number >80 2) Single-circuit cooling system. * Adjustable NOX range according to local requirements. Heat rates given at the marked NOX optimization level. Heat rates at other NOX optimization levels to be checked case by case. Note! 1 ppm-v dry @ 15% O2 » 2.054 mg/Nm3 dry @ 15% O2, NOX calculated as NO2, Nm3 defined at NTP (273.15 K and 101.3 kPa). Performance data as guidelines for CHP calculations – Wärtsilä liquid fuelled generating sets at 50 and 60 Hz Wärtsilä diesel engines at frequency 50 Hz Performance data Engine ppmvol Engine optimization: + NOX (dry @ 15 vol-% O2) Wärtsilä diesel engines at frequency 60 Hz 9L20 12V32 16V32 18V32 20V32 18V46 9L20 12V32 16V32 18V32 20V32 18V46 710*-780 710*-970 710*-970 710*-970 710*-970 900*-970 710*-780 710*-970 710*-970 710*-970 710*-970 900*-970 Electric power kW 1539 5327 7124 8032 8924 17076 1454 5211 6970 7841 8730 17076 Heat rate 1) kJ/kWh 8604 7880 7856 7840 7840 7698 8561 7880 7856 7861 7840 7698 Efficiency 1) % 41.8 45.7 45.8 45.9 45.9 46.8 42.0 45.7 45.8 45.8 45.9 46.8 High temperature circuit inlet/outlet °C 84/91 84/91 –– HTCAC temperature inlet/outlet °C 79/96 80/96 80/96 80/96 80/91 87/96 87/96 88/96 87/96 83/91 80/96 80/96 80/96 80/96 80/91 87/96 87/96 88/96 88/96 83/91 –– Cylinder temperature inlet/outlet °C 84/91 79/87 80/87 80/88 80/87 80/83 84/91 80/87 80/87 80/88 80/88 80/83 Low temperature circuit inlet/outlet °C 34/47 38/49 38/49 38/49 38/49 42/55 34/48 38/49 38/49 38/49 38/49 42/55 –– Lubrication oil circuit inlet/outlet °C 63/78 63/77 63/78 63/78 63/79 63/80 63/77 63/77 63/78 63/78 63/79 63/80 –– LTCAC temperature inlet/outlet °C 34/44 38/43 38/43 38/43 38/43 42/47 34/44 38/43 38/43 38/43 38/43 42/47 Charge air flow ± 5% kg/s 3.5 10.2 13.6 15.3 17.0 31.6 3.3 9.7 13.0 14.6 16.2 31.6 Exhaust gas flow ± 5% kg/s 3.6 10.5 14.0 15.7 17.5 32.5 3.4 10.0 13.3 15.0 16.7 32.7 Exhaust gas temperature ± 15 °C 303 347 348 349 349 346 302 352 352 354 354 344 Exhaust gas heat ± 10% kW 1052 3629 4849 5472 6082 11212 991 3515 4698 5306 5897 11222 High temperature circuit-energy ± 10% kW 371 1891 2453 2726 3030 5135 345 1805 2427 2654 2949 5141 –– HTCAC energy ± 10% kW 1044 1319 1443 1604 3484 971 1309 1388 1543 3490 –– Cylinder cooling energy ± 10% kW 371 847 1134 1283 1426 1651 345 834 1118 1266 1407 1651 Low temperature circuit-energy ± 10% kW 832 1246 1668 1885 2093 3750 776 1205 1623 1829 2032 3753 –– Lubrication oil energy ± 10% kW 246 657 877 988 1097 2249 221 646 862 972 1080 2249 –– LTCAC energy ± 10% kW 586 589 791 897 996 1501 556 559 761 857 951 1504 Heat losses by radiation ± 20% kW 68 185 247 278 308 451 68 180 240 270 300 451 Note: Heat and mass balances are dependent on ambient conditions and plant application, above given figures are for guidance only and calculated at ISO 3046 reference conditions; 25°C ambient temperature, 100m above sea level and 30% relative humidity. 1) Electrical output at generator terminals, including engine-driven pumps at 100% load. ISO conditions and LHV (42700 kJ/kg). Tolerance 5 %. Power factor 0.8. * Adjustable NOX range according to local requirements. Heat rates given at the marked NOX optimization level. Heat rates at other NOX optimization levels to be checked case by case. Note! 1 ppm-v dry @ 15% O2 » 2.054 mg/Nm3 dry @ 15% O2, NOX calculated as NO2, Nm3 defined at NTP (273.15 K and 101.3 kPa). 15 marine and energy markets. By emphasising technological innovation and total efficiency, Wärtsilä maximises the environmental and economic performance of the vessels and power plants of its customers. In 2008, Wärtsilä’s net sales totalled EUR 4.6 billion with 19,000 employees. The company has operations in 160 locations in 70 countries around the world. Wärtsilä is listed on the NASDAQ OMX Helsinki, Finland. WÄRTSILÄ® is a registered trademark. Copyright © 2005 Wärtsilä Corporation. WÄRTSILÄ® is a registered trademark. Copyright © 2010 Wärtsilä Corporation. 01.2010 / Bock´s Office / Litoset Wärtsilä is a global leader in complete lifecycle power solutions for the