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 ef ficiency and high total efficiency throughout the load range, have very low CO 2 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 recover y 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.
WÄRTSILÄ CHP – WIN-WIN CONCEPT
Typical specific CO2 emissions by different power plant types
+
CO2 emissions in g/kWh 800
750 600
+
670
+
600 450 340 240 1)
2) +
Coal fired steam boiler
Gas turbine natural gas single cycle
Gas turbine fuel oil single cycle
Diesel engine fuel oil single cycle
Diesel engine emulsified fuel single cycle
Gas engine natural gas CHP
Gas engine natural gas 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).
=
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 flexibility and uncompromising performance wherever power and heat are required. Wärtsilä’s gas and diesel engines have by far the highest electrical efficiency for prime movers in the market. The exhaust gases and cooling water from the engine can flexibly be utilized for numerous applications – as low-pressure steam for industrial entities, as district heating and/or chilled water for cities, office complexes and municipalities; or the exhaust gases can be used directly for drying, etc. Depending on customer needs, the CHP plant’s total efficiency 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 efficiency 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 benefits of Wärtsilä’s modular plant concept is the unique flexibility of
operation enabled by the cascading multiengine structure of the plants. Multi-unit installations provide load flexibility: extra generating sets can be turned off, while the plant continues to run at peak efficiency 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 MW e (engines) + 11 MWe (turbine) Fuel ..............................................Liquid biofuel Emission control ................ SCR NO X 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 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.
+15,500
Combined SCR/OXI-CAT (option)
CHP-module
Engine-generator set
22,500
5
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,
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.
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 MW e Total heat output ............................... 19.2 MW th Total efficiency........................................84.6% Fuel .............................................................Gas
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)
1 r o
Wärtsilä 20V34SG (radiator cooling)
0.95 t c a f g ni t
Aeroderivate gas turbine
0.9 a r e D
Industrial gas turbine
0.85 Source: GE Ger-3567 Ger-3695; Wärtsilä perf
0.8 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 efficient 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 emulsified 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 b uildings. 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, genera ting 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
1
1
1
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
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
Engine optimization: NOX (dry @ 15 vol-% O 2 )
Liquid Liquid Liquid Liquid Gas Gas Gas Gas fuel fuel fuel fuel mode mode 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* 2000* 1600–2000 (HFO) 1600–2000 (HFO)
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
%
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
Efficiency
1)
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
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
± 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 fa ctor 0.8. Gas Methane Number >80
2) Single-circuit cooling system. * Adjustable NOX range according to local requirements. Heat rates given at the marked NO X optimization level. Heat rates at other NOX optimization levels to be checked case by case. Note! 1 ppm-v dry @ 15% O 2 2.054 mg/Nm 3 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 Engine optimization: NOX (dry @ 15 vol-% O 2 )
ppmvol
Electric power
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
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
79/96
80/96
80/96
80/96
80/91
84/91
– HTCAC temperature inlet/outlet
°C
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 NO X 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/Nm 3 dry @ 15% O2, NOX calculated as NO2, Nm3 defined at NTP (273.15 K and 101.3 kPa). »
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Wärtsilä is a global leader in complete lifecycle power solutions for the 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.
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