Wärtsilä produces highly efficient combined heat and power (CHP) plants that run on various fuels. Their modular design allows for flexible operation and scalability. Key features include:
- Electrical efficiencies of 43-45% for engines and total efficiencies over 90% when waste heat is recovered.
- Engines can use natural gas, liquid fuels, or dual-fuels to provide reliable, low-emission power.
- Heat recovery systems maximize efficiency and flexibility by producing steam, hot water, or chilled water depending on customer needs.
2. 2)
240
1)
340
450
600
670
600
750
800
Gas engine
natural gas
single cycle
Diesel engine
emulsified fuel
single cycle
Gas turbine
fuel oil
single cycle
Gas engine
natural gas CHP
Diesel engine
fuel oil
single cycle
Gas turbine
natural gas
single cycle
Coal fired
steam
boiler
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).
CO emissions in g/kWhe2
Typical specific CO emission by
different power plant types
2
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.
WÄRTSILÄ CHP – WIN-WIN CONCEPT
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!
•
•
•
•
•
•
•
•
=
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.
3. 4
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 the “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
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
PISTICCI, ITALY
Type of customer...........Industry - IPP
Engine type....... 4 x Wärtsilä 18V34SG
Total electrical output...............22 MW
Total heat output...................17.3 MW
Total efficiency............................ 74%
operation enabled by the cascading multi-
engine 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.
4. 5
Combined
SCR/OXI-CAT
+15,500
CHP-module Engine-generator set
Radiator
22,500
(option)
Pre-engineered and
pretested modules
minimizes construction time
and maximize reliability.
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 heavy-
duty silencers have to be installed to eliminate
any noice problems.
RINGSTED, DENMARK
Type of customer.......................Utility
Engine type....... 2 x Wärtsilä 18V34SG
Total electric output .................11 MW
Total heat output...................10.4 MW
Total efficiency......................... 87.6%
FIELD CONCEPT EXAMPLE
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.
Exhaust gas silencer
Exhaust gas boiler
+10,950
21,250
CHP-module Engine-generator set
5. HOT WATER GENERATION FOR DISTRICT HEATING APPLICATIONS
LOW-PRESSURE STEAM GENERATION FOR INDUSTRIAL APPLICATIONS
Steam
consumer
Hot water
consumer
(optional)
Steam generator
Lube oil cooler
CAC 1 and 2
Electricity
Engine EAM module CHP module
Exhaust gas boiler
HT water
heat
exchanger
Lube oil
cooler
District
heating
network
LT
CAG
HT
CAG
Lube oil
backup
cooler
HT backup
cooler (option)
Electricity
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,
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
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.
6. COGEN FOR MAXIMUM STEAM GENERATION
Steam
consumer
CAC 1 and 2
Burner
Electricity
1-stage
absorption
chiller
CAC1/
jacket water
Lube oil cooler
95-105 °C
80-90 °C
70-105 °C
45-55 °C
Circulation pump
Hot water
or district
heating
Electricity
7 °C
12 °C
Chilled water
or district cooling
Boiler
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%
TRI-GENERATION
Typical tri-generation solution for airports
7. ENGINE TECHNOLOGY
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....................... 96.45%
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
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
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.
8
8. The Wärtsilä 20V34SG engine featuresthe
latest design in gas technology.
9
Wärtsilä reciprocating gas engines offer
stable output and high performance in hot
and dry conditions. No water consumed for
plant cooling = remote area suitability!
0.8
0.85
0.9
0.95
1
1.05
15 20 25 30 35 40 45
Ambient temperature (°C)
Industrial gas turbine
Wärtsilä 20V34SG
(radiator cooling)
Aeroderivate gas turbine
Source: GE Ger-3567 Ger-3695; Wärtsilä perf
Derating due to cooling water temperature.
(Derating due to inlet air temperature starts at 45 °C)
Deratingfactor
Air intake and gas injection in the
pre-chamber and intake manifold
Compression of gas/air mixture Ignition in pre-chamber
Exh. Air Exh. Air Exh. Air
SG PRINCIPLE
Air intake and gas injection Compression of gas/air mixture Pilot fuel injection and ignition
Exh. Air Exh. Air Exh. Air
DF PRINCIPLE
Air intake Compression of air Injection of diesel fuel and ignition
Exh. Air Exh. Air Exh. Air
DIESEL PRINCIPLE
9. 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.
Wärtsilä Operations Maintenance currently
runs more than 130 plants around the world,
GYÖR, HUNGARY
Type of customer..............Municipality
Engine type........ 3 x Wärtsilä 18V34SG
Total electrical output.............19 MWe
Total heat output.................16.4 MWth
Total efficiency.......................... 82.9%
making it the world’s leading power plant OM
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.
10
11. THIS IS NOT THE FUTURE.
THIS IS TODAY.
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.
12
12. 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....................................33600 kWe
Total heat output.........................................24,000 kWth
Total absorption cooling output ......................18,000kWc
Total efficiency........................................................74%
Academisch Medisch Centrum (AMC),
The Netherlands
In June 2005 the AMC hospital ordered three Wärtsilä
dual-fuel engine driven generator sets to secure the
supply of energy to the largest hospital in Amsterdam.
Island operation: emergency power supply with excellent
load-step response of the gas engines due to the cylinder-
specific fuel gas injection.
Parallel operation with the public grid: combined heat and
power supply with superior fuel efficiency.
In general, this baseload plant provides high fuel efficiency,
emergency power, fuel flexibility and a good return on
investment.
Engines:........................................3 x Wärtsilä 12V32DF
Total electrical output:..................................12,273 kWe
Total heating output:....................................12,000 kWth
Total absorption cooling output:........................2600 kWc
1
13. Wärtsilä 50DF
GAS ENGINES
Wärtsilä 34SG
DUAL-FUEL ENGINES
Wärtsilä 32DF
LIQUID FUEL
(LFO, HFO, CRO, LBF, Emulsified)
Wärtsilä 20
Wärtsilä 32
Wärtsilä 46
LFO = light fuel oil
HFO = heavy fuel oil
CRO = crude fuel oi
LBF = liquid bio fuell
MW 1 5 10 50 100 200 300
Boiler and absorption chillers at
Madrid’s Barajas airport, Spain.
POWER PLANT OUTPUT RANGE
14
14. Performance data as guidelines for CHP calculations
Wärtsilä liquid fuelled generating sets at 50 and 60 Hz
Engine 12V32 16V32 18V32 20V32 12V46 18V46
Frequency Hz 50 60 50 60 50 60 50 60 50 60 50 60
Electric power kW 5327 5211 7124 6970 8032 7841 8924 8730 11349 11349 17076 17076
Heat rate 1) kJ/kWh 7986 7901 7961 7877 7944 7877 7818 7818 7692 7692 7669 7669
Electrical efficiency 1) % 45.1 45.6 45.2 45.7 45.3 45.7 46.0 46.0 46.8 46.8 46.9 46.9
High-temperature cooling water circuit 2) °C 82/96 83/96 82/96 83/96 82/96 83/96 80/96 80/96 81/91 81/91 81/91 81/91
High-temperature cooling water circuit, heat power ± 10% kW 1573 1506 2072 1984 2300 2196 2994 2916 3098 3125 4650 4692
High-temperature charge
air cooler, water 2)
–
°C 89/96 89/96 89/96 89/96 89/96 89/96 87/96 88/96 84/91 84/91 84/91 84/91
High-temperature charge
air cooler, heat power
–
± 10% kW 845 807 1102 1052 1209 1149 1597 1536 1992 2019 2990 3032
Jacket cooling water 2)– °C 82/89 83/89 82/89 83/89 82/89 83/89 80/87 80/88 81/84 81/84 81/84 81/84
Jacket cooling, heat power– ± 10% kW 728 699 970 932 1091 1047 1397 1380 1106 1106 1660 1660
Low-temperature cooling water circuit 2) °C 35/46 35/46 35/46 35/45 35/46 35/46 35/46 35/46 35/47 35/47 35/48 35/48
Low-temperature cooling water circuit, heat power ± 10% kW 1263 1212 1688 1619 1899 1817 2118 2056 2519 2534 3797 3820
Lubricating oil 2)– °C 63/74 63/74 63/74 63/74 63/74 63/74 63/74 63/74 63/78 63/78 63/77 63/77
Lubricating oil, heat power– ± 10% kW 640 620 853 826 960 929 1083 1067 1473 1473 2210 2210
Low-temperature charge
air cooler, water 2)
–
°C 35/40 35/40 35/40 35/40 35/40 35/40 35/41 35/40 35/40 35/40 35/41 35/41
Low-temperature charge
air cooler, heat power
–
± 10% kW 623 592 835 793 939 888 1035 989 1046 1061 1587 1610
Charge air flow ± 5% kg/s 10.9 10.3 14.5 13.7 16.3 15.4 17.0 16.2 19.7 20.0 29.5 30
Exhaust gas flow ± 5% kg/s 11.2 10.6 14.9 14.1 16.8 15.8 17.5 16.7 20.3 20.6 30.5 30.9
Exhaust gas temperature ± 10°C °C 348 350 348 350 348 350 346 351 374 369 374 369
Exhaust gas heat power 3) ± 10% kW 3846 3687 5094 4865 5762 5541 5729 5635 7845 7803 11806 11741
Heat power losses by radiation ± 15% kW 398 394 564 574 617 617 584 570 651 651 864 864
Note:
Heat and mass balances dependent of ambient conditions and plant application. The above figures are for guidance only and
calculated at ISO 3046-1 standard reference conditions: 25°C ambient temperature. 100 kPa total barometric pressure. 30%
relative humidity. Charge air coolant temperature according to tabulated data. Lower Heating Value 42700 kJ/kg.
1) Heat rate and electrical efficiency at generator terminals, including engine-driven pumps, Tolerance 5%. Power factor 0.8.
2) inlet / outlet temperatures
3) In reference to ambient temperature
Performance data as guidelines for CHP calculations
Wärtsilä gas fuelled generating sets at 50 and 60 Hz
Engine 9L34SG 16V34SG 20V34SG 18V32DF 18V50DF
Gas mode LFO mode Gas mode LFO mode
Frequency Hz 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60
Engine optimization:
NOX (dry @ 5 vol-% O2)
mg/Nm3 250 250 500 500 250 250 500 500 250 250 500 500 500 500 500 500
Electric power kW 3888 3758 3888 3758 6970 6737 6970 6737 8730 8439 8730 8439 6080 5819 6080 5819 16621 16621 16621 16621
Heat rate 1) kJ/kWh 8065 8065 7817 7817 7999 7999 7753 7753 7982 7982 7737 7737 8074 8074 8201 8201 7616 7616 8184 8184
Electrical efficiency 1) % 44.6 44.6 46.1 46.1 45.0 45.0 46.4 46.4 45.1 45.1 46.5 46.5 44.6 44.6 43.9 43.9 47.3 47.3 44.0 44.0
Engine cooling water circuit 2) °C 38/67 38/66 38/65 38/64 38/69 38/68 38/67 38/66 38/70 38/70 38/68 38/67 37/59 37/58 37/63 37/62 37/69 37/69 37/79 37/79
Engine cooling water circuit,
heat power
± 10% kW 2012 1942 1894 1832 3558 3451 3357 3252 4445 4291 4187 4052 3120 2984 3809 3655 7363 7363 9576 9576
High-temperature charge
air cooler, water 2)
–
°C 46/60 46/59 46/58 45/57 47/61 47/60 47/59 46/58 48/62 47/61 47/60 47/59 43/52 43/51 44/55 44/55 47/60 47/60 51/68 51/68
High-temperature charge
air cooler, heat power
–
± 10% kW 948 924 839 817 1614 1576 1432 1395 1971 1925 1750 1707 1267 1217 1648 1595 2886 2886 3837 3837
Jacket cooling water 2)– °C 86/91 86/91 86/91 86/91 86/91 86/91 86/91 86/91 85/91 85/91 85/91 85/91 87/91 87/91 86/91 87/91 86/91 86/91 85/91 85/91
Jacket cooling, heat power– ± 10% kW 504 486 513 495 890 860 910 880 1120 1080 1140 1100 952 913 1154 1105 2129 2129 2512 2512
Lubricating oil 2)– °C 63/71 63/70 63/71 63/71 63/73 63/72 63/73 63/72 63/74 63/73 63/74 63/73 62/74 62/74 62/75 62/74 62/74 62/74 62/78 62/78
Lubricating oil, heat power– ± 10% kW 414 396 419 405 730 710 740 720 920 880 930 900 729 700 750 720 1544 1544 1940 1940
Low-temperature charge
air cooler, water 2)
–
°C 38/40 38/40 38/40 38/40 38/41 38/41 38/40 38/40 38/41 38/41 38/41 38/41 37/38 37/38 37/39 37/39 37/41 37/41 37/43 37/43
Low-temperature charge
air cooler, heat power
–
± 10% kW 146 136 123 115 324 305 275 257 434 406 368 345 172 154 257 235 804 804 1287 1287
Charge air flow ± 5% kg/s 6.9 6.7 6.4 6.2 12.3 11.9 11.5 11.1 15.3 14.8 14.3 13.8 9.9 9.4 11.7 11.2 26.4 26.4 32.6 32.6
Exhaust gas flow ± 5% kg/s 7.1 6.8 6.6 6.4 12.6 12.2 11.8 11.4 15.7 15.2 14.7 14.2 10.2 9.7 12.0 11.5 27.2 27.2 33.5 33.5
Exhaust gas temperature ± 10°C °C 375 375 390 390 375 375 390 390 375 375 390 390 397 397 357 357 402 402 365 364
Exhaust gas heat power 3) ± 10% kW 2976 2878 2813 2719 5302 5117 5013 4843 6640 6417 6270 6058 4666 4470 4202 4014 12068 12068 12609 12609
Heat power losses by radiation ± 15% kW 270 263 270 261 430 413 420 403 510 501 510 491 451 431 451 431 869 869 869 869
Note:
Heat and mass balances dependend of ambient conditions and plant application. The above figures are for guidance only and
calculated at ISO 3046-1 standard reference conditions: 25°C ambient temperature. 100 kPa total barometric pressure. 30%
relative humidity. Charge air coolant temperature according to tabulated data.
Natural gas (Lower Heating Value 35300 kJ/Nm3).
Gas Methane Number 80. LFO (Lower Heating Value 42700 kJ/kg). Nm3 defined at NTP (273.15 K and 101.3 kPa)
1) Heat rate and electrical efficiency at generator terminals, including engine-driven pumps, Tolerance 5%. Power factor 0.8.
2) Single-circuit cooling system, inlet / outlet temperatures
3) In reference to ambient temperature
15
