characteristics of wärtsiläpower plants · w20v32 cmpp, section view cmpp ... 100 200 300 plant...
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1 ©Wärtsilä Niklas Haga
“Energy innovation as Key Driver for responsibility”
LIQUID BIOFUELS and GAS
Philippine-Finland Society 22nd May 2012
Characteristics of Wärtsilä power plants
MultiMode operations•Base load
•Load following, wind chasing, peaking
•Regulation
•Fast reserve
Agility of dispatch•Megawatts to grid in 1 minute from start
•5/10 minutes to full load from start
•Fast shut down - 1 minute
•Fast ramp rates up & down
•Unrestricted up/down times
•High starting reliability
•Remote operator access including start & stop
•Black start capability
Low generation costs•High electrical efficiency
– High dispatch with low CO2
•Wide economic load range
– Multiple units
– Any plant output with high efficiency
•No derating - Higher dispatch
•Low maintenance costs, not influenced by cyclic operation
•Low/no water consumption
High plant reliability and availability•Typical unit availability > 96%
•Typical unit reliability ~ 99%
•Typical unit starting reliability > 99 %
Optimum plant location and size•Industrial outlook to the plant enables location inside load pockets i.e. cities
•Flexible, stepwise expandable plant size
– Same high performance independent of plant size
•Low pipeline gas pressure requirement (5 bar)
Fuel flexibility•Natural gas (with back-up fuel)
•Liquid fuels (LBF, LFO, HFO)
•Fuel conversions
Low environmental impact•Low CO2 and local emissions even when ramping and on part load
•The best thermal technology to provide sustainable grid stability
How Do We Serve Our Customers
25 April 2012
The Wärtsilä Engine Portfolio
Wärtsilä 20
1.0 – 1.6 MW
6 – 9 cylinders
Wärtsilä 46
Wärtsilä 50DF
11.7 – 17.6 MW
12 – 18 cylinders
Wärtsilä 50SG
19.3 MW
18 cylinders
Wärtsilä 46F
23 MW
20 cylinders
Wärtsilä 32
Wärtsilä 32GD
Wärtsilä 34DF
2.5 – 9.2 MW
6 – 20 cylinders
Wärtsilä 34SG
4.5 – 10 MW
9 – 20 cylinders
Three frame sizes of turbocharged, inter-cooled, heavy duty
medium speed engines.
25 April 2012
Summary of gas and dual fuel power plants
W34DF / W50DF CMPP
CMPP = Compact Modular Power Plant
W32GD / W46GD CMPPW34SG GAScube 8 – 30 MW
W50SG CMPP 20–500MWW34SG CMPP 100-300 MWW34SG CMPP 10-100 MW
53 MW Wärtsilä 6x20V32 Power Plant – 3D View
110000
196800
25 April 2012
W20V32 CMPP, SECTION VIEW
CMPP = Compact Modular Power
Plant25 April 2012
OilCube W32
Overhead
crane
Generator air
outlet duct
Engine maintenance
platform
Compressed air
units
The OilCube a fully pre-designed
power plant and optimized for a single engine
and lowest possible own consumption
25 April 2012
Wärtsilä 20 Containerised Power Plant
Stack
Cooling water
expansion vessel
Satellite antenna
(optional)
Radiator fans
Cooling elements
Generating
Set
Container
Auxiliary
Container
Alarm indicator
Radiator guide
vanes /
transportation
cover
Pipe connection
to Customer
systems
9
Auxiliary
containers
Generating
Set
Containers
Example of
multiple container
piping connection
Wärtsilä W20 Containerised Power Plant
1
Generating Set Container
LV switchgearW9L20 Engine
+ generator
Container leak fuel unit
Charge air filter and
ventilation unit
Genset container
module
Ventilation unit
1
Auxiliary Container
Radiator elements
W20 Power Skid
Ventilation unit
Radiator fans
Cable ladders
Radiator guide vanes /
transportation cover
1
13 ©Wärtsilä Niklas Haga
1970 1980 1990 2000 2010
Diesel Oil (LFO)
Heavy Fuel Oil (HFO)
Natural Gas (NG)
Crude Oil (CRO)
Liquid Biofuels (LBF)
Emulsified Fuels
High Viscosity HFO
Wärtsilä Fuel Versatility
14 ©Wärtsilä Niklas Haga
Wärtsilä Liquid Biofuel Power Plants
300200100
Plant size [MW]
501051
W20
W32
W46
LFO, HFO, CRO, LBF
LFO, HFO, CRO, LBF,
Emulsified Oils
LFO, HFO, CRO, LBF
LFO = Liquid Fuel Oil
HFO = Heavy Fuel Oil
CRO = Crude Oil
LBF = Liquid Bio Fuel
NG = Natural Gas
W34DF
W50DF
LFO, HFO, LBF, NG
LFO, HFO, LBF, NG
Fuel strategy
FOSSIL FUELS
RENEW
ABLE FUELS
LIQUID FUELS
Liquid Bio Fuels (LBF)
• Palm oil
• Jatropha oil
• Fish oil (tested)
• Chicken oil (tested)
In R&D phase
• Glycerol (tested)
• Algae
• Other animal Fats
• Ethanol
Heavy Fuel Oil (HFO)
• HFO1-Low S, ash etc.
• HFO2-High S, ash etc.
• NSER HFO (2009 >50%)
Light Fuel Oil (LFO)
Fuel Water Emulsions (FWE)
• FWE O/W (oil in water,visc)
• FWE W/O (water in oil,NOx)
Crude Oil (CRO)
• By nature compositions vary
GAS FUELS SOLID FUELS
Biogas
• MN > 90, LHV>17MJ/Nm3
Gasification gas (R&D)
• MN?, LHV> 4MJ/Nm3
Natural Gas (NG)
• MN >60, LHV>24MJ/Nm3
Associated Gas (AG)
• MN>30, LHV> 24MJ/Nm3
Coal Bed Methane (CBM)
• MN >90, LHV > 17MJ/Nm3
Coal Mine Ventilation Gas
• MN > 90, LHV > 17MJ/Nm3
MW Power fuel range
Fuels for gasifier (R&D)
• Wood based fuels
• Eucalyptus
Potential fuels (R&D)
• Bagasse
• Straw
• Rice husk
• Municipal solid waste (directives?)
• LBF residues (jatropha, palm oil)
25 April 2012 16 ©Wärtsilä Niklas Haga
1995. Engine test with wood pyrolysis oil on a Wärtsilä Vasa 4R32 engine at VTT in Espoo, Finland. The engine was able to operate on pyrolysis oil. The conclusion was that pyrolysis oil operation requires further R&D which was not justified based on the market outlook at that time.
Wärtsilä Renewable Fuel Milestones
1990 1995 2000 2005 2010
September 2001. A 50 hour engine test with waste vegetable oil from the food processing
industry on a Wärtsilä 6L26 engine at the test laboratory in Zwolle, Netherlands.
October 2002. A 18 hour verification test with refined palm oil, palm stearin and
olive olein on a Wärtsilä 6L32 engine at the engine laboratory in Vaasa, Finland.
April 1995. A 200 hour engine test with rapeseed oil on a Wärtsilä Vasa 4R32 engine was performed at VTT in Espoo, Finland. The test was successful and vegetable oil was approved as fuel for Wärtsilä diesel engines.
February-September 2009. Successful engine
tests with jatropha oil and animal based fish oil
and chicken oil on a Wärtsilä Vasa 4R32 engine
at VTT in Espoo, Finland.
Power plants in commercial operation
17 ©Wärtsilä Niklas Haga
Palm Oil
– Oil palm is Southeast Asia’s most rapidly expanding crop
– Palm oil is mainly used for food or in the food industry
– Over 85% of the production is in Asia (Indonesia and Malaysia), Africa and Latin America also harvest significant areas of oil palm
– The oil palm can yield 6000 litres of oil per hectare, average yield in Malaysia ~4000 litres/ha
– Malaysia and Indonesia are planning to set aside 40 % of their annual palm output for biofuel (biodiesel)
18 ©Wärtsilä Niklas Haga
Jatropha Oil
• Jatropha, or most typically the crop species
Jatropha Curcas L. (also called physic nut), is a
large shrub or tree producing oil containing seeds.
• Jatroha originates from Central America, but has
spread all over the world
• The Jatropha plant grows on marginal land with
more than 600mm rainfall per year, and it can
withstand long drought periods but can’t withstand
frost.
• The straight oil is pressed out of the seeds inside
the fruits.
• The oil is inedible
19 ©Wärtsilä Niklas Haga
Jatropha Oil
• The jatropha oil industry is still young
• There are huge variations in yield potential predictions, it is estimated to
be 1000..2200 litres per hectare per year depending on soil conditions,
climate, irrigation etc.
• Plantations are being started up in Africa, Asia and Latin America.
• The plantations reach maturity and full production in 3-4 years
• There is no commodity market for jatropha oil yet.
20 ©Wärtsilä Niklas Haga
IGE Block 1 (Pentesilea)
• Location: Monopoli, Italy
• Prime movers: 3 x Wärtsilä 18V32
• Output: 24 MWe
• Fuel: Liquid biofuel (Mainly palm oil)
• Steam is generated with exhaust gas boilers
for a olive oil refinery & biodiesel
production plant
• SCR is installed for NOx abatement
• The power plant started up in August 2004
– Engines 1 & 2 have over
40,000 operating hours
– Engine 3 has over 35,000 operating
hours since July 2005
– Availability > 95%
21 ©Wärtsilä Niklas Haga
IGE Block 2
Location: Monopoli, Italy
Prime movers: 6 x Wärtsilä 18V46 + Steam turbine
Output: 100 MWe (engines) + 11 MWe (turbine)
Fuel: Liquid biofuel (mainly palm oil)
Emission control: SCR NOx abatement
Operation of the 3 first engines started in January 2008
22 ©Wärtsilä Niklas Haga
Unigrà
• Location: Conselice, Italy
• Prime movers: 3 x W18V46 +
combined cycle
• Output: 50 MWel (engines) + 6
MWel (steam turbine)
• Fuel: Liquid biofuel (palm oil)
• Emission control: SCR NOx
abatement
• Handed over in September 2008
23 ©Wärtsilä Niklas Haga
Koekhoven
• Location: Merksplas, Belgium
• Prime mover: 1 x W20V32
• Output: 9 MWel + 7.5 MWth (Hot water)
• Main fuel: Liquid biofuel (Jatropha oil)
• Emission control: SCR NOx abatement
• The heat produced by the plant is supplied to:
– a drying facility for digested biomass recovered
from a manure fermentation plant
– a greenhouse producing tomatoes
• The 9 MW Wärtsilä 20V32 engine will provide
electrical power sufficient to serve
approximately 20,000 households
• The gross electrical efficiency is 44.2% and
an overall efficiency of more than 85%,
annual savings of CO2 will total more than
36,000 tons.
• Expected start up during Q4 2009
24 ©Wärtsilä Niklas Haga
Liquid Biofuel Refernces
Project Location Country Engine type MW Heat recovery Year sold
SFIR Brindisi Brindisi Italy W18V46 33.3 steam 2008
Merksplas Jatropha Merksplas Belgium W20V32 9 hot water 2008
SEA Molise Italy W20V32 9 CHP 2008
FATER 01 Pescara, Abruzzo region Italy W18V32 8.1 2008
Lepori Cairate Cairate Italy W18V32 8 CHP 2008
Cef la Gres 2000 Ostellato, Ferrara Italy W16V32 7.2 2007
Piano Lago Energia Figline Vegliaturo Italy W9L20 4.6 2007
STC Ferrero 1 Sant 'Angelo dei Lombardi Italy W20V32 16.8 2007
STC Ferrero 2 Balvano Italy W20V32 8.4 2007
CEG CASTELLANZA Castellanza, Lombardy Italy W18V46 51.2 2007
CEG PARMA Parma Italy W18V46 51.2 2007
SECA PIOMBINO Piombino, Tuscany Italy W18V32 24.1 2007
Ricciarell i piramide molfetta Molfetta Italy W18V32 8 CHP 2007
EUROPEA Isola Dovarese Italy W9L20 3.2 CHP 2007
Ricciarell i Alimonti Teverola Teverola Italy W18V32 8 CHP 2007
Ricciarell i Melfi Melfi Italy W18V32 8 CHP 2007
Ricciarelli Melfi extension Melfi Italy W18V32 16.1 CHP 2007
FERPOWER TREVIGLIO Treviglio Italy W6L20 1 2007
ItalGreen Molfetta Molfetta Italy W18V46 34.2 2007
Cerealdocks Portogruaro Portogruaro Italy W16V32 7.1 2006
Distercoop Faenza Faenza Italy W20V32 26.8 CHP 2006
Green Energy Pozzallo Pozzallo Italy W18V46 17.1 Combined Cycle 2006
PISTICHI PISTICCI Italy W18V32 12.1 CHP 2006
FRIEL ACERRA ACERRA Italy W18V46 68.3 Combined cycle 2006
Energy Care OCCIMIANO Italy 9R32LN 3.2 CHP 2006
Monopoli IGE BL-2 Monopoli Italy 18V46 102.5 Combined Cycle 2005
Unigra Conselice Italy 18V46 51.3 Combined Cycle 2005
I talian Alps ValSenales Italy 6L20 0.8 CHP 2005
Pentesilea extension Monopoli Italy W18V32 8 CHP 2004
Pentesilea Monopoli Italy W18V32 16 CHP 2003
KARLBURG Karlburg Germany W6L32 2.6 2002
VTT ESPOO ESPOO Finland 4R32 1.5 1994
Unconventional gases
Shale Gas
Overview
Coalbed Methane
Origin of the gas
Typical compositions and other parameters
Market Potential for Wärtsilä
Shale Gas – Overview
• Shale gas is in every way very similar to CBM, it is only found in shale
seams instead of coal seams
• Shale gases that tend to be “wet” (i.e. contain high amounts of higher
hydro carbons) have however also been reported
• The power production alternative is often referred to as ”gas by wire”
Shale is a fine-grained, clastic
sedimentary rock composed of
mud that is a mix of flakes of clay
minerals and tiny fragments (silt-
sized particles) of other minerals,
especially quartz and calcite.
Wikipedia
14.10.2010
Coalbed Methane - Origin
• The gas present in untapped coal
seams is called coalbed methane
• Most coalbeds are permeated with
methane but only certain ranks of coal
are suitable for CBM production
• Within coal seams, methane is present
on the surface of the solid material
• Wells similar to those drilled for natural
gas has traditionally been used
(vertical)
• Development of more advanced
drilling technologies (horizontal and in-
seam drilling) have led to an increase
in production rates
28 © Wärtsilä 23 May 2012 09-013 - Large gas plants.ppt / M. Wideskog
� Minimum cost, pre-designed, single engine power plant solution using:
� W20V34SG (16V34SG option)
� Targeted for power plants with 1…3 engines
� Features
� High electrical efficiency through minimization of plant own consumption
� Simple technical solutions
� 100% detail design
� No changes in the cube, options outside (tanks, switchgear-room etc.)
What is GasCube?
Wärtsilä GasCube
29 © Wärtsilä 23 May 2012 09-013 - Large gas plants.ppt / M. Wideskog
2 1. Maintenance water tank 3,2 m3
2. Starting air vessel 3,0 m3
3. Exhaust Gas Module
4. Cube Auxiliary Module
5. Wärtsilä 20V34SG gas engine
6. Generator
14
3
56
1
2
3
4
GasCube Mechanical Systems - inside
Wärtsilä GasCube CBM – Required fuel system changes
Compact gas ramp
-All materials of
Stainless steel
-Gas filter changed to
coalescing type
Shut off valves
-All materials of
Stainless steel
-Additional vent
valves neededGas compressor
-Designed for humid gas
-Coalescing filter at
compressor outlet
Gas Filter
-Designed for humid
gas
-Water and fine
particle removal
All piping down stream of compressor
shall be stainless steel
24 April 2012
1x 18V50SG in Aksa Samsun, Turkey
� Commercial operation since
5 August 2011
� 1 year test program defined
together with WIO
� Running hours >3000
� Some issues with
oCylinder pressure sensors
oPre chamber tip material
24 April 2012
Wärtsilä 18V50SG
Natural gas fuelled, spark ignited, lean-burn, medium-speed engine
50 Hz 60 Hz
Speed 500 rpm 514 rpm
Power 18321 kWel 18759 kWel
Emissions (NOx)(without back end cleaning)
90 ppm at 15% O2 dry (TA Luft)
45 ppm at 15% O2 dry (½ TA Luft)
24 April 2012
Engine technology as a function of gas quality
Methane
Number100 90 80 70 60 50 40 …
SG
DF
GD
Gas composition in %-vol (as guidance)
Methane C1 100 97 93 90 87 85 85
Ethane C2 3 5 6 7 7 8 x
Propane C3 2 3 3 4 3 x
Butane C4 1 2 2 1 x
Pentane C5 1 1 1 x
Hexane C6 1 1 x
Heptane C7 1 x
Gas composition values presented for guidance only!
N2 and/ or CO2 will improve Methane Number
Exact values to be calculated by Methane Number calculator
If gas content exceeds 1% >C4 contact PPT
Gas products and business / M. Wideskog34 © Wärtsilä 23 May 2012 09-013 - Large gas plants.ppt / M. Wideskog
The End
Thank you for your
attention!
Doc.ID: Revision: Status:1/ © Wärtsilä
Jatropha Oil
Thermal Energy Value of Jatropha Oil: 16,264 BTU/lb (37748 kJ/kg)Heat Rate of W20: 8561 kJ/kwhSpecific Fuel Consumption: 0.2267kg/KwhYield of Jatropha: 6 kg of seeds per plantNo. of plants per hectare: 1000 plantsTotal weight of Jatropha seed per hectare: 6000 kgsTotal Wt of Jatropha seed for 1000 hectares; 6,000,000 kgsOil contents of Jatropha seed: 35%No. of harvest per year: 2Total Jatropha Oil produced per year: 4, 200,000 kgsEffective Energy produced per year: 18,519,416 kwhNo of operating hours per yr: 8000 hrsEffective Power can be generated: 2314 kW
May 21, 2012 bingtomas22may2012
ASIAN INSTITUTE OF PETROLEUM STUDIES INC. Date : Sept. 22, 2007 Subject : LABORATORY ANALYSIS OF JATROPHA METHYL ESTER ( as Biodiesel ) Client : The Asian Institute of Petroleum Studies, Inc. (AIPSI) Notes : Jatropha Oil submitted by RS Diaz & FC Galindo of the Asian Institute of Petroleum Studies, Inc (AIPSI) to Chemrez Laboratories for testing. Jatropha nuts were supplied by PNOC- Alternative Fuel Corporation; mechanical oil extraction was
done by Technological University of the Philippines for AIPSI; esterification was done by Chemrez technologies, Inc.; Technical Analysis for fuel application done by AIPSI
Research Chemist: Glenn Apostol
- OFA – other fatty acids - Jathropa Oil is highly unsaturated (78.77%) with oxidation stability of less than 1 hour. - Other properties were not tested due to insufficient sample quantity. - Thermal Energy Value of Jatropha Seeds = 4,980 cal/g. at 0% moisture or 8,963 Btu/lb - Thermal Energy Value of Jatropha Oil = 9,036 cal/g. or 16,264 Btu /lb (slightly lower than Bunker C) The foregoing is proprietary data of the Asian Institute of Petroleum Studies, Inc. ( AIPSI ) and Chemrez Tech. Inc.: email: [email protected] or [email protected]
Properties
Expelled Oil
( Crude Oil )
Degummed, Neutralized
( Refined Oil )
Esterified Oil
( Jatropha Methyl Ester )
Appearance in liquid Slightly hazy yellow Clear orange Slightly hazy, light yellow Acid Value 5.58 0.14 0.70 %FFA As Oleic 2.81 0.07 0.35 Kinematic visc., 100ºC 7.11 8.13 1.87 Kinematic visc. at 40ºC 34.40 36.33 4.37 %Moisture 0.08 0.03 0.04 Iodine Value 100 100 100 CFPP, C +6 +4 -2 Cloud Point, C +8 +2 +1 Flash Point, C n/a n/a 165 %Total Glycerine n/a n/a 0.16 Carbon Distribution; C6:0 - - C8:0 - - C10:0 - - C12:0 - - C14:0 0.05 0.05 0.41 C16:0 14.45 14.45 14.21 Saturated C18:0 6.54 6.54 6.57 21.2% C18:1 46.14 46.14 46.63 C18:2 32.10 32.10 32..00 Unsaturated C18:3 0.25 0.25 0.14 78.8% OFA 0.47 0.47 0.04