Report

Title: Evaluation of ORC/steam turbine cycle DocID: DAAB525315

and ? with KTH
Revision: -.3
Created by: Anders Ahnger / 16-Nov-2005 Status: Draft
Draft by: Anders Ahnger / 16-Nov-2005 Pages: 1 (1)
Power Plants Project: IN023 - WFI-P PPTECH
Description:

Projekt for KTH studenter

1) Organic Rankin Cycle (ORC) fr gas motordrivna kraftvrmeanlggningar

Bakgrund: Wrtsil levererar idag ca. 50 gasmotordrivna kraftverk per r. Gas motorerna som
anvnds r Wrtsil 20V34SG p 8,7 MWe eleffekt eller Wrtsil 18V50DF p 16,6
MWe eleffekt. Antalet motorer per kraftverk varierar i allmnhet mellan 1-6 st. och r
beroende p kundens nskeml. Fr att ka kraftverksinvesteringens lnsamhet och i
lnder med hgt el-pris evalueras ofta mjligheter till tillggsgenerering av el med att
utrusta motorkraftverket med en ngturbincykel, dr motorernas avgas- och andra
rest-energier utnyttjas. P senare tid har ven Organic Rankin Cycle (ORC) tekniken
kommit starkt in i bilden och leverantrer av denna teknik pstr att ORC:n r en
bttre lsning n den konventionella ngturbincykeln speciellt fr mindre kraftverk, typ
Wrtsils gasmotorer med relativt lga temperaturer p motorns restvrmeflden.

Frgestllning: Wrtsil br veta mera om ORC tekniken, veta i vilka fall den kan anvndas, nr den
r konkurrenskraftig gentemot en ngturbincykel och veta i vilka fall denna teknik kan
rekommenderas fr kunder (ett klart stllningstagande i frgan). Wrtsil skall ven
kunna offerera dylik teknik som en del av en kraftverksleverans samt veta vilka
relevanta leverantrer finns p marknaden.

Utgngslge: Som bas fr evalueringen tas tv olika kraftverkalternativ, a) kraftverk med 2 stycken
W20V34SG motorer b) kraftverk med 3 stycken W18V50DF. Tekniska data p
motorerna finns p Wrtsils Internet sidor. Tekniska data p ngcykeln samt ORC:n
mste skas hos leverantrer fr utrustningen. Evalueringen grs s att ORC tekniken
jmfrs tekniskt och ekonomiskt med den vanliga ngturbincykeln fr de tv
alternativa kraftverken.

Mlsttning: Mlsttningen fr Wrtsil r att f ett grepp p vilka r de kriterier som br uppfyllas
fr att ORC tekniken kan fredras gentemot ngturbincykeln.

Wrtsil-kontakt: Thomas Stenhede, thomas.stenhede@wartsila.com, Anders Ahnger,

anders.ahnger@wartsila.com
 Gas Engine & CHP Plants

Anders Ahnger
General Manager
Combined Heat & Power

Wrtsil
 The Gas Engines

Wrtsil 2
 Wrtsil 34SG
Wrtsil Gas Engine Portfolio 2004:
Type Output 50Hz Output 60 Hz
SG engines: 12V34SGA 3995 kWe 3821 kWe
18V34SGA 5993 kWe 5732 kWe
(9R34SGB 3925 kWe 3800 kWe)
16V34SGB 6984 kWe 6752 kWe
20V34SGB 8730 kWe 8440 kWe
DF engines: 18V32DF 6080 kWe 5819 kWe
18V50DF 16638 kWe 16638 kWe
GD engines 12V32GD 4339 kWe 4282 kWe
16V32GD 5808 kWe 5731 kWe
18V32GD 6534 kWe 6447 kWe

SG = Spark Ignited, lean-burn (otto principle) & low pressure natural gas engine
DF = Pilot Fuel Ignited, lean burn (otto principle) & low pressure natural gas engine
GD = Dual Fuel Diesel engine (diesel principle) & high pressure gas
Wrtsil 3
 SG engine BMEP development

W34SGB
450 kW/cyl

345 kW/cyl 400 kW/cyl

W34SGA
315 kW/cyl

W25SG

Wrtsil 4
 SG engine efficiency development

W34SGB

W34SGA

W25SG

Wrtsil 5
 Wrtsil 34SG

Wrtsil 20V34SG Engine Design

Based on the new Wrtsil 32
diesel engine
Combustion technology same
as the well proven 18V34SG
Reliability and easy
maintenance in focus
Integrated channels for
Lubricating Oil and Cooling
Water
On engine built Lubricating oil
module ( pumps, heat
exchanger, filters etc)
Designed for modern
manufacturing methods

Wrtsil 6
 Wrtsil 18V34SG & 20V34SG

Main technical data W18V34SGA W20V34SGB

Cylinder bore 340 mm 340 mm

Piston stroke 350 mm 400 mm

Engine speed 720/750 rpm 720/750 rpm

Mean piston speed 8.4/8.75 m/s 9.6/10.0 m/s

Mean effective pressure 17.4 bar 19.8 bar

Engine output 5940 / 6210 kW 8700 / 9000 kW

Wrtsil 7
 Wrtsil 18V34SG & 20V34SG

!" !" !"

**
****** * *
***
** *
** *
*

Wrtsil 8
 Wrtsil 18V34SG & 20V34SG

Lean Burn Concept

Ported gas admission
Air/fuel mixture ignited by a spark
plug in the pre-chamber
Electrically controlled prechamber
gas duration W18V34SG
Mechanically controlled pre-
chamber gas duration
W20V34SG
Electronically controlled gas valves
for main gas duration
Individual and cylinder wise control
of combustion

Wrtsil 9
 Prechamber gas admission
# # $%
&
"
! ' "
"

Maintenace interval 1000 h (cleaning) Maintenace interval > 4000 hours

Wrtsil 10
 Main gas valve location

W18V34SGA W20V34SGB

Wrtsil 11
 WECS - Engine control system

cylinder
control modules
Sensors Main cabinet
connected
to IOM
module(s)
Ethernet (&
profibus) to
ext. systems

CAN-bus

IOM in/out module(s)

H:\PDFOL\W34SG\34-9625.PPT - Ud 21.10.1996 (Updated 10.03.1998 Ud)

Wrtsil 12
 Wrtsil 18V34SG

( )

Wrtsil 13
 Wrtsil 20V34SG

( )
Engine compression ratio 12.0:1 High efficiency Low NOx

Heat rate at generator kJ/kWh 8265 8120 8455 8360

Electrical efficiency % 43.6 44.3 42.6 43.1
NOx ( as NO2) mg/m3N at 5 % O2, dry 500 500 250 250
CO mg/m3N at 5 % O2, dry 750 750 1200 1200
THC ( as CH4) mg/m3N at 5 % O2, wet 1500 1500 2500 2500

Engine compression ratio 11.0:1

Heat rate at generator kJ/kWh 8510 8300 8710 8550

Electrical efficiency % 42.3 43.4 41.3 42.1
NOx ( as NO2) mg/m3N at 5 % O2, dry 500 500 250 250
CO mg/m3N at 5 % O2, dry 750 750 1200 1200
THC ( as CH4) mg/m3N at 5 % O2, wet 1200 1200 2200 2200

# $ !% & % $ ' ' ( ) * ' $ * + , - . / ' * + 0

Wrtsil 14
 Combined Heat & Power, CHP

* " + , - .* + ,/

* 0, 0 0 1

Wrtsil 15
 Wrtsils CHP plants

2 ( *+ ,
- 0 " 1
+ (( 1
3 4 ( - 0 - 0
- 0 1
( (( ((
5 6 "
& 7 0(
" 7 8 ( - 0 ( )
- (
& " ( 7 '
5 ( - (

Wrtsil 16
 Combined Heat & Power, CHP

Power plant for pure power production

Performance W18V34SG:
Power output: 6000 kWe
Electrical efficiency: 44%

Wrtsil 17
 Combined Heat & Power, CHP

Energy sources available for heat recovery

The Customers requirements & needs

Engine heat balance - To be checked !
Steam, hot water, chilled water,
Exhaust gas at ~400 C / 32 -33 % thermal oil or desalination?
Heat load versus el-load ?
Jacket water at ~90 C / 6,6 %
What kind of industrial process ?
HT charge air at ~100 C / 4,7 %
Existing boilers & equipment ?
Lubrication oil at ~60 C / 5,1 %
Intended running philosophy &
LT charge air at ~40 C / 3,6 % Control Philosophy ?
Generator cooling at~35 C / 1,5 % Pressures, pressure variations ?
Temperatures, temperature
variations ?
Can the engine low grade energy
The Heat Recovery
be used ?
System
etc.
- Optimised to the
customers process
requirements

Wrtsil 18
 Combined Heat & Power, CHP

CHP plant for power, steam

Performance: W18V34SG
Power output: 6000 kWe % $
* + 2
Electrical efficiency: 43.4%
Steam 9 bar sat: 3.6 ton/h
% $
Hot water 90/50 C: 2350 kWth 1 $*

Total efficiency: 77%

- 2 * . * $ 3 $
* * * + 2

) # )
4

Wrtsil 19
 Combined Heat & Power, CHP

CHP, Hot Water generation & District Heating

!"# $
# % & ' ! # $

Natural gas
Electricity input
output Central DH-
heat consumers
exchanger
Charge air
first stage

Lube oil

Charge air
second stage

Cooling radiator

Wrtsil 20
 Combined Heat & Power, CHP

Optimal heat recovery of a hot water CHP plant

Wrtsil 21
 Combined Heat & Power, CHP
Engine Aux. Module with Heat recovery, EAM + CHP module

Engine Auxilliary Module

(EAM)

CHP Module

Wrtsil 20V34SG

Wrtsil 22
 Combined Heat & Power, CHP
Tri-Generation (CHP)
! " # !
$ !% & " ' ! " " () $ * &
"$ !! & * +
"$ " !
, - " # ( $ . "$ !! & * & #
!" " ( * ) /" !" " ( !& &
0 % & " 1( & ($ * & " $ (
2 $ 3 & 42 3 5 1 % "$ !! "$ !! & * % & " )
$ * & #
61 % "$ !! 7 "" & 89 : % ;& &4 # <"
5< , ; "$ !! & &" # & 1( & (" % "$ !!
"$ !! & * <
(% " ! %%! " &"
6 % ) = != 1 %
> & ( $ " !. ! )? &. 3 * () ,$ " " !. @ & " )
% . !" "
A " " %! / ) $ %% & @ !!
"<
Wrtsil 23
 Combined Heat & Power, CHP
Typical Tri-generation system for Airports
Generating set Primary loop Secondary loop
7C
Three Products:
Cold
water Electricity and
storage
power
12C

District cooling Chilled water or

120C Absorption district cooling
chiller

Hot water or
Boiler
district heating
70-80C

CAC1/
80-100C
jacket water

District heating
Lubricating oil

45-55C

Optimized for engine and 120C Circulation pump

Always in Wrtsils Usually in Wrtsils Often in Wrtsils scope

scope scope

Wrtsil 24
 Gas & CHP plants

1 ,

Wrtsil 25
 Wrtsil 18V34SG & 20V34SG

Wrtsil 34SG Gensets

Principle genset dimensions (mm) and weights (tonnes)

Engine A B C D E Engine Genset
type weight weight
W20V34SG 12666 3300 4909 1845 3064 76.4 137.5
W16V34SG 11692 3300 4909 1845 3064 66,5 115,0
18V34SG 11780 2780 4770 1850 2920 58,0 100,0
Wrtsil 26
 Wrtsil 34SG

20V34SG generator set with auxiliary modules

Inlet air/ exhaust gas module

Auxiliary module
Engine genset

Wrtsil 27
 Wrtsil 34SG
+ 30000

Type lay out for 2x20V34SG CHP plant

Section Expansion
vessel Radiator

+14700 Exhaust gas

silencer
Oxidation catalyst
+12500

Ventilation unit

Space for Rupture

SCR Disc
reactor
Oil wetted
charge air filter +5800
Exhaust gas
boiler

Ventilation
Charge air unit
silencer
000

Engine
CHP- Engine-Generator set
auxiliary
module
module
2125
0
Wrtsil 28
 Wrtsil 34SG

Type lay out for 2x20V34SG CHP plant

Charge air Engine-Generator set
silencer
Ground floor Tackle 2 ton

Oil wetted
charge air filter

+235 Ventilation unit

3-way valve 0

+000

Gas regulating unit

18200

+1190
CHP module

Engine auxilary module

Tank area
LO tank (clean)
+1600
Maintenace water Switchgear room
tank
Space for heat
recovery +000
LO tank (dirty)
auxiliaries
Stair
hall Station transformer

2125
0

Wrtsil 29
 Wrtsil CHP plant

2 - ( )$ % *+ ,

Wrtsil 30
 Wrtsil 18V34SG & 20V34SG

9 (

Wrtsil 31
 Gas Engines

9 ( 0

Full engine output with

Methane Number of natural gases 55 to 90 (dep. on engine

optim.)
Ambient air temperature up to 40 oC (sea level)
Altitude > 2500 m (25C)
Gas feeding pressure > 4,5 bar(g)
Exhaust gas back pressure &
air inlet pressure drop up to 7 kPa

Above values can vary according to the engine optimization, compression ratio and gas quality

Wrtsil 32
 Gas Engines

Hot & Dry conditions

Wrtsil reciprocating engines offer stable output and high performance in hot and

dry conditions. No water consumed for plant cooling!

1.05
Derating due to cooling
water temperature.
Derating due to inlet air
temperature starts at 40C

1
20V34SG
(radiator cooling)

0.95
Derating factor

18V50DF
(radiator cooling)

0.9
Aeroderivate Gas turbine
No water consumption with
radiator cooling!
0.85

Industrial Gas turbine

0.8
15 20 25 30 35 40 45
Ambient temperature [C]
Source: GE Ger-3567 Ger-3695; Wrtsil perf

Wrtsil 33
 Gas Engines

High Altitude

Wrtsil reciprocating engines offer stable output and high performance high

altitudes as well.
1.1

1.05

1
18V50DF
(radiator cooling)
0.95
20V34SG
18V32GD
(radiator cooling)
Derating factor

(radiator cooling)
0.9

0.85

0.8
Industrial Gas turbine

0.75

0.7
Aeroderivate Gas turbine

0.65
0 500 1000 1500 2000 2500 3000
Altitude [m]
Source: Termoflow calculation program; Wrtsil perf

Wrtsil 34
 Gas Engines

Part Load Performance

The high part load efficiency of one unit if further improved in multi-unit installations.

45%

40%
5 x 20V34SG
35%
Industrial GT
Electrical efficiency (%)

30%

25%

20%

15%

10%

5%

0%
0 5 10 15 20 25 30 35 40
Plant Electrical Power (MW)
Source: Alstom product broschure 01; Wrtsil perf

Wrtsil 35
 Gas Turbine vs. Gas Engine

Gas turbine and gas engine ageing influence on performance

%
Heat rate change

3
Industrial gas turbine

GT Major GT Hot section

2
GT Hot section overhaul overhaul
overhaul LM2500
1

Wrtsil gas engine

0
0 10000 20000 30000 40000 50000 60000 70000 80000 90000
Running
Gas engine
hours [h]
-1 overhaul
Output will
Output change

remain
-2 unchanged
for gas LM2500
engines
-3

-4

-5

Industrial gas turbine

-6 Source: GE GER-3965/GER-4208; Wrtsil

Wrtsil 36
 Gas Engines

Start-up times

Every unit in a reciprocating engine plant has the flexibility to operate in peaking,

back-up and reserve power markets, making fast production changes possible.

Typical start-up procedure with 20V34SG

100 1000

90 900

80 800

70 700

60 600

Speed (rpm)
Load (%)

50 500

40 400

30 300

20 200

10 100

0 0
0 1 2 3 4 5 6 7 8 9 10
Time (min)

Load Speed

Wrtsil 37
 Operations & Service

3 0 2 (

-0 0 1

Wrtsil 38
 Service Products

Service Agreements Field Service Workshops Technical Support

Training O&M Systems OEM Parts Upgrades

Wrtsil 39
 Lifecycle cost

Levelised unit cost split

Insurance
Example case: cost
Interest
100 MW Power Plant
over 15 years ROE

Fuel cost
Loan
repayment

O&M cost

Wrtsil 40
 Service schedules
Job & Service times 1 x Wrtsil 34SG / 8000 hours/year
Men Total No. Tot. service
Interval Description req. time of jobs time

50 Various interval 50h jobs 1 1,50 2 400 3 600,0

50 Water cleaning of compressor 1 0,38 2 400 900,0
500 Take oil Sample (engine) 1 0,75 240 180,0
500 Check water quality 1 1,50 240 360,0
1 000 Regrease prelubricating oil pump 1 0,15 120 18,0
1 000 Cleaning of TC air filters 1 3,00 120 360,0
1 000 Clean and check the condition of the ignition coil 1 1,50 120 180,0
1 000 Replace spark plugs 1 1,50 120 180,0
2 000 Regrease the drive shaft of turning device 1 0,15 60 9,0
2 000 Change lubricating oil 1 9,00 60 540,0
2 000 Check valve clearances 1 7,50 60 450,0
: : : : : :

48 000 Check flexible coupling, replace spring packs 2 30,00 2 60,0

48 000 Check flexible elements of engine foundation 1 3,24 2 6,5
64 000 Replace piston 1 90,00 1 90,0
96 000 Replace cylinder head 1 45,00 1 45,0
96 000 Replace cylinder liners 1 15,00 1 15,0

Wrtsil 41
 Service schedules
Maintenance costs 1 x Wrtsil 20V34SG / 8000 hours/year
Labour
Cost /Euro Spare parts
1 000 000
900 000
800 000
700 000
600 000
500 000
1
400 000
300 000
200 000
100 000
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Year
Costs are based upon standard technical specification and are for
guidance only

Wrtsil 42
 Service schedules
Maintenance costs 1 x Wrtsil 20V34SG / 8000 hours/year

Running Spare part Labour Total Costs Costs /

hours costs costs costs per MWh Rh/eng
Year /MWh
Start up: 0
1 8 000 9 180 36 448 45 627 0,65 5,70
2 16 000 88 477 96 730 185 207 2,65 23,15
3 24 000 33 873 41 755 75 628 1,08 9,45
4 32 000 200 595 95 199 295 793 4,24 36,97
5 40 000 13 744 39 841 53 585 0,77 6,70
6 48 000 204 355 100 942 305 297 4,37 38,16
7 56 000 9 180 36 448 45 627 0,65 5,70
8 64 000 431 209 95 112 526 321 7,54 65,79
9 72 000 45 391 41 755 87 146 1,25 10,89
10 80 000 83 913 93 337 177 250 2,54 22,16
11 88 000 13 744 39 841 53 585 0,77 6,70
12 96 000 838 187 82 794 920 981 13,19 115,12
13 104 000 9 180 36 448 45 627 0,65 5,70
14 112 000 88 477 96 730 185 207 2,65 23,15
15 120 000 45 391 41 755 87 146 1,25 10,89
Summary 2 114 894 975 133 3 090 027 2,95 25,75

Costs are based upon standard technical specification and are for
guidance only
Wrtsil 43
 O&M Reference Projects

Cementos Diamante, Colombia

Main data:
MW capacity 25 MW
Prime movers 5 x 18V34SG
COD October, 1998
Term of O&M contract 15 years
Operational data in December 2004
Running hours 42000 h (mean value)
Efficiency (gross) 40,3 %
(net) 39,5 %
Availability 96,1 %
Reliability 99,2 %
Utilisation factor 97,8 %
Capacity factor 82,9 %
Load factor 88,2 %
(COD) Commercial Operation Date
Wrtsil 44
 O&M Reference Projects

Cementos Diamante, Colombia

Since the start of operation, the power

plant has provided the cement plant with
substantial savings in energy costs.

The power plant operates in parallel with

the grid but has the ability to run
independently should there be grid
problems.

Up to May 2004, the power plant has

operated 574 times in island mode due
the disturbances in grid supply.
This reliability in energy supply ensures
an uninterrupted cement production

Wrtsil 45
 Wrtsil 34SG references

Owner: PG&E National Energy Group

Location: Plains End, Colorado, USA
Engine: 20 x Wrtsil 18V34SG
Output: 111 MWe

COD of the project *) May 2002

Terms of O&M contract 5 years

*) (COD) Commercial Operation Date

Wrtsil 46
 Plains End

99,9
99,8
99,7
99,6
99,5
99,4
99,3
99,2
Jan Feb Mar Apr May Jun Jul Aug Sep Oct

Wrtsil 47
 Reference list W18V34SG

# #
First plant delivered 1995 to city of
Gram, Denmark. 1 x W18V34SG
Totally 72 Plants delivered with
184 engines, totally 1044 MWe
10 plants above 30 MWe size
43 CHP plants with 77 engines,
442 MWe
Biggest plant delivered: Plains End
in USA 20 x W18V34SG,
113,4 MWe (peaking)

Wrtsil 48
 Reference list W20V34SG

# # $%
8.73
! " 69.84
# $ % & ' ! ( ) (* ' # 118.146
# +! ' , ( - 8.69
# 17.46
# -. ) ! ) ( / 24.249
# $ . ) ( )0 & # 34.92
# $ . ,! ) 17.46
# $ . $( &!1 2 8.73
First plant
# $ . . !% 3! 4 8.69
# $ . & ( 5( 9
delivered 2001 to city
# $ . 6 ' 4$ 8.73
8.73
of Ringkping,1Denmark. 1 x W20V34SG
#
#
$
$
.
.
!
1
4
18
# 7$ . & ( ,7+ 8 9 / 19.995
Totally 28 plants with 78 engines, totally 662 MWe
/ $ . 1 1 / 25.5
/ + 4
! '! % 15.44
5 plants above
)
$
30 MWe size , !: ! * ;
=5
); + <, !: !
=5 (>4 % %?
7.3
8
@@@ + & ) 0 <A1' &+++ 7.8
19 CHP
TOTAL plants with 42 engines, 354 MWe
Engines 53 445.41 MW
Cylinders 1060
Biggest plant delivered: Berrick Goldstrike Inc. in USA14 x W20V34SG,
118,1 MWe (Base Load)
Wrtsil 49
 Wrtsil 34SG references

Owner: Ringkbing Fjernvarmevrk

Location: Ringkbing, Denmark
Engine: 1 x Wrtsil 20V34SG
Output: 8 MWe
CHP Power plant

Wrtsil 50
 Wrtsil 34SG references

Gyrh gas power plant in Hungary,

combined heat and power (CHP),
2 x Wrtsil 18V34SG,
Output: 12 MWe, 10.92 MWth,
Efficiency 82.9 %

Wrtsil 51
 Wrtsil 52