projekt for kth · pdf filecan-bus ethernet (& profibus) to ext. systems ... altitude...

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

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) för gas motordrivna kraftvärmeanläggningar Bakgrund: Wärtsilä levererar idag ca. 50 gasmotordrivna kraftverk per år. Gas motorerna som

används är Wärtsilä 20V34SG på 8,7 MWe eleffekt eller Wärtsilä 18V50DF på 16,6 MWe eleffekt. Antalet motorer per kraftverk varierar i allmänhet mellan 1-6 st. och är beroende på kundens önskemål. För att öka kraftverksinvesteringens lönsamhet och i länder med högt el-pris evalueras ofta möjligheter till tilläggsgenerering av el med att utrusta motorkraftverket med en ångturbincykel, där motorernas avgas- och andra rest-energier utnyttjas. På senare tid har även Organic Rankin Cycle (ORC) tekniken kommit starkt in i bilden och leverantörer av denna teknik påstår att ORC:n är en bättre lösning än den konventionella ångturbincykeln speciellt för mindre kraftverk, typ Wärtsiläs gasmotorer med relativt låga temperaturer på motorns restvärmeflöden.

Frågeställning: Wärtsilä bör veta mera om ORC tekniken, veta i vilka fall den kan användas, när den är konkurrenskraftig gentemot en ångturbincykel och veta i vilka fall denna teknik kan rekommenderas för kunder (ett klart ställningstagande i frågan). Wärtsilä skall även kunna offerera dylik teknik som en del av en kraftverksleverans samt veta vilka relevanta leverantörer finns på marknaden.

Utgångsläge: Som bas för evalueringen tas två olika kraftverkalternativ, a) kraftverk med 2 stycken W20V34SG motorer b) kraftverk med 3 stycken W18V50DF. Tekniska data på motorerna finns på Wärtsiläs Internet sidor. Tekniska data på ångcykeln samt ORC:n måste sökas hos leverantörer för utrustningen. Evalueringen görs så att ORC tekniken jämförs tekniskt och ekonomiskt med den vanliga ångturbincykeln för de två alternativa kraftverken.

Målsättning: Målsättningen för Wärtsilä är att få ett grepp på vilka är de kriterier som bör uppfyllas för att ORC tekniken kan föredras gentemot ångturbincykeln.

Wärtsilä-kontakt: Thomas Stenhede, [email protected], Anders Ahnger,

[email protected]

© Wärtsilä

GasGas EngineEngine & CHP & CHP PlantsPlants

Anders AhngerAnders Ahnger

General General ManagerManagerCombinedCombined HeatHeat & & PowerPower

2© Wärtsilä

The Gas Engines

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3© Wärtsilä

Wärtsilä Gas Engine Portfolio 2004:

Type Output 50Hz Output 60 Hz

SG engines: 12V34SGA 3995 kWe 3821 kWe18V34SGA 5993 kWe 5732 kWe(9R34SGB 3925 kWe 3800 kWe)

16V34SGB 6984 kWe 6752 kWe20V34SGB 8730 kWe 8440 kWe

DF engines: 18V32DF 6080 kWe 5819 kWe18V50DF 16638 kWe 16638 kWe

GD engines 12V32GD 4339 kWe 4282 kWe16V32GD 5808 kWe 5731 kWe18V32GD 6534 kWe 6447 kWe

SG = Spark Ignited, lean-burn (otto principle) & low pressure natural gas engineDF = Pilot Fuel Ignited, lean burn (otto principle) & low pressure natural gas engineGD = Dual Fuel Diesel engine (diesel principle) & high pressure gas

Wärtsilä® 34SG

4© Wärtsilä

SG engine BMEP development

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W25SG

W34SGA

W34SGB450 kW/cyl

400 kW/cyl345 kW/cyl

315 kW/cyl

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SG engine efficiency development

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W25SG

W34SGA

W34SGB

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Wärtsilä 20V34SG Engine Design

Wärtsilä® 34SG

� Based on the new Wärtsilä 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

7© Wärtsilä

Wärtsilä 18V34SG & 20V34SG

Main technical data W18V34SGA W20V34SGB

Cylinder bore

Piston stroke

Engine speed

Mean piston speed

Mean effective pressure

Engine output

340 mm

350 mm

720/750 rpm

8.4/8.75 m/s

17.4 bar

5940 / 6210 kW

340 mm

400 mm

720/750 rpm

9.6/10.0 m/s

19.8 bar

8700 / 9000 kW

8© Wärtsilä

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� Lean Burn Concept

� Ported gas admission

� Air/fuel mixture ignited by a spark plug in the pre-chamber

� Electrically controlled prechambergas duration – W18V34SG

� Mechanically controlled pre-chamber gas duration –W20V34SG

� Electronically controlled gas valves for main gas duration

� Individual and cylinder wise control of combustion


10© Wärtsilä

Prechamber gas admission

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

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Main gas valve location

W20V34SGBW18V34SGA

12© Wärtsilä

WECS - Engine control system

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

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CAN-bus

Ethernet (&profibus) toext. systems

Main cabinet

IOM in/out module(s)

cylindercontrol modules

Sensorsconnectedto IOMmodule(s)

13© Wärtsilä

Wärtsilä 18V34SG

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14© Wärtsilä

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

Engine compression ratio 12.0:1 High efficiency Low NOx

Heat rate at generator kJ/kWh 8265 8120 8455 8360Electrical efficiency % 43.6 44.3 42.6 43.1NOx ( as NO2) mg/m3

N at 5 % O2, dry 500 500 250 250CO mg/m3N at 5 % O2, dry 750 750 1200 1200THC ( 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 8550Electrical efficiency % 42.3 43.4 41.3 42.1NOx ( as NO2) mg/m3N at 5 % O2, dry 500 500 250 250CO mg/m3N at 5 % O2, dry 750 750 1200 1200THC ( as CH4) mg/m3N at 5 % O2, wet 1200 1200 2200 2200

Wärtsilä® 20V34SG

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Combined Heat & Power, CHP

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Wärtsiläs CHP plants

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Performance W18V34SG:

Power output: 6000 kWe

Electrical efficiency: 44%

Power plant for pure power production


18© Wärtsilä

Engine heat balance

� Exhaust gas at ~400 °C / 32 -33 %� Jacket water at ~90 °C / 6,6 %� HT charge air at ~100 °C / 4,7 %� Lubrication oil at ~60 °C / 5,1 %� LT charge air at ~40 °C / 3,6 %� Generator cooling at~35 °C / 1,5 %

The Customers requirements & needs - To be checked !

� Steam, hot water, chilled water, thermal oil or desalination?

� Heat load versus el-load ?� What kind of industrial process ? � Existing boilers & equipment ?� Intended running philosophy &

Control Philosophy ?� Pressures, pressure variations ?� Temperatures, temperature

variations ?� Can the engine low grade energy

be used ?� etc.

Energy sources available for heat recovery

The Heat Recovery The Heat Recovery SystemSystem

-- Optimised to the Optimised to the customers process customers process

requirementsrequirements


19© Wärtsilä

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CHP plant for power, steam

Performance: W18V34SG

Power output: 6000 kWe

Electrical efficiency: 43.4%

Steam 9 bar sat: 3.6 ton/h

Hot water 90/50 C: 2350 kWth

Total efficiency: 77%


20© Wärtsilä

� � � � � � � �� ! " # $ ��

# % & ' ! � # $

Electricityoutput

Natural gas input

Charge air second stage

Cooling radiator

Charge airfirst stage

Lube oil

DH-consumers

Central heat

exchanger

CHP, Hot Water generation & District Heating


21© Wärtsilä

Optimal heat recovery of a hot water CHP plant


22© Wärtsilä


Engine Aux. Module with Heat recovery, EAM + CHP module

Wärtsilä 20V34SG

Engine Auxilliary Module(EAM)

CHP Module

23© Wärtsilä

Tri-Generation (CHP)� �� !�� "��#�� !��

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Absorption chiller

Generating set

Boiler

CAC1/jacket water

Lubricating oil

120°C

7°C

12°C

70-80°C

80-100°C

District cooling

District heating

45-55°C

Circulation pump

Primary loop Secondary loop

Optimized for engine and 120°C

Cold water

storage

Typical Tri-generation system for Airports

Always in Wärtsilässcope

Usually in Wärtsilässcope

Often in Wärtsiläs scope

Three Products:

� Electricity and power

� Chilled water or district cooling

� Hot water or district heating


25© Wärtsilä

Gas & CHP plants

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26© Wärtsilä

Principle genset dimensions (mm) and weights (tonnes)

Enginetype

A B C D E Engineweight

Gensetweight

W20V34SG 12666 3300 4909 1845 3064 76.4 137.5

W16V34SG 11692 3300 4909 1845 3064 66,5 115,0

Wärtsilä 34SG Gensets

18V34SG 11780 2780 4770 1850 2920 58,0 100,0


27© Wärtsilä

Auxiliary module

Inlet air/ exhaust gas module

Engine genset

20V34SG generator set with auxiliary modules

Wärtsilä® 34SG

28© Wärtsilä

Section

Exhaust gassilencer

Expansionvessel

RuptureDisc

Ventilation unit

Oil wettedcharge air filter

Exhaust gasboiler

Ventilationunit

Space for SCR reactor

Engine-Generator setEngineauxiliarymodule

CHP-module

Charge airsilencer

Radiator

Oxidation catalyst

+ 30000

+12500

±000

+5800

21250

+14700

Type lay out for 2x20V34SG CHP plant

Wärtsilä® 34SG

29© Wärtsilä

Ground floor

+2350

+1600

+000

Station transformer

Switchgear room

Stairhall

Space for heatrecoveryauxiliaries

Gas regulating unit

+000

Engine-Generator set

Ventilation unit

Maintenace watertank

Engine auxilary module

+1190

CHP module

Charge air silencer

Oil wettedcharge air filter

3-way valve

LO tank (clean)

LO tank (dirty)

Tank area

21250

1820

0

Tackle 2 ton

Wärtsilä® 34SG

Type lay out for 2x20V34SG CHP plant

30© Wärtsilä

Wärtsilä CHP plant

2 �� - �(�)$%� �� *+ ,��

31© Wärtsilä


9 �� (��

32© Wärtsilä

9 ��(��0��

Full engine output with

� Methane Number of natural gases 55 to 90 (dep. on engineoptim.)

� Ambient air temperature up to 40 oC (sea level)

� Altitude > 2500 m (25°C)

� 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

Gas Engines

33© Wärtsilä

•”Hot & Dry conditions”•Wärtsilä reciprocating engines offer stable output and high performance in hot and dry conditions. No water consumed for plant cooling!

Gas Engines

No water consumption with radiator cooling!

0.8

0.85

0.9

0.95

1

1.05

15 20 25 30 35 40 45

Ambient temperature [C]

Der

atin

g f

acto

r

Industrial Gas turbine

20V34SG(radiator cooling)

Aeroderivate Gas turbine

Source: GE Ger-3567 Ger-3695; Wärtsilä perf

18V50DF(radiator cooling)

Derating due to cooling water temperature.

Derating due to inlet airtemperature starts at 40C

34© Wärtsilä

•High Altitude•Wärtsilä reciprocating engines offer stable output and high performance high altitudes as well.

Gas Engines

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1

1.05

1.1

0 500 1000 1500 2000 2500 3000

Altitude [m]

Der

atin

g f

acto

r

Industrial Gas turbine

20V34SG(radiator cooling)

Aeroderivate Gas turbine

Source: Termoflow calculation program; Wärtsilä perf

18V50DF(radiator cooling)

18V32GD(radiator cooling)

35© Wärtsilä

Gas Engines

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

0 5 10 15 20 25 30 35 40

Plant Electrical Power (MW)

Ele

ctri

cal e

ffici

ency

(%)

Source: Alstom product broschure 01; Wärtsilä perf

5 x 20V34SG

Industrial GT

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

36© Wärtsilä

Gas Turbine vs. Gas Engine

Gas turbine and gas engine ageing influence on performance

-6

-5

-4

-3

-2

-1

0

1

2

3

0 10000 20000 30000 40000 50000 60000 70000 80000 90000 Running hours [h]

%

Hea

t rat

e ch

ange

Out

put c

hang

e

Source: GE GER-3965/GER-4208; Wärtsilä

Industrial gas turbine

Wärtsilä gas engine

LM2500

Industrial gas turbine

LM2500

GT Hot sectionoverhaul

GT Hot sectionoverhaul

GT Major overhaul

Gas engineoverhaul

Output will remain

unchangedfor gas engines

37© Wärtsilä

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.

0

10

20

30

40

50

60

70

80

90

100

0 1 2 3 4 5 6 7 8 9 10

Time (min)

Lo

ad (

%)

0

100

200

300

400

500

600

700

800

900

1000

Sp

eed

(rp

m)

Load Speed

Typical start-up procedure with 20V34SG

39© Wärtsilä

Service Products

Service Agreements Field Service Workshops Technical Support

Training O&M Systems OEM Parts Upgrades

40© Wärtsilä

Lifecycle cost

Example case:

� 100 MW Power Plant over 15 years

Levelised unit cost split

Fuel cost

O&M cost

Loan repayment

ROE

Interest

Insurance cost

41© Wärtsilä

Service schedules

Job & Service times – 1 x Wärtsilä 34SG / 8000 hours/year

Men Total No. Tot. serviceInterval Description req. time of jobs time

50 Various interval 50h jobs 1 1,50 2 400 3 600,050 Water cleaning of compressor 1 0,38 2 400 900,0500 Take oil Sample (engine) 1 0,75 240 180,0500 Check water quality 1 1,50 240 360,0

1 000 Regrease prelubricating oil pump 1 0,15 120 18,01 000 Cleaning of TC air filters 1 3,00 120 360,01 000 Clean and check the condition of the ignition coil 1 1,50 120 180,01 000 Replace spark plugs 1 1,50 120 180,02 000 Regrease the drive shaft of turning device 1 0,15 60 9,02 000 Change lubricating oil 1 9,00 60 540,02 000 Check valve clearances 1 7,50 60 450,0

: : : : : :

48 000 Check flexible coupling, replace spring packs 2 30,00 2 60,048 000 Check flexible elements of engine foundation 1 3,24 2 6,564 000 Replace piston 1 90,00 1 90,096 000 Replace cylinder head 1 45,00 1 45,096 000 Replace cylinder liners 1 15,00 1 15,0

42© Wärtsilä

Service schedules

Maintenance costs – 1 x Wärtsilä 20V34SG / 8000 hours/year

0100 000200 000300 000400 000500 000600 000700 000800 000900 000

1 000 000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Year

Cost /EuroLabourSpare parts

1

Costs are based upon standard technical specification and are for guidance only

43© Wärtsilä

Service schedules

Maintenance costs – 1 x Wärtsilä 20V34SG / 8000 hours/year

Costs are based upon standard technical specification and are for guidance only

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 5,702 16 000 88 477 96 730 185 207 2,65 23,153 24 000 33 873 41 755 75 628 1,08 9,454 32 000 200 595 95 199 295 793 4,24 36,975 40 000 13 744 39 841 53 585 0,77 6,706 48 000 204 355 100 942 305 297 4,37 38,167 56 000 9 180 36 448 45 627 0,65 5,708 64 000 431 209 95 112 526 321 7,54 65,799 72 000 45 391 41 755 87 146 1,25 10,8910 80 000 83 913 93 337 177 250 2,54 22,1611 88 000 13 744 39 841 53 585 0,77 6,7012 96 000 838 187 82 794 920 981 13,19 115,1213 104 000 9 180 36 448 45 627 0,65 5,7014 112 000 88 477 96 730 185 207 2,65 23,1515 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

44© Wärtsilä

Cementos Diamante, Colombia

Main data:

MW capacity 25 MWPrime movers 5 x 18V34SGCOD October, 1998Term 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

O&M Reference Projects

45© Wärtsilä

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

O&M Reference Projects

46© Wärtsilä

Wärtsilä 34SG references

Owner: PG&E National Energy GroupLocation: Plains End, Colorado, USAEngine: 20 x Wärtsilä 18V34SGOutput: 111 MWe

COD of the project *) May 2002Terms of O&M contract 5 years

*) (COD) Commercial Operation Date

48© Wärtsilä

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 Endin USA 20 x W18V34SG, 113,4 MWe (peaking)

49© Wärtsilä

Reference list – W20V34SG

�� 8.73�� !� " 69.84��# $�� %� &��'�� !��(��)��(*��' �# 118.146��# �� +!��'�� ,�� (��-�� 8.69��# �� 17.46��# ��-. )��! )� ��(�� / 24.249��# �$��. )��( )0�& # 34.92��# �$��. ,!�� )�� 17.46��# �$��. $(� &!1��2�� 8.73��# �$��. .�!% 3!��4� � 8.69��# �$��. &��( ��5(�� 9��# �$��. ��6� ��'��4��$�� 8.73��# �$��. �� !��4� � 8.73��# �$��. �1�� 1�� 18��# 7$� ��. &�� (� ,7+��89 / 19.995��/ �$��. �1�� 1 / 25.5��/ �+�� 4!� �'!��%�� 15.44�� $�� ,��!:��!�*��;); ��+��<�,��!:��!� � 7.3�� )�� =5�� =5��(�>4��%��%?�� 8�@@@ �+�� &��)�0�<�A�1'� &+++�� 7.8

TOTAL Engines 53 445.41 MWCylinders 1060

�#��# $%� ��

� First plantdelivered 2001 to cityof Ringköping, Denmark. 1 x W20V34SG

� Totally 28 plants with 78 engines, totally 662 MWe

� 5 plants above 30 MWe size

� 19 CHP plants with 42 engines, 354 MWe

� Biggest plant delivered: Berrick Goldstrike Inc. in USA14 x W20V34SG, 118,1 MWe (Base Load)

50© Wärtsilä


Owner: Ringkøbing FjernvarmeværkLocation: Ringkøbing, DenmarkEngine: 1 x Wärtsilä 20V34SGOutput: 8 MWeCHP Power plant

51© Wärtsilä


Györhö gas power plant in Hungary,combined heat and power (CHP), 2 x Wärtsilä 18V34SG, Output: 12 MWe, 10.92 MWth, Efficiency 82.9 %

52© Wärtsilä

projekt for kth · pdf filecan-bus ethernet (& profibus) to ext. systems ... altitude...

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