COMBINED HEAT AND POWER

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.

Wrtsil 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
Wrtsil CHP plants is unequalled in the market. Wrtsil 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 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.
Wrtsil 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.

Typical specific CO2 emissions by

different power plant types

WRTSIL CHP WIN-WIN CONCEPT

CO2 emissions in g/kWh

800

750
600

670

600
450

340
1)

Coal fired
steam
boiler

Gas turbine
natural gas
single cycle

Gas turbine
fuel oil
single cycle

Diesel engine
fuel oil
single cycle

2)

Gas engine
natural gas CHP

Diesel engine Gas engine

emulsified fuel natural gas
single cycle
single cycle

1) 7 bar (g) saturated steam production.

2) Hot water production (45C in/85C out).
Single cycle: g/kWhe.
CHP-mode: g/kWhtot (heat + electricity).

240

++ 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 Wrtsil 18V34SG (Gas)
3 x Wrtsil 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
Wrtsil+CHP+plants+powered+by+reciprocating+
engines+offer+fl+exibility+and+uncompromising+
performance+wherever+power+and+heat+are+
required.
Wrtsils+gas+and+diesel+engines+have+by+
far+the+highest+electrical+effi+ciency+for+prime+
movers+in+the+market.+The+exhaust+gases+and+
cooling+water+from+the+engine+can+fl+exibly+
be+utilized+for+numerous+applications++as+
low-pressure+steam+for+industrial+entities,+as+
district+heating+and/or+chilled+water+for+cities,+
offi+ce+complexes+and+municipalities;+or+the+
exhaust+gases+can+be+used+directly+for+drying,+
etc.+Depending+on+customer+needs,+the+CHP+
plants+total+effi+ciency+can+even+exceed+90+%.
Typical+heat+recovery+systems,+between+the+
prime+mover+and+the+customers+equipment,+
are+of+hang-on+type+and+ensure+both+
optimized+heat+production+and+effective+engine+
cooling+and+operation.+Wrtsils+heat+recovery+
design+takes+into+account+all+the+customers+
seasonal,+monthly,+weekly+and+daily+variations+
in+running+and+operational+heat+production+
conditions.+Heat+production+does+not+affect+the+
electrical+output+or+the+electrical+effi+ciency+of+
the+prime+mover.
The+modular+design+of+Wrtsil+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.+
Wrtsil+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+benefi+ts+of+Wrtsils+modular+
plant+concept+is+the+unique+fl+exibility+of+

operation+enabled+by+the+cascading+multiengine+structure+of+the+plants.+Multi-unit+
installations+provide+load+fl+exibility:+extra+
generating+sets+can+be+turned+off,+while+the+
plant+continues+to+run+at+peak+effi+ciency+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

Wrtsil 20V34SG

Engine auxiliary module (EAM)

MONOPOLI, ITALY
Engines ............................... 6 x Wrtsil 18V46
+ Steam turbine
Output ................................ 100 MWe (engines)
+ 11 MWe (turbine)
Fuel ..............................................Liquid biofuel
Emission control ................ SCR NOX 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 oor 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

+15,500

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 oor 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.

Combined
SCR/OXI-CAT
(option)

CHP-module

Engine-generator set

22,500

industrial process steam or even chilled

water, Wrtsil 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 Wrtsil CHP plant but is also carefully
integrated with all necessary signals and
connections to existing systems to guarantee a
fully compatible plant.

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,

LOW-PRESSURE STEAM GENERATION FOR INDUSTRIAL APPLICATIONS

POWERFUL CHOICES
The high efficiency of Wrtsils CHP plants
translates into considerable savings in fuel
costs compared to other technologies. For
optimized balance and profitability, the
plants are customized to the customers
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

UJPALOTA, HUNGARY
Type of customer...........................................IPP
Engine type....................... 3 x Wrtsil 20V34SG
Total electrical output............................ 20 MWe
Total heat output................................ 19.2 MWth
Total efficiency......................................... 84.6%
Fuel..............................................................Gas

7 C

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

RINGKBING, DENMARK:
Type of customer ......................................Utility
Engine type...................... 1 x Wrtsil 20V34SG
Total electrical output............................ 7.9 MW
Total heat output ................................... 9.7 MW
Total efficiency........................................... 96%
Fuel .............................................................Gas

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 45C)

Derating factor

Wrtsil 20V34SG
(radiator cooling)

0.95
Aeroderivate gas turbine

0.9

Industrial gas turbine

0.85
0.8

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

15

20

25

30

35

40

45

Ambient temperature (C)

Wrtsil 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+effi+cient+
means+of+converting+liquid+or+gaseous+fuels+
into+energy.
The+Wrtsil+CHP+plant+can+run+on+most+
natural+gas+types,+heavy+and+light+fuel+oils,+and+
emulsifi+ed+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+Wrtsils+generating+sets+is+
Wrtsils+reliable+engine+technology,+the+result+
of+long+experience+of+demanding+marine+and+
power+plant+applications.+All+Wrtsil+engines+
have+a+simple+and+straightforward+modern+
design+with+facilities+for+easy+and+rapid+on-site+
maintenance.

The Wrtsil 20V34SG engine features

the latest design in gas technology.
9

Typical interior and design of a control room

in Wrtsil power plants.

CUSTOMER CARE
Wrtsils 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?
Wrtsil provides a comprehensive range
of services built on the concept of enhancing
the customers 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

Wrtsil Operations & Maintenance currently

runs more than 130 plants around the world,
making it the worlds 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. Wrtsils
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

Wrtsils 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 buildings. 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 Wrtsil 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
Wrtsil 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, generating a net electric power of 33 MW, is
connected to the airports 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 Wrtsil 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 Wrtsil 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+WRTSIL+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

MW

10

50

100

300

Wrtsil 34SG
Dual-fuel engines (gaseous fuel/liquid fuel)
Wrtsil 32GD
Wrtsil 34DF
Wrtsil 50DF
Liquid fuel (LFO, HFO, CRO, emulsified, LBF)
Wrtsil 20
Wrtsil 32
Wrtsil 46

LFO = light fuel oil

HFO = heavy fuel oil

CRO = crude oil

LBF = liquid biofuel

Boiler and absorption chillers at

Madrids Barajas airport, Spain.

14

500

Performance data as guidelines for CHP calculations Wrtsil gas fuelled generating sets at 50 and 60 Hz
Performance data

Wrtsil gas engines

at frequency 50 Hz

Wrtsil gas engines

at frequency 60 Hz

Engine

9L34SG 16V34SG 20V34SG

20V34DF

18V50DF

9L34SG 16V34SG 20V34SG

20V34DF

18V50DF

Liquid +
Liquid
Liquid +
Gas +
Gas +
Gas +
fuel+
fuel +
fuel+
mode
mode
mode
mode
mode
mode
14602000* (LFO)+
14602000* (LFO)+
mg/Nm3 95190* 95190* 95190* 190380*
190380* 2000* 95190* 95190* 95190* 190380*
190380*
16002000 (HFO)
16002000 (HFO)
Gas +
mode

Engine optimization: +
NOX (dry @ 15 vol-% O2)

Liquid +
fuel+
mode
2000*

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

Efficiency 1)

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

Cooling circuit inlet/outlet 2)

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

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

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

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

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

5%

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

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

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; 25C 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 factor 0.8. Gas Methane Number >80

2) Single-circuit cooling system.

* Adjustable NOX range according to local requirements. Heat rates given at the marked NOX 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/Nm3 dry @ 15% O2, NOX calculated as NO2, Nm3 defined at NTP
(273.15K and 101.3 kPa).

Performance data as guidelines for CHP calculations Wrtsil liquid fuelled generating sets at 50 and 60 Hz
Wrtsil diesel engines
at frequency 50 Hz

Performance data
Engine
ppmvol

Engine optimization: +
NOX (dry @ 15 vol-% O2)

Wrtsil 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

Electric power

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

84/91

84/91

HTCAC temperature inlet/outlet

79/96

80/96

80/96

80/96

80/91

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

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

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

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

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

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; 25C 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 NOX 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/Nm3 dry @ 15% O2, NOX calculated as NO2, Nm3 defined at NTP (273.15K
and 101.3 kPa).

15

marine and energy markets. By emphasising technological innovation

and total efficiency, Wrtsil maximises the environmental and economic
performance of the vessels and power plants of its customers.
In 2008, Wrtsils net sales totalled EUR 4.6 billion with 19,000 employees.
The company has operations in 160 locations in 70 countries around the
world. Wrtsil is listed on the NASDAQ OMX Helsinki, Finland.
WRTSIL is a registered trademark. Copyright 2005 Wrtsil Corporation.

WRTSIL is a registered trademark. Copyright 2010 Wrtsil Corporation.

01.2010 / Bocks Office / Litoset

Wrtsil is a global leader in complete lifecycle power solutions for the