Wartsila Liquid Biofuel Plants

LIQUID BIOFUEL POWER PLANTS

Refinery process

Unrefined vegetable oil

Refined oil

Food industry

Waste oil

Diesel power plant

Power

Heat

Refinery by-products

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VEGETABLE OIL UTILIZATION

NOW, IT IS POWER OF THE GREENER KIND.The virtuous circle in power generation is the

dream of the modern world: a power plant

that does not increase the sum of greenhouse

gases, that uses renewable fuel and that brings

the energy required to raise the standard of

living where it is most needed. A few years ago

that would have seemed a pipe dream. Today

it is reality.

Wärtsilä liquid biofuel power plants use

highly effi cient reciprocating diesel engines

to turn clarifi ed crude vegetable oils into

electricity and heat. Liquid biofuel can be

produced from practically any oil-rich crop,

from oil palm, soy, rapeseed and olive to

sunfl ower seeds, grown in many regions all

around the world.

“The use of vegetable oils for engine

fuels may seem insignifi cant today. But

such oils may in the course of time

become as important as petroleum

and the coal tar products of the

present time.”

Rudolf Diesel, 1912

IT LOOKS LIKE VEGETABLE OIL.IT TASTES LIKE VEGETABLE OIL.IT IS VEGETABLE OIL – STRAIGHT AND UNPROCESSED.

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RAIN OR SHINE.

Electricity provided for the grid should be

stable. Many green energy solutions – like

solar and wind power – depend on weather

conditions. Wärtsilä liquid biofuel power plants

rely on dependable, renewable resources and

offer high overall plant performance at all

times.

Surprisingly, biofuels have to offer

just as much to business people as to

environmentalists. Making money while

taking the environmental issues of today into

consideration is a good investment – now and

for the future.

World energy demand is increasing steadily.

At the same time, the Kyoto agreement and

general concern about the environment are

raising the need to reduce greenhouse gas

emissions. Wärtsilä has developed technical

solutions to meet both needs: liquid biofuel

power plants offer sustainable power

generation with practically zero greenhouse

gas emissions.

In many countries, owners of power plants

with low greenhouse emissions benefit twice

over: firstly from selling their electricity to

the national grids, and secondly from green

incentives.

Still, the future of liquid biofuels depends

on the availability of the fuel and the solutions

to produce it in an environmentally and

RELIABLE ENERGY. ECONOMIC VIABILITY.

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GREEN ENERGY INCENTIVE SYSTEMS

There are various incentive mechanisms,

including the Green Certificate, for

motivating companies to enforce green

energy. These are financial contributions

at community, national and regional levels,

the renewable energy certificate system,

and grants of origin.

The EU Emission Trading Scheme

was launched on 1 January 2005 to

gain market experience before the Kyoto

Protocol enters into force in 2008. The

Kyoto Protocol commits the European

Union to reduce the 1990 levels of

greenhouse gas emissions by 8% between

2008 and 2012. Now the EU countries

are working towards a cross-union trading

system, the details of which are still

evolving.

The Clean Development Mechanism

(CDM) and Joint Implementation (JI) are

flexible project-based mechanisms that

operate under the Kyoto Protocol.

Interest in the abatement of greenhouse

gases is also rising outside Europe, e.g.

in Japan, Malaysia and India. Japan, for

instance, has passed laws to promote

the development and introduction of

petroleum-substituting energy since

the 1980s. In Malaysia the target share

of renewable energy is 5% of the total

supply. Also biomass residues from the

palm oil sector offer huge potential energy

resources for meeting Malaysia’s target.

Renewable energy already accounts for

4% of the Indian power sector and the

target is to reach 12% by 2012.

economically sound manner. At its best, biofuel

production creates local job opportunities, thus

promoting social and economic cohesion. It

also improves regional fuel supply security by

reducing the need for imported fuels. In some

cases, energy crop cultivation might even help

to fight soil erosion.

Sound economics combined with superior

eco-friendliness!

LBFstorage

tankLBFdaytank

LBFbuffertank

LFO/biodiesel storage

tank

Transferpumpunit

Unloadingpumpunit

Mixingtank

Feeder unit

Booster unit

Filter

Heater

Viscositymeter

Safetyfilter

Boosterpump

F

FlowPump

Return fuel cooler

Flowmeter

Back-upfuel

heater

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THIS IS NO NEWS.

Liquid biofuel has been known since the

beginning of the industrial revolution.

But it is only recently that environmental

and commercial pressures have resulted

in substantial research into maximizing

efficiency for electrical power generation.

Biofuel is derived from biological material

and can be produced from any carbon

source, usually plants but it can also be of

animal origin. Common liquid biofuel sources

approved for use in Wärtsilä engines are

oils from various oilseeds, such as palm oil,

palm stearin, rape seed oil, sunflower oil and

jatropha oil. Transesterification of the liquid

biofuels produces biodiesel, which is also

approved to run in Wärtsilä engines.

The diesel engine, based on compression

ignition technology, turns vegetable oil more

or less straight from the crop into electric

energy.

It is in the fuel feed system where the

major research on the larger medium-speed

engines has taken place. Medium-speed

engines can run on most qualities of heavy

fuel oil (HFO). These engines have for years

proven their worth as power generating

sets for electricity under the most extreme

conditions on the planet.

While optimizing our standard engine

design, we developed a fuel feed system

which controls the temperature and viscosity

throughout the power plant. This eliminates

over-heating or cold points which can lead to

changes in fuel characteristics.

STRAIGHT8 LIQUID BIOFUEL SPECIFICATION

Property Unit Limit Test method reference

Viscosity, max. Injection viscosity, min. Injection viscosity, max.

cSt @ 40 °C cSt cSt

100 1)

1.8 – 2.8 2)

24ISO 3104

Density, max. kg/m³ @ 15 °C 991 ISO 3675 or 12185

Ignition properties 3) FIA test

Sulphur, max. % m/m 0.05 ISO 8754

Total sediment existent, max. % m/m 0.05 ISO 10307-1

Water, max. before engine % v/v 0.20 ISO 3733

Micro carbon residue, max. % m/m 0.50 ISO 10370

Ash, max. % m/m 0.05 ISO 6245 / LP1001

Phosphorus, max. mg/kg 100 ISO 10478

Silicon, max. mg/kg 15 ISO 10478

Alkali content (Na+K), max. mg/kg 30 ISO 10478

Flash point (PMCC), min. °C 60 ISO 2719

Cloud point, max. °C 4) ISO 3015

Cold filter plugging point, max. °C 4) IP 309

Copper strip corrosion (3 hrs @ 50 °C), max. Rating 1b ASTM D130

Steel corrosion (24 / 72 hours @ 20, 60 and 120 °C), max.

RatingNo signs of corrosion

LP 2902

Acid number, max. mg KOH/g 15.0 ASTM D664

Strong acid number, max. mg KOH/g 0.0 ASTM D664

Iodine number, max. g iodine /100 g 120 ISO 3961

1) If injection viscosity of max. 24 cSt can not be achieved with an unheated fuel, fuel system has to be equipped with a heater2) Min. limit at engine inlet in running conditions; W20: 1,8 cSt, W32: 2,0 cSt, W46: 2,8 cSt, W34DF: 2,0 cSt, W50DF: 2,8 cSt3) Ignition properties have to be equal to or better than the requirements for fossil fuels, i.e., CN min. 35 for LFO and CCAI max. 870 for HFO.4) Cloud point and cold filter plugging point have to be at least 10 °C below fuel injection temperature.

Decades of experience and a system of

filters, separators, preheaters and coolers

have helped us to develop optimal solutions

for maximum fuel efficiency and a minimum

of emissions.

LBF FUEL SYSTEM

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LIQUID BIOFUEL DEVELOPMENT MILESTONES

• April 1995. A 200 hour engine test with rape seed oil on a Wärtsilä Vasa 4R32 engine at VTT in Espoo, Finland. Vegetable oil was approved as fuel for Wärtsilä diesel engines.

• September 2001. A 50 hour engine test with vegetable oil on a Wärtsilä 6L26 engine at the test laboratory in Zwolle, Netherlands

• October 2002. A 18 hour verifi cation test with refi ned palm oil, palm stearin and olive olein on a Wärtsilä 6L32 engine at the engine laboratory in Vaasa, Finland.

• January 2003. Start up of fi rst commercial power plant on liquid biofuel in Karlburg, Germany. One Wärtsilä 6L32 engine with 2.6 MW output.

• August 2004. Start up of the Ital Green Energy power plant in Monopoli, Italy. Two Wärtsilä 18V32 engines with a total output of 16 MW.

• July 2005. Start up of the third engine at the Ital Green Energy power plant. Total output extended to 24 MW.

• January 2008. Start up of Ital Green Energy Block 2 in Monopoly Italy, Six Wärtsilä 18V46 engines with a total output of 100 MW.

• 2008: Several power plants started up in Italy

• 2009: More start ups in Italy and the fi rst power plant using jatropha oil will start in Koekhoven, Belgium.

A TYPICAL COMBINED CYCLE PLANT

Exhaust gas silencer

SCR-unit(option)

Engine-generator set

Exhaust gas boiler

Steam turbine

COMBINED CYCLE PLANTSIn order to meet market needs and demands, we are continuously developing new plant concepts, among them Combined Cycle plants. For biofuel plants below 50 MWe, using both Wärtsilä 32 and Wärtsilä 46 engines, very high electrical effi ciencies are achieved when utilising waste heat for generation of additional electricity. The ORC (Organic Rankine Cycle) as well as ordinary steam based solutions are used for this purpose.

50 MWE COMBINED CYCLE PLANTEngine type ........................................3 x Wärtsilä 18V46Turbine type ........................... Condensing steam turbineTotal electrical output......................................51.2 MWeElectrical effi ciency ................................... 49.2% (gross)

LOOK! IT´S PRACTICALLY EMISSION-FREE.

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A LIFETIME OF CLEAN ENERGY IS ENSURED BY SOLUTIONS BEYOND THE FUEL.

To reduce the total of greenhouse emissions,

Wärtsilä liquid biofuel power plants are

designed to operate on straight vegetable

oils – without any supplementary energy for

fuel refinement needed. The oils can typically

be extracted with simple methods so that even

the CO2 emissions associated with the fuel

refinement are minimized.

The sulphur emissions are insignificant

compared to those associated with fossil

fuels because vegetable oils do not contain

significant amounts of sulphur.

The selective catalyst reduction

technologies for NOX abatement typically

enable an 85…90% reduction of NOX

emissions from the exhaust gases.

Particle emissions (PM) in liquid-biofuel-

based power plants depend mainly on the ash

content of the source fuel. Experience has

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shown that with good-quality liquid biofuels it

is possible to reach low PM levels that meet

stringent European standards.

Moreover, with vegetable oils the carbon

monoxide and hydrocarbon emissions are

low due to the highly efficient diesel engine

process.

The power is also generated with minimal

use of water, so the impact on water resources

is negligible.

Last but not least, Wärtsilä liquid biofuel

power plants offer a very high simple cycle

electrical efficiency. You get more output for

your input!

Our aim is to ensure you get the best possible

performance from your power plant investment

throughout its lifecycle. After all, who could be

better at this than the people who designed

and built the plant?

We provide a comprehensive range of

services built on the concept of enhancing

the customer’s profi tability 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 you to focus on your core

business.

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SUSTAINED PARTNERSHIP FOR SUSTAINED DEVELOPMENT.

KOEKHOVE, MERKSPLAS, BELGIUMEngine: ..............................................1 x Wärtsilä 20V32 Output: ...........................9 MWe + 7.5 MWth (Hot water)Fuel: .....................................Liquid biofuel (Jatropha oil)Emission control: .............................SCR NOX abatementDelivered: ........................................................ Q3 2009The heat produced by the plant is supplied to a drying facility for digested biomass recovered from a manure fermentation plant as well as a greenhouse producing tomatoes The 9 MW Wärtsilä 20V32 engine will provide electrical power suffi cient to serve approximately 20,000 households. The gross electrical effi ciency is 44.2% and an overall effi ciency of more than 85%, annual CO reduction will be more than 36,000 tons.

Wärtsilä Operations & Management

currently runs more than 130 plants around

the world, making it the world’s leading power

plant O&M contractor.

If you choose to operate the plant yourself,

you can still rest assured that you have the

best possible support available when and

where you need it – from training to online

support and service or modernization and

upgrading of the plant. Our global network is

always ready to make sure your power plant

performs fl awlessly, free of breakdowns and

unwanted downtime throughout its lifetime.

BY THE END OF 2009 THERE WILL BE ABOUT 700 MW OF WÄRTSILÄ LIQUID BIOFUEL POWER PLANTS IN OPERATION.

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Wärtsilä 34DF

Wärtsilä 50DF

Dual-fuel engines (gaseous fuel/liquid fuel)

Liquid biofuel engines

Wärtsilä 20

Wärtsilä 32

Wärtsilä 46

MW 1 5 10 50 100 300 500

POWER PLANT OUTPUT RANGE

MONOPOLI, ITALYItalGreen Energy in Italy and Wärtsilä combined to build the world’s largest power plant for simultaneous generation of electricity and heat fuelled exclusively by straight vegetable oil. The plant commissioned the first two Wärtsilä 18V32 generating sets in August 2004 with a total capacity of some 16 MW. In 2005 the plant extended its capacity to 24 MW and the latest extension of 100 MW is under construction and will be in commercial use early in 2007.Located inside the existing vegetable oil refinery, the plant supplies both green electricity to the national grid and steam and power to satisfy the factory process demand. Fuel testing, detailed engineering, delivery of the full generating set package, start-up and erection supervision were all included in our delivery. Operation of the 3 first engines started in January 2008

Engines: ...................6 x Wärtsilä 18V46 + Steam turbineOutput: ..............100 MWe (engines) + 11 MWe (turbine)Fuel: ................................Liquid biofuel (mainly palm oil)Emission control: .............................SCR NOX abatement

LIQUID FUEL ENGINESWärtsilä 20Technical data 50 Hz/1000 rpm Unit 6L20 8L20 9L20Power, electrical kW 1026 1368 1539Heat rate kJ/kWh 8584 8670 8604Electrical efficiency % 41.9 41.5 41.8Technical data 60 Hz/900 rpmPower, electrical kW 969 1292 1454Heat rate kJ/kWh 8541 8627 8561Electrical efficiency % 42.2 41.7 42.0Dimensions and dry weight with generating setLength mm 5400 6540 6820Width mm 1850 1950 1950Height mm 2375 2620 2620Weight tonne 18 23 24

Heat rate and electrical efficiency at generator terminals, including engine-driven pumps. ISO 3046 conditions and LHV. Tolerance 5%. Power factor 0.8.

Wärtsilä 46Technical data 50 Hz/500 rpm Unit 12V46 18V46 20V46F/600 rpmPower, electrical kW 11349 17076 22425Heat rate kJ/kWh 7692 7698 7669Electrical efficiency % 46.8 46.8 46.9Technical data 60 Hz/514 rpmPower, electrical kW 11349 17076 22425Heat rate kJ/kWh 7692 7698 7669Electrical efficiency % 46.8 46.8 46.9Dimensions and dry weight with generating setLength mm 15400 18260 20710Width mm 5090 5090 6275Height mm 5700 5885 6230Weight tonne 265 358 424


Wärtsilä 32Technical data 50 Hz/750 rpm 6L32 9L32 12V32 16V32 18V32 20V32Power, electrical kW 2636 3974 5327 7124 8032 8924Heat rate kJ/kWh 8069 8027 7880 7856 7840 7840Electrical efficiency % 44.6 44.8 45.7 45.8 45.9 45.9Technical data 60 Hz/720rpmPower, electrical kW 2579 3888 5211 6970 7841 8730Heat rate kJ/kWh 8069 8027 7880 7856 7861 7840Electrical efficiency % 44.6 44.8 45.7 45.8 45.8 45.9Dimensions and dry weight with generating setLength mm 8766 11200 10030 11239 11500 12200Width mm 2418 2410 3050 3300 3300 3300Height mm 3738 3740 4420 4343 4220 4420Weight tonne 58 82 92 119 127 130


UNIGRÀ, CONSELICE, ITALYEngines: ................ 3 x Wärtsilä 18V46 + combined cycle Output: ....... 50 MWe (engines) + 6 MWe (steam turbine)Fuel: ....................................Liquid biofuel (vegetable oil)Emission control: .............................SCR NOX abatementDelivered: .............................................September 2008

Wärtsilä 50DFTechnical data 50 Hz/500 rpm Unit 18V50DF 18V50DF*Power, electrical kW 16621 16621Heat rate kJ/kWh 7616 8139Electrical efficiency % 47.3 44,0Technical data 60 Hz/514 rpm Power, electrical kW 17076 17076Heat rate kJ/kWh 7616 8139 Electrical efficiency % 47.3 44,0Dimensions and dry weight with generating setLength mm 18780 18780Width mm 4090 4090Height mm 6020 6020Weight tonne 355 355

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. *in liquid mode..

DUAL-FUEL ENGINESWärtsilä 34DFTechnical data 50 Hz/750 rpm Unit 9L34DF 16V34DF 20V34DFPower, electrical kW 3888 6970 8730Heat rate kJ/kWh 8048 (8127)* 8048 (8127)* 8036 (8127)*Electrical efficiency % 44.7 (44.3)* 44.7 (44.3)* 44.8 (44.3)* Technical data 60 Hz/720rpmPower, electrical kW 3758 6737 8439Heat rate kJ/kWh 8048 (8127)* 8048 (8127)* 8036 (8127)*Electrical efficiency % 44.7 (44.3)* 44.7 (44.3)* 44.8 (44.3)* Dimensions and dry weight with generating setLength mm 10400 11303 12890Width mm 2780 3300 3300Height mm 3842 4472 4243Weight tonne 77 120 132

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. * In liquid mode.

WÄRTSILÄ® is a registered trademark. Copyright © 2005 Wärtsilä Corporation.

WÄRTSILÄ® is a registered trademark. Copyright © 2009 Wärtsilä Corporation.

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

marine and energy markets. By emphasising technological innovation

and total efficiency, Wärtsilä maximises the environmental and economic

performance of the vessels and power plants of its customers. Wärtsilä

is listed on the NASDAQ OMX Helsinki, Finland.

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Wartsila Liquid Biofuel Plants