Gas diesel power plant

running on shale oil retort gas

Priit Heinla
Wrtsil

Wrtsil February 14 WRTSIL POWER PLANTS

Utilising retorn gas by gas diesel plant

Plant is based on reciprocating Gas Diesel engines. It has a modular
structure and consists of multiple parallel engine-generator sets with an
output of 9.73 MWel each.
Modules are mutually independent from functional point of view, their
only common systems are high-pressure gas supply system, MV
switchgear and MV/HV transformer station, and other systems used to
top-up process media.
All electrical, automation, cooling and exhaust systems are enginespecific, thus improving general reliability of the plant.
Gas diesel is only machinery which can utilise retort gases with high
efficiency.

Wrtsil February 14 WRTSIL POWER PLANTS

Wrtsil Gas Engines, History

W34DF

Wrtsil gas/dual fuel

engine development

W20V34SG

W50DF

W32DF

W34SG

W46GD

W32GD

1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 ......... 2007 2008 2009

Wrtsil 01/02/2014

Wrtsil Gas-Diesel Engine development history

New W32GD

W46GD

W32GD

1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 ......... 2007 2008 2009

Wrtsil February 14 WRTSIL POWER PLANTS

Wrtsil Gas Engines

Wrtsil gas/dual fuel

engine technologies
50

SPARK IGNITED
LEAN BURN

- Otto principle
- Low pressure gas
- Mono fuel

34

PILOT FUEL IGNITED

LEAN BURN

46
GAS DIESEL

Wrtsil 01/02/2014

- Otto principle
- Low pressure gas
- Dual fuel
- Diesel principle
- High pressure gas
- Real dual fuel

Wrtsil 32GD Engine Performance

Bore
Stroke
Compression ratio
Engine speed
Efficiency in gas mode
Efficiency in oil mode
Power per cylinder
Mean effective pressure

Wrtsil February 14 WRTSIL POWER PLANTS

mm
mm
rpm
%
%
kW
bar

320
400
16:1
750
43,9
43,7
460
22,9

Wrtsil 32GD, Summary

GD Engine Features
Output and thermal efficiency as
optimized diesel engine
No derating because of methane
number
Large fuel flexibility
Tolerant to fuel quality
Fuel sharing
High thermal efficiency
Low emissions
Fast load response
Good loading capacity
Short start-up time
Automatic transfer to back-up fuel
Double wall pipe system for highest
safety
Long maintenance free periods
Easy to maintain
8

Wrtsil 01/02/2014

Wrtsil 32GD Engine Operation Principle

Gas Mode:
5% Pilot injection
Fuel Sharing Mode:
15-80% Gas Fuel
85-20% Oil Fuel
Oil Mode:
100% Oil Fuel
9

Wrtsil February 14 WRTSIL POWER PLANTS

Wrtsil 32GD Engine Technology

ERV
Injection valve

QCV

Double walled pipe

Gas combustion system with pilot injection

Electronically controlled pilot fuel injection
High pressure direct gas injection

10

Wrtsil February 14 WRTSIL POWER PLANTS

Wrtsil 32GD Engine Technology

gas o.p.
adjust. screw

gas spring
gas inlet
control cylinder

diesel o.p.
adjust. screw
diesel spring

gas needle
diesel needle
nozzle orifices

11

Wrtsil February 14 WRTSIL POWER PLANTS

GD engine main components: fuel system on the engine

ELECTRONIC RAIL
VALVE

QUICK CLOSING VALVE

DOUBLE WALLED GAS PIPE

12

Wrtsil 01/02/2014

LNG Production: Technology a Gas Diesel

GD/Fuel Sharing operation window
Diesel
share %
0

Gas
share %
100

10

90

20

80

30

70

40

60

50

50

60

40

70

30

80

20

GD operation

Fuel Sharing
Fuel Sharing

Transfer window
90

10

100

Fuel oil operation

0

10

20

30

40

50

60

70

80

90 100

Engine load%

1 February 2014

Wrtsil 32GD Engine Gas Fuel Requirements

Fuel requirements for continuous gas mode operation with full output
Lower heating value

min.

30 MJ/m3

Gas supply pressure to engine

min.

350 bar

Gas temperature before engine

max.

80 C

Chlorines + fluorines

max.

0.005 % (vol.)

Hydrogen Sulphide

max.

0.2 % (vol.)

Water or other condensates

Particles or solids

14

Wrtsil February 14 WRTSIL POWER PLANTS

Not allowed
size max.

10 m

Main components Gas Compressor Skid

Gas compressor Skid (350 bar)

The gas fuel system is designed to supply
the GD engine(s) with a clean gas at
correct pressure and temperature
The main components of the gas fuel
system are:
- Gas compressor skid
- Buffer tank(s)
- Valve skid(s), with regulating valve
for 250-350bar
The equipment is designed for hazardous
area zone 2(1).

15

Wrtsil 01/02/2014

Wrtsil 32GD Engine High Pressure Gas Supply

350
bar

Gas LHV = 30 MJ/Nm3, dicharge pressure = 350 bar(a)

kW

500

450
400

350

20V32GD

300

16V32GD
12V32GD

250

200
150
100
50
0
0
16

10

20

30

Wrtsil February 14 WRTSIL POWER PLANTS

40

50

60

70

80

90

100

bar

Wrtsil 32GD Engine Gas Fuel System

Blow down/Vent
Double wall ventilation fan

Safety vent
GE

Safe Area (Power house)

Gas
250-350 Bar Gas Pressure
after regulating valve
Inert Gas
Other Gas Compr.
Next Valve Skid

Gas Compressor Skids

17

Wrtsil February 14 WRTSIL POWER PLANTS

Buffer Tanks

Valve Skids

Double Wall Piping

Wrtsil 20V32GD Dimensions & Weights

dimension

mm / tonnes 12890

18

Wrtsil February 14 WRTSIL POWER PLANTS

Engine
weight

Genset
weight

3300

4243

1825

2418

89

132

Wrtsil 32GD Reference

Secoya (Dygoil), Ecuador
2 x Wrtsil 16V32GD
Electrical output: 11 MW
Fuel sharing, Island mode
Delivered: 2003
Operates on associated gas and
crude oil

19

Wrtsil February 14 WRTSIL POWER PLANTS

Wrtsil 32GD Reference

Fuel composition from Secoya (Dygoil) power plant

20

Wrtsil February 14 WRTSIL POWER PLANTS

Wrtsil 32GD Reference

Example of fuel analyses from Secoya (Dygoil) power plant
GAS COMPONENT [Mole %]
Methane
Ethane
Propane
i - Butane
n - Butane
i - Pentane
n - Pentane
n - Hexane
n - Heptane
Water (vapor)
Carbon monoxide
Carbon dioxide
Hydrogen sulphfide
Hydrogen
Nitrogen
Oxygen
Argon
Helium
MN
LHV [kJ/nm^3@0C, 100 kPa]
Density [kg/m^3 @0C, 100 kPa]

21

Wrtsil February 14 WRTSIL POWER PLANTS

CH4
C2H6
C3H8
i-C4H10
n-C4H10
i-C5H12
n-C5H12
n-C6H14
n-C7H16
H2O
CO
CO2
H2S
H2
N2
O2
Ar
He

43,74
10,21
12,25
1,2
2,32
0
0
0
0
0
0
27,49
0
0
2,79
0
0
0

42,81
13,36
14,05
1,87
4,81
0,93
0,84
0
0
0
0
18,77
0
0
2,56
0
0
0

35,83
9,04
18,21
2,21
5,39
0
1,91
4,66
0
0
0
19,9
0
0
2,85
0
0
0

~71
36927
1,339903976

~57
46526
1,3747

~49
54927
1,5921

Wrtsil 32GD Reference

Tamanrasset, Algeria
18 x Wrtsil 6L32GD
Mechanical drive
Water pumping
Delivery 2009

22

Wrtsil February 14 WRTSIL POWER PLANTS

Reference - Wrtsil 8x18V46GD

Haripur, Bangladesh

Wrtsil

Check our solutions at www.wartsila.com

24

Wrtsil 01/02/2014