CHP Wartsila Combined Heat and Power

8/12/2019 CHP Wartsila Combined Heat and Power

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COMBINED HEAT AND POWER



2



2)

2401)

340450

600670

600

750800

Gas engine

natural gas

single cycle

Diesel engineemulsified fuel

single cycle

Gas turbine

fuel oil

single cycle

Gas enginenatural gas CHP

Diesel engine

fuel oil

single cycle

Gas turbinenatural gas

single cycle

Coal firedsteam

boiler

1) 7 bar (g) saturated steam production.2) Hot water production (45°C in/85°C out).Single cycle: g/kWh .CHP-mode:g/kWh (heat + electricity).

e

tot

CO emissions in g/kWh2

Typical specific CO emissions by

different power plant types2 WÄRTSILÄ CHP – WIN-WIN CONCEPT

+ Extremely efficient utilization of primary fuels + Decentralized energy production (DE)

enables individual CHP solutions that areeconomical and efficient

+ Optimized plant size with step-by-stepinvestment thanks to multi-unit design.Gives lower investment risk in a changingmarket

+ Maximized plant availability in all operatingsituations

+ Flexible operation for changes in power andheat demands

+ Electrical output and efficiency areunaffected by the rate of heat production

+ Lower power transmission costs

+

On-site maintenance without productiondown-time

= Low capital and operational costs peroutput unit. High profitability!

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, pushingpower 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.

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COMBINED BENEFITS OFDISTRIBUTED COGENERATION

Wärtsilä 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

Wärtsilä CHP plants is unequalled in the market. Wärtsilä 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.

Wärtsilä CHP plants can run on various grades of natural gas andliquid 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.



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PLANT CONCEPTWärtsilä CHP plants powered by reciprocating

engines offer flexibility and uncompromising

performance wherever power and heat are

required.

Wärtsilä’s gas and diesel engines have by

far the highest electrical efficiency for primemovers in the market. The exhaust gases and

cooling water from the engine can flexibly

be utilized for numerous applications – as

low-pressure steam for industrial entities, as

district heating and/or chilled water for cities,

office complexes and municipalities; or the

exhaust gases can be used directly for drying,

etc. Depending on customer needs, the CHP

plant’s total efficiency can even exceed 90 %.

Typical heat recovery systems, between the

prime mover and the customer’s equipment,

are of “hang-on” type and ensure both

optimized heat production and effective engine

cooling and operation. Wärtsilä’s heat recovery

design takes into account all the customer’s

seasonal, monthly, weekly and daily variations

in running and operational heat production

conditions. Heat production does not affect the

electrical output or the electrical efficiency of

the prime mover.

The modular design of Wärtsilä CHP plantsenables rapid delivery anywhere in the world.

Prefabricated, functionally pre-tested modules

guarantee consistent quality and performance

and make on-site installation a matter of

assembling and connecting the modules.

Wärtsilä 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 benefits of Wärtsilä’s modular

plant concept is the unique flexibility of

PISTICCI, ITALY

Type of customer ..........................Industry - IPP

Engine type............. 4 x Wärtsilä 18V34SG (Gas)

3 x Wärtsilä 18V32 (LBF)

Total electrical output...............22 MW + 24MW

Total heat output .................17.3 MW + 2.1 MW

Total efficiency ........................................... 59%

Fuel .......................................Gas/Liquid biofuel

operation enabled by the cascading multi-

engine structure of the plants. Multi-unit

installations provide load flexibility: extra

generating sets can be turned off, while the

plant continues to run at peak efficiency 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.

Wärtsilä 20V34SG

Engine auxiliary module (EAM)

CHP module



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+15,500

22,500

Combined

SCR/OXI-CAT

CHP-module Engine-generator set

Radiator

(option)

Pre-engineered and

pretested modules

minimizes construction time

and maximize reliability.

TOWN CONCEPT EXAMPLEWhen 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 floor 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 heavy-

duty silencers have to be installed to eliminate

any noice problems.

MONOPOLI, ITALY

Engines ............................... 6 x Wärtsilä 18V46

+ Steam turbine

Output ................................ 100 MWe (engines)

+ 11 MWe (turbine)

Fuel ..............................................Liquid biofuel

Emission control ................ SCR NOX abatement

FIELD CONCEPT EXAMPLEWhere the building site is ample and not situated

in the midst of a densely populated area, the

single floor 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.

+10,950

21,250

Exhaust gas silencer

Exhaust gas boiler

CHP-module

Engine-generator set



COGEN FOR MAXIMUM STEAM GENERATION

Steam

consumer

CAC 1 and 2

Burner

Electricity

LOW-PRESSURE STEAM GENERATION FOR INDUSTRIAL APPLICATIONS

Steamconsumer

Hot water

consumer(optional)

Steam generator

Lube oil cooler

CAC 1 and 2

Electricity

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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 heator 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,

POWERFUL CHOICESThe high efficiency of Wärtsilä’s CHP plants

translates into considerable savings in fuel

costs compared to other technologies. For

optimized balance and profitability, the

plants are customized to the customer’s

specific needs.

A decentralized combined heat andpower 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

industrial process steam or even chilled

water, Wärtsilä provides a design that ensures

maximum efficiency and the best possible

overall solution. The automation system notonly controls all the internal processes in

the Wärtsilä CHP plant but is also carefully

integrated with all necessary signals and

connections to existing systems to guarantee a

fully compatible plant.



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1-stage

absorption

chiller

CAC1/

jacket water

Lube oil cooler

95-105 °C

80-90 °C

70-105 °C

45-55 °C

Circulation pump

Hot wateror districtheating

Electricity

12 °C

Chilled wateror district cooling

Boiler

HOT WATER GENERATION FOR DISTRICT HEATING APPLICATIONS

UJPALOTA, HUNGARY

Type of customer ..........................................IPP

Engine type......................3 x Wärtsilä 20V34SG

Total electrical output............................20 MWe

Total heat output ............................... 19.2 MWth

Total efficiency ........................................84.6%

Fuel .............................................................Gas

TRIGENERATIONTypical trigeneration solution for airports



RINGKØBING, DENMARK:

Type of customer ......................................Utility

Engine type......................1 x Wärtsilä 20V34SG

Total electrical output............................ 7.9 MW

Total heat output ................................... 9.7 MWTotal efficiency ........................................... 96%

Fuel .............................................................Gas

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ENGINE TECHNOLOGYA reciprocating engine is the most efficient

means of converting liquid or gaseous fuels

into energy.

The Wärtsilä CHP plant can run on most

natural gas types, heavy and light fuel oils, and

emulsified fuels. Dual-fuel engines give added

reliability to the CHP plant, since they can use

whichever fuel is available at the lowest cost.

The Wärtsilä 20V34SG engine features

the latest design in gas technology.

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Wärtsilä reciprocating gas engines offer stable output

and high performance in hot and dry conditions. No water

consumed for plant cooling = remote area suitability!

0.8

0.85

0.9

0.95

1

1.05

15 20 25 30 35 40 45

Ambient temperature (°C)

Industrial gas turbine

Wärtsilä 20V34SG

(radiator cooling)

Aeroderivate gas turbine

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

Derating due to cooling water temperature.(Derating due to inlet air temperature starts at 45°C)

Derating

factor

Diesel operationGD operationSG operation Dual-fuel operation

ENGINE WORKING PRINCIPLES

The heart of Wärtsilä’s generating sets is

Wärtsilä’s reliable engine technology, the result

of long experience of demanding marine and

power plant applications. All Wärtsilä engines

have a simple and straightforward modern

design with facilities for easy and rapid on-site

maintenance.

GasGas fuel

Gas fuel

Gas

Liquid fuel

Liquidfuel

Liquid fuel



Wärtsilä’s 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?

Wärtsilä provides a comprehensive range

of services built on the concept of enhancing

the customer’s profitability by optimizing all

aspects of the power plant operation.

The services range from rapid spareparts delivery to a complete operation and

maintenance partnership, allowing the

customer to focus on their core business.

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Typical interior and design of a control room

in Wärtsilä power plants.

Wärtsilä Operations & Maintenance currently

runs more than 130 plants around the world,

making it the world’s 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. Wärtsilä’s

global network is always ready to make surethe power plant performs flawlessly, free

of breakdowns and unwanted downtime

throughout its lifetime.

CUSTOMER CARE



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 Wärtsilä 20V34SGTotal electricity output ............... ................ ................. ............ 16.9 MW

Total heat output ............... ................ ................ ................. .... 14.2 MW

Total efficiency ............... ................ ................. ................ ........... 85.1%

Fuel ................ ................. ................ ................ ................. . Natural gas

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Wärtsilä’s 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

COMBINED CYCLE SOLUTIONSusing 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



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BARAJAS AIRPORT, SPAINIn 2003, AENA, the Spanish Airport Authority, called for bids to supply

thermal and electrical energy to the major Barajas airport in Madrid undera twenty-year power purchase agreement.

The trigeneration plant, generating a net electric power of 33 MW, is

connected to the airport’s 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 Wärtsilä 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, ITALYType: ............... ................ ........... Industrial self generation, Trigeneration

Engines ...............................................................3 x Wärtsilä 20V34SG

Total electrical output ...............................................................24 MWeTotal heat output ................. ................ ................. ................ 17.5 MWth

Total efficiency .............. ................. ................ ................. .......... 80.2 %

Fuel ................ ................ ................. ................ ................ .. Natural gas

THE SINGLE-SOURCESUPPLIER THATSTAYS WITH YOU

Wärtsilä 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.



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THE WÄRTSILÄ TOWN CONCEPT is a

Combined Heat and Power plant designed fordecentralized 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

THIS IS NOT THE FUTURE.THIS IS TODAY.

architecture. As the heat recovery system

and other auxiliaries are built into functionalmodules 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.

Module for hot water generation

Cooling radiators

Lubrication

oil tank

Control room

Transformer

Engine exhaust outlet

Engine generator set

Exhaust stacks

Exhaust gas boiler

District heating pump

Engine air intake filters

Feed and return for district



Wärtsilä 34SG

Wärtsilä 34DF

Wärtsilä 50DF

Gas engines

Dual-fuel engines (gaseous fuel/liquid fuel)

Liquid fuel (LFO, HFO, CRO, emulsified,LBF)

Wärtsilä 20

Wärtsilä 32

Wärtsilä 46

1 1 1

LFO = light fuel oil

HFO = heavy fuel oil

CRO = crude oil

LBF = liquid biofuel

Wärtsilä 32GD

Boiler and absorption chillers at

Madrid’s Barajas airport, Spain.

POWER PLANT OUTPUT RANGE

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

Performance data Wärtsilä gas enginesat frequency 50 Hz

Wärtsilä gas enginesat frequency 60 Hz

Engine 9L34SG 16V34SG 20V34SG 20V34DF 18V50DF 9L34SG 16V34SG 20V34SG 20V34DF 18V50DF

Gasmode

Liquidfuel

mode

Gasmode

Liquidfuel

mode

Gasmode

Liquidfuel

mode

Gasmode

Liquidfuel

mode

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

mg/Nm3 95–190* 95–190* 95–190* 190–380*1460–2000* (LFO)1600–2000 (HFO)

190–380* 2000* 95–190* 95–190* 95–190* 190–380*1460–2000* (LFO)1600–2000 (HFO)

190–380* 2000*

Electric power kW 3888 6970 8730 8730 8730 16621 16621 3758 6737 8439 8439 8439 17076 17076

Heat rate1)

kJ/kWh 7817 7753 7737 8036 8127 7616 8185 7817 7753 7737 8036 8127 7616 8186Efficiency 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) °C 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 °C 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 °C 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 °C 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 °C 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 °C 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 12415Cooling 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 figuresare for guidance only and calculated at ISO 3046 reference conditions; 25°C ambient temperature, 100m abovesea level and 30% relative humidity.1) Heat rate and electrical efficiency at generator terminals, including engine-driven pumps, ISO 3046 conditionsand LHV. Tolerance 5%. Power fa ctor 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(273.15 K and 101.3 kPa).

Performance data as guidelines for CHP calculations – Wärtsilä liquid fuelled generating sets at 50 and 60 Hz

Performance data Wärtsilä diesel enginesat frequency 50 Hz Wärtsilä diesel enginesat frequency 60 Hz

Engine 9L20 12V32 16V32 18V32 20V32 18V46 9L20 12V32 16V32 18V32 20V32 18V46

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

ppm-vol

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 °C 84/91 79/96 80/96 80/96 80/96 80/91 84/91 80/96 80/96 80/96 80/96 80/91

– HTCAC temperature inlet/outlet °C 87/96 87/96 88/96 87/96 83/91 87/96 87/96 88/96 88/96 83/91

– Cylinder temperature inlet/outlet °C 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 °C 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 °C 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 °C 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 °C 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 figuresare for guidance only and calculated at ISO 3046 reference conditions; 25°C ambient temperature, 100m abovesea 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 ratesat 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 (273.15 Kand 101.3 kPa).



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

0 1 . 2

0 1 0 / B o c k ´ s O f fi c e / L i t o s e t

WÄRTSILÄ ® is a registered trademark. Copyright © 2010 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.

In 2008, Wärtsilä’s net sales totalled EUR 4.6 billion with 19,000 employees.

The company has operations in 160 locations in 70 countries around the

world. Wärtsilä is listed on the NASDAQ OMX Helsinki, Finland.

CHP Wartsila Combined Heat and Power

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