ETC boosts payback on new power plants

Wärtsilä is a global provider of power solutions for the power industry, and marine, gas and oil sectors, with customers in over 170 countries. The company is a leader in the energy sector, with a strong focus on engine optimisation and technological innovation.

In 2011, Wärtsilä began working with us in Bermeo, Spain, to evaluate the effectiveness of our Electric Turbo Compounding (ETC) exhaust recovery system. Wärtsilä was seeking ways to improve engine efficiency and deliver additional power output without increasing fuel consumption. The trials in Spain demonstrated that the ETC system would increase net power output by 1.4%, with no impact on engine operation.

Based on this success, in 2012 Wärtsilä’s Energy Solutions division challenged us to prove the long-term performance of the system over a 4,000-hour trial in Tirenda, Turkey, with rigorous durability tests carried out on a 9MW Wärtsilä 34SG engine, in a Wärtsilä operated power plant.

We designed a bespoke high-speed electrical machine in which the ETC system was housed within a frame and connected via a valve system to the engine. The system recovers exhaust gas which is normally lost through the exhaust outlet, and generates additional usable electricity, thereby improving the overall efficiency of the engine.

Project results:

During this project we achieved and exceed all project goals, including:

  • 1.5% additional free power generated
  • Zero impact on engine reliability
  • Over 600 trouble free engine shut-downs and start-ups
  • Over 450MWh of free energy generated in total
  • Over 8,200 system running hours
  • Accelerated payback on an entire power plant project

ETC now available for new power plants

As a result of the long-term trials, ETC technology is now available on new Wärtsilä power plant projects, equipped with Wärtsilä 34SG/50SG gas engines, and can also be retrofitted to Wärtsilä liquid fuel engines converted to gas operation.

Click here to download the case study.

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