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power plants

Rolls-Royce is showcasing its medium-speed power solutions at stand 1435 of The Green Expo trade fair in Mexico from 5 to 8 September. Its product portfolio covers a variety of power generation solutions for different applications, from generator sets delivering 3,700 to 9,400 kWe to fully engineered power plants capable of outputs from 5 to 200 MWe and beyond.

Rolls-Royce has supplied power generation customers all over the world with system solutions based on medium-speed engines and currently boasts a global installed base of over 3,500 MWe. It recently entered Mexico’s energy market and has so far sold power plant to diverse customers delivering a total of 33 MWe.

 

Markku Aspholm, Sales Director of Medium-Speed Engines for power generation in the Americas – Rolls-Royce says, “We will be establishing a new service workshop next year to better serve the needs of our newly won customers in Mexico. Rolls-Royce sees big potential for expanding its business in this region by supporting the industry with flexible system solutions tailored to the customer’s individual needs.

Having closed an EPC consortium agreement with engineering company Sampol Ingenieria y obras, Rolls-Royce’s first 18 MWe power plant based on medium-speed engines went into operation in June 2017 in Sonora, Mexico. The plant has now clocked up almost 2000 operating hours without any complications, even at 45°C. It is a cogeneration (CHP) plant owned by utility company Union Energetica del Noroeste (UEN), who sells the generated electricity onwards to various companies. The plant is equipped with two Rolls- Royce Bergen B35:40V20 gas-fuelled generator sets covered by a 12-year service agreement.

Another two CHP modules supplied by Rolls-Royce are scheduled for commissioning at the end of 2017/early 2018, and will be the first two power plants to have been supplied under Mexico’s Energy Reform that came into force in 2016.

The first is a Rolls-Royce Bergen B35:40V20 gas-fuelled generator set that will be installed at an altitude of 2,300 metres in the Mexican city of Perote. It will be responsible for providing steam and electricity to power the industrial processes run by pork producer Granjas Carrol. Surplus energy will be sold to the national grid through the newly structured energy market.

The second is a Rolls-Royce Bergen B35:40V12 generator set to be installed in the trigeneration plant operated by energy service company INCO Renovables S.A.P.I. de C.V.. This particular plant is to provide electrical power, cooling water and steam to a factory being run by Coca Cola producer FEMSA.

Source: Rolls-Royce

Siemens continues to be on a successful course with its energy business in Argentina: the company has secured orders to supply a total of four turnkey industrial power plants to the country. Six SGT-A65 TR (former Industrial Trent 60) gas turbines will form the heart of two plants in the cities of Luján and Matheu in Buenos Aires Province in eastern Argentina. Siemens has also been awarded a contract to supply six industrial gas turbines of type SGT-800 for two power plants in Las Palmas and San Pedro in the cities of San Pedro and Zarate. Siemens’ customers are the two Canadian private equity companies Stoneway Capital and Araucaria Energy led by Roger Nores. They will operate the plants as independent power producers with the support of Siemens. The total order volume for Siemens is approximately USD 570 million. Siemens has also committed a USD 115 million loan to support the power plants’ construction.

These orders mark another major success for Siemens in Argentina,” explains José Aparicio, Vice President for the Sales Region Latin America in Siemens’ Power and Gas Division. “This is the first time we have sold a turnkey industrial power plant equipped with aeroderivative gas turbines, as well as long-term service. What’s more, these four power plants will help to alleviate the power shortages in Argentina and increase the security of power supplies“.

 

Siemens has also signed long-term service agreements for the four sites. These contracts include operation maintenance (OM) and long-term agreements for each location for a period of ten years and include operation and maintenance staff, remote monitoring, 24/7 helpdesk, overhauls, spare parts for stock and reliability guarantees. Siemens service and maintenance is centered on the company’s Digital Services for Energy portfolio, combining advanced data analytics with Siemens’ proven expertise to help customers fully realize the full potential of their power assets for improved reliability and profitability.

With an electrical generating capacity of 127 MW, the plant in Luján will be fitted with two SGT-A65 TR gas turbines and with two SGen5-100A-series electrical generators. The four model SGT-A65 TR turbines destined for the power plant in Matheu will provide a total electrical generating capacity of 254 megawatts (MW). The Las Palmas site will be equipped with four SGT-800 gas turbines with an electrical generating capacity of 202 MW. The other two SGT-800 gas turbines destined for the power plant in San Pedro will generate a total electrical output of 104 MW; commissioning for the four sites is scheduled for the end of 2017.

All the sites have the option to be retrofitted as combined cycle power plants in the near future. The SGT-A65 TR gas turbines are being manufactured as fast-track units at Siemens’ production locations in Mount Vernon, Ohio, in the United States, and in Montreal, Canada. The corresponding generators will be provided by the Siemens’ manufacturing facility in Erfurt, Germany. The SGT-800 gas turbines will be manufactured in Finspang, Sweden.

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Siemens is paving the way for the next level of efficiency with the development of its HL-class. In June 2017, Siemens announced the company will validate the technologies of its HL-class at Duke Energy’s Lincoln County site in North Carolina. Siemens is developing this class in an evolutionary development step derived from its proven SGT-8000H technology. The advanced Siemens HL-class gas turbines combine a series of new but already tested technologies and design features with the best of past experience – resulting in a technology carrier to the next level of efficiency and performance. The HL-class is clearing the way to efficiency levels beyond 63% with a mid-term goal to reach 65%.

Furthermore, Siemens is gaining speed to drive technological upgrades and competitiveness by transferring newly developed key technologies to its entire gas turbine portfolio. In the near future, all customers will benefit from further efficiency and performance increases. This approach is part of a series of activities to help Siemens’ customers compete in a rapidly changing market – working to significantly reduce lead and construction times through standardization and modularization.
The new Siemens HL-class consists of three engines: SGT5-9000HL, SGT6-9000HL and SGT5-8000HL. In simple-cycle operation the air-cooled SGT-9000HL gas turbine will provide a capacity of 545 MW for the 50-Hertz market and 374 MW in the 60-Hertz version. SGT5-8000HL will provide 453 MW in simple-cycle operation. All engines reach more than 63% combined cycle efficiency.

To achieve top performance, the turbines operate at high combustion temperatures. For this purpose, Siemens’ specialists have developed advanced combustion technologies, innovative multi-layer coatings, super-efficient internal cooling features as well as an optimized water-steam cycle. Furthermore, optimized sealings minimize cooling and air leakage. At the same time, evolutionary 3D-blading is enabling higher aero-efficiency for the compressor. Predefined and prefabricated solution elements as well as pre-selected vendors and products allow a significantly reduced construction time and a fast start for projects. The turbines are designed to plug in to Siemens’ digital offering for plant operators and utilities alike, incorporating connectivity to MindSphere, the cloud-based Siemens operating system for the Internet of Things. MindSphere offers access to powerful analytics from Siemens and its partners – using intuitive insights in engine operation and decision support to deliver benefits to customers.

Driven by digitalization, speed in technology development is rapidly gaining momentum in the power generation arena,” said Willi Meixner, CEO of the Siemens Power and Gas Division. “It took us 10 years from 2000 to 2010 to increase the efficiency of our combined cycle power plants from 58 to 60%, a further six years to reach 61.5% in 2016 and now we are taking the next step to 63% and beyond. That’s amazing. But we know that speed and efficiency alone are not sufficient – reliability and cost effectiveness of our solutions as well as partnership, support in financing and insurability are also key to our customers,” said Meixner.

To minimize customer risk, Siemens is following an extensive and thorough validation and testing approach. After component testing and prototype testing in Siemens-owned facilities, the company is now pursuing validation under real field conditions. “With the new HL-class our customers will be prepared for whatever digitalization brings in the future,” Meixner added.

Worldwide we see renewables are growing rapidly, but gas-fired power plants will still play a vital role in the energy mix for the next decades,” said Meixner. “With the growing share of fluctuation power from renewables, flexibility will be a key feature of gas turbines. Our HL-class offers a simple-cycle ramp-up of 85 MW per minute. Therefore, highly efficient and flexible gas turbines like our HL-class are the perfect fit to energy systems with a rapidly increasing share of fluctuating renewables,” said Meixner.

Source: Siemens

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German Chancellor Angela Merkel and Egyptian President Abdel Fattah El-Sisi symbolically inaugurated the first phase of Siemens’ megaproject in Egypt. The event marks an important milestone towards the completion of the project, which will boost the country’s power generation capacity by 45 percent when finished. Together with its local partners, Orascom Construction and Elsewedy Electric, Siemens broke all records in modern power plant construction by connecting 4.8 GW of new capacity to the grid in only 18 months after the signing of the contract for the company’s biggest single order ever.

Complementary to the megaproject, Siemens supports the development of future highly skilled Egyptian workforce, and has announced the details of a strategic alliance agreement between Germany’s Federal Ministry for Economic Cooperation and Development (BMZ) and the company to support occupational training in Egypt. The announcement was made by Joe Kaeser, President and CEO of Siemens AG at an event, which was attended by local officials and business leaders.

 

As part of the agreement, Siemens will join forces with the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH on behalf of BMZ, for the establishment and the operation of a joint training center as well as the strengthening of one selected Egyptian public vocational training institute. The program was designed in line with Egypt’s objectives outlined in “Egypt Vision 2030” to promote long-term economic growth, create new jobs and increase the competiveness of Egyptian industries.

Occupational training and the development of local skills are crucial to boosting local growth and increasing hiring prospects in the power industry and other sectors of the economy. For instance, in the energy sector alone, more than 20,000 workers and technicians are engaged at Siemens’ three power plant sites during implementation.

The new training center will serve as a sustainable vocational and industry-specific training provider that enriches the country’s technical talent pool. When completed, the approximately 2,000 square meter facility, which will be built in the Ain Sokhna area, will serve to train 5,500 selected technicians and engineers over four years. Career starters will be trained in advanced skills such as operation, maintenance, and repair in the energy sector; in addition to vast range of cross-industrial electrical and mechanical trades; automation and control, mechatronics as well as other areas that are important for the Egyptian economy.

Located at the New Suez Canal Development Zone, the facility will offer the latest technology, simulating ‘real-life’ conditions, using a variety of training courses and different approaches to prepare technicians and engineers throughout the region with specific skills that will be needed in their careers.

Siemens and GIZ will also strengthen one public vocational training institute, following the example of the German vocational education system to meet future professional and business demands. Successful graduates will be offered the opportunity to join the BMZ-Siemens training center and later on have the chance to join the expanding industry sectors in Egypt.

The construction of the training center is scheduled to begin in 2017, with the facility scheduled to open in 2018. Siemens is one of Germany’s largest private educational institutions with training programs for 9,000 apprentices and university students.

The construction works for Siemens’ megaproject in Egypt are enormous. More than 1,600,000 tons of material – including 960,000 tons of concrete and 48,000 tons of rebar steel – will be processed until completion. At Beni Suef, massive excavation works were necessary to prepare the site, leading to the removal of around 1,750,000 m3 of rocks. This is equivalent to the volume of the smaller Giza pyramid. When completed, each of the three power plants, located at Beni Suef, New Capital and Burullus, is set to become the biggest gas-fired combined-cycle power station in the world. Altogether, the three power plants will have a combined capacity of 14.4 GW.

To increase the capacity of the transmission network nationwide, Siemens has successfully put the first three substations into operation that will transmit the electricity generated by the three power plants to Egypt’s power grid. The three substations, Etay El-Baroud, Maghagha and Kafr El Zayat, were ready for operation within ten months from signing the contracts, to match the implementation timeframe of the power plants. In December 2016, Siemens and El Sewedy Electric T&D, signed a contract with the Egyptian Electricity Transmission Company (EETC) for the design, engineering, supply and installation of six substations, located in the cities of Maghagha, Etay El-Baroud, Banha, Wadi El-Natroun, Assiut and Kafr El Zayat. The remaining substations will be completed and connected to the grid by the end of December 2017.

Siemens’ megaproject in Egypt also comprises 9-year service and maintenance agreements for the three power plants to help ensure the long-term reliability, availability and optimal performance of the units. The service and maintenance operations will be supported by Siemens digital services products and offerings, tapping into the company’s advanced data analytics.

Financing was also an important source of support for the megaproject: The financing package for the Siemens part of the contracts was structured by Siemens Financial Services (SFS). It also included a tailored guarantee concept. The financing of major parts of Siemens’ and its local partners’ scope, for the three power plants, was provided by a consortium of international and regional banks. The credit facilities are largely covered by Export Credit Agencies.

Source: Siemens

Oct 26th-28th, the Green EXPO 2016 was held in Mexico City. As the global leader in the PV industry, Huawei took part in the exhibition with the FusionSolar Smart PV Solution. In addition, the solution was demonstrated from multiple dimensions and scenarios, like ground and rooftop plant, presenting Huawei’s high technologies to participating customers.

During the exhibition, Huawei showed the most advanced 1500V Solution and products, global success cases and company development. The 1500V Solution is much more safe, reliable and higher efficiency. Huawei has already constructed high generation power plants in England, Germany, Japan, and China. And in 2015, Huawei ranked the global No.1 shipment, according to the latest reports of IHS and GTM Research.

Mexico is an essential inverter market to Huawei. There were many prominent guests come to Huawei booth. Huawei had deep discussions on the development prospect of renewable energy and the intelligent O&M of PV plants with these senior leaders. Both sides look forward to the cooperation in the future.

In this exhibition, Huawei promoted the SUN2000-36/42KTL smart PV inverter for the Latin American market. The inverter European efficiency is 98.6%, and the maximum efficiency is 98.8%. Four maximum power point tracks (MPPTs) can minimize energy yield loss due to PV array mismatch and improve the energy yield of the power plant by more than 2%. High-precision sensors can accurately detect information about each string and the states of key components to remotely manage PV power plants. IP65 protection, no-fuse, and natural cooling design enable smart PV power plants versatile for all the hostile outdoor environment like high temperature, high dampness, high altitude, extreme cold, sandy, salt and mist areas and ensure secure and reliable running of inverters in the power plant lifecycle.

Huawei smart PV inverters adopt Hisilicon chipsets and operating system, use fewer copper devices, changes the traditional power converter to a smart controller that can “think” as the “brain” of a power plant to improve inverter efficiency and performance. In addition, the PLC technology substitutes for RS485 communications cables, ensuring secure and reliable power plant communication. Inverters can supply power to tracking supports and provide high-speed communication channels to simply the system networking and reduce costs. With higher reliability, the inverter uptime can reach to 99.996%, which is certified by TÜV, if sufficient the spare parts are maintained on site. Equivalent CAPEX as central inverter, higher yield up 2%, simple O&M saving maintenance cost, and safe and reliable system are the key reasons for the company’s rapid growth, that continuously upgrade and innovate its product offering as per the market need.

According to the new act legislated by Mexican Government, the power ratio generated by clean energy should be 35% in 2024. Huawei will continue to increase the investment especially in Mexico, Brazil and Chile, to assist the rapid growth of the renewable energy market in Latin American market.

Source: Huawei

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La turbina de gas SGT-800 de Siemens en el edificio de fabricación del taller de turbina de gas en Finspong, Suecia / The Siemens SGT-800 gas turbine in the manufacturing building of the gas turbine workshop in Finspong, Sweden

Siemens has received an order from Israel for the first time for the turnkey construction of two industrial combined cycle power plants. The two natural gas-fired power plants, Alon Tavor and Ramat Gabriel, are to be built in northern Israel. Alon Tavor will supply a creamery with electricity and process steam, while Ramat Gabriel will supply a fiber factory. The Israeli energy provider, RD Energy, is the customer for both power plants. Commissioning of the plants is scheduled for mid-2018.

Siemens will handle the turnkey construction of both plants and will supply one SGT-800 industrial gas turbine, one SST-300 industrial steam turbine as well as the SPPA-T3000 control system for each project. The industrial plants will each have an electrical capacity of 70 megawatts and feature steam extraction. Electricity will be fed into the Israeli power grid. The turbines will be manufactured in Finspong, Sweden and Brno, Czech Republic.

The Israeli power plant market offers enormous potential, and Siemens has a strong presence in the country,” says Shmuel Fledel, CEO of Siemens Israel and country division lead of the Power and Gas Division. “We are now supplying our first entirely combined cycle plants to an Israeli independent power producer. This is a good opportunity to establish ourselves in the country as a supplier of turnkey power plant solutions and services. The order will also make an important contribution toward Siemens’ targeted growth for industrial power plants.” Approximately 40 percent of Israel’s power generation capacity is already based on Siemens technology.

Source: Siemens

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Wärtsilä has been awarded five power plant projects, which will support development of the national grid in Argentina. Contracts for three power plants, totalling EUR 78 million, have been signed with Industrias J.F.Secco S.A. (Secco) and are included in Wärtsilä’s order book for the second quarter of 2016. Additionally, Wärtsilä has been awarded two projects with two other Argentinian independent power producers, which are expected to be included in Wärtsilä’s order book in the third quarter of 2016. The combined output of all five plants will be 382 MW. The total value of these orders is estimated to be approximately EUR 150 million.

The three power plants for Secco, with a total output of 192 MW, are all based on Wärtsilä dual-fuel engines. The plants will be run primarily on gas and heavy fuel oil will be used as the back-up fuel. Thirteen Wärtsilä 34DF dual-fuel engines are included in the deliveries for two of the plants, while four Wärtsilä 50DF dual-fuel engines will power the third plant. All three locations are in the Santa Fe province in central Argentina. The equipment is scheduled to be delivered in early 2017. The plants will be fully operational during the second half of 2017. The contract includes extended engineering and equipment (EEQ).

These projects stem from a tender issued by CAMMESA, the national grid system operator, on behalf of the Ministry of Energy in Argentina. The Ministry aims to further develop and strengthen the national grid in order to supply Argentina’s population and industry with reliable power. Natural gas, the primary fuel for power plants, is not available for several months during the year, thus making the highly efficient Wärtsilä dual-fuel technology a very suitable solution. It is also particularly competitive, due to its ability to employ heavy fuel oil as a backup at a much lower cost than light fuel oil. The Wärtsilä plants will feed power into Argentina’s national grid under a PPA (power purchase agreement) between Secco and the government of Argentina.

 

Source: Wärtsilä

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Wärtsilä is entering the solar energy business by offering utility-scale solar photo-voltaic (PV) solutions. The new solutions include solar PV power plants of 10 MW and above, and hybrid power plants comprising solar PV plants and internal combustion engines. Both solutions are offered with full engineering, procurement and construction (EPC) delivery. Wärtsilä’s first solar project will be built in Jordan.

“We are excited to expand our portfolio with new sustainable innovations and help our customers reduce their carbon emissions. Large-scale solar is a big business, with the installed base expected to grow four-fold to 450 GW by 2025. Our competitive edge builds on three things: global EPC capability, a wide sales and service network, and an existing customer base in 176 countries,” says Javier Cavada, President of Wärtsilä Energy Solutions.

Wärtsilä expects rapid growth in solar business, resulting in annual sales of 300 million euros in 2020. Target customers for Wärtsilä’s solar solutions are utilities, independent power producers (IPPs) and industrial customers. The focus areas include Africa, the Middle-East, Latin America and South East Asia. Wärtsilä will acquire the solar PV modules for the EPC projects from leading module suppliers.

Wärtsilä is the first company to offer utility-scale solar hybrid plants. The hybrid solution couples a solar PV park with an ultra-flexible Wärtsilä Smart Power Generation power plant. The two units operate in synchronisation to reduce the engines’ fuel consumption.

Wärtsilä’s first solar project is a retrofit hybrid plant in Jordan. It combines a solar PV farm with IPP4, a 250 MW Smart Power Generation plant comprising sixteen Wärtsilä 50DF engines, delivered to AES Jordan in 2014. Wärtsilä’s EPC scope includes 46 MW of solar modules, covering an area of 81 hectares, as well as inverters, switchgear, control systems and overhead transmission lines. The project will be included in Wärtsilä’s order book in the fourth quarter of 2016.

“The solar unit will reduce the carbon footprint of the power plant by saving fuel during the daytime. Experience has shown we can trust Wärtsilä’s EPC capability. We consider Wärtsilä to be a partner with a reputation for quality,” says Meftaur Rahman, President and CEO of AES Jordan.

Wärtsilä’s installed power plant base is 60 GW in 176 countries.

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Combined-cycle plants are arguably the least well-known electrical plants, but in Spain they account for 25% of the country’s installed capacity. There are ten units based on this technology, manufactured by Siemens: two in Campo de Gibraltar (Cádiz), three in Palos de la Frontera (Huelva), two in Arrúbal (La Rioja) and three more in Sagunto (Valencia). Today, these plants continue to work as the most useful safeguard to guarantee Europe’s energy generation system, counted among the least contaminant fossil fuel combustion plants in the world. Their thermodynamic efficiency, in other words, the percentage of energy that can be obtained from the fuel, is around 60% (much higher than that generated by a coal-fired plant).

The key lies in its operation. This technology generates electricity from the rotation of a turbine propelled by the combustion of natural gas. Apart from the electrical energy generated by the gas turbine itself, the resultant heat from this combustion is used to heat water, converting it into steam
to be used in a second turbine that also produces electricity. Moreover, the application of Siemens technology improves these ratios, by reducing CO2 emissions by one third. Siemens’ SGT5-8000H gas turbine has broken a world record by exceeding 60.75% efficiency at the Irsching plant in Germany.

Despite the advantages of combined-cycle plants, they only covered 8.5% of electricity demand in 2015, at the same time as playing a leading role in complementing renewable energy sources; as clean and they are unpredictable as they only produce where there is sun and wind. As such, combined-cycle plants, that were originally designed to mainly operate at full load, are able to handle difficult market conditions: fewer operating hours, a reduction in megawatts generated, a higher number of start-ups and greater market control as regards gas reserves. And they are achieving this in a scenario in which energy demand is once again on the up, at the same time as the ageing of the plants is becoming more pronounced. Read more…

Laurent Dendrael
Head of Service for Combined Cycle Power Plants, Siemens Spain

Article published in: FuturENERGY January-February 2016

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Even though subsidies are declining in Europe, it will remain the world’s most important market for biomass power plants, with 75 billion € to be invested within the next 10 years. The market in Asia is flagging at a high level and still shows the worldwide largest capacity increases. These are the results of ecoprog’s latest market analysis, “Biomass to Power”.

Today, there are almost 2,900 active biomass power plants (BMPPs) worldwide, with an electrical capacity of around 47 GWe. Additionally, biomass is co-incinerated in coal power plants. This is so far mainly happening in European countries such as Denmark, the Netherlands and the UK. However, Japan and South Korea are also steadily increasing the combustion of pellets in coal-fired power stations.

By 2024, the number of BMPPs will increase to 4,250, the overall capacity to 71 GWe. This means that the plants’ total capacities will almost double. The countries with the strongest developments will be the USA, Brazil, China, India, the UK and France.

The most important market stimulus is the granting of subsidies for electricity generation from renewable energy sources, and by now more than 140 countries have introduced such support schemes. The most attractive schemes for electricity generation from solid biomass are established in Europe. In the past years, more and more Asian countries have also introduced such biomass subsidies.

The support schemes in Europe have been established for a long time and are thus very versatile. At present, however, subsidies are declining in many countries, due to high costs and for ecological reasons. The Czech Republic has even stopped subsidisation completely. Germany, which had been a large growth market, reduced and capped financial incentives to an extent that the construction of additional plants has almost come to a standstill.

France and the UK have by contrast newer and quite attractive legislation, which makes them the most dynamic markets in Europe. Planning reliability will also return to Poland in early 2016, when, after many years of delay, a new support scheme based on auctions will be introduced.

The Asian biomass market is not developing as dynamically as expected. Large markets such as China and India show first signs of saturation, e.g. high fuel prices and project withdrawals. Additionally, smaller Asian states such as the Philippines only grant low and limited subsidies. Many market players furthermore state problems with logistics and funding shortfalls as main reasons for the sometimes sluggish development of capacities.

Still, from 2017 onwards, Asia will see a stronger increase of capacities than Europe. This is due to the fact that mostly large-scale projects are realised in Asia, with capacities between 10 and 30 MWe. In Europe, by contrast, small-scale plants of up to 5 MWe benefit the most from the local support schemes, which is why most newly constructed facilities will have such a capacity range.

Furthermore, using the plants’ waste heat is obligatory in many European countries. The plants there are thus equipped with efficient heat use technology and located at industrial sites or district heating grids.

The small plant size, the common design as CHP facilities and high environmental standards in Europe result in average investment costs of 5.6 million € per MWe, which is significantly more than in Asia. The investment costs in Asia, and especially in China, are lower due to standardised plants that generate electricity only.

In monetary terms, Europe will thus remain the most important BMPP market in the next 10 years – even though the development of capacities will decrease considerably when compared to the past 5 years.

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