Efficient and reliable solution for harsh operating conditions

Increased efficiency with waste heat recovery system

Under an engineering, procurement & construction (EPC) contract, Wärtsilä delivered a Flexicycle^TM power plant capable of using excess exhaust heat to generate even more electricity. The plant features 10 Wärtsilä 18V50DF dual-fuel engines with one redundant engine (N+1 configuration).

The dual-fuel power plant operates primarily on natural gas with light fuel oil and crude oil as backup fuels. The plant will provide power to run the Yamama facility, which has a daily production capacity of 20,000 tonnes of cement. The power plant contributes significant energy generation for Saudi Arabia's cement sector, with a total output of 161 MW.

As a full EPC project, Wärtsilä was responsible for handling all aspects of the construction and delivery of the plant. A 5-year Operation & Maintenance (O&M) agreement with a 10-year spare parts supply agreement was signed to cover every aspect of the day-to-day operation and all related maintenance and administration tasks.

Meeting customer needs

Yamama Cement is Wärtsilä's first gas-fired Flexicycle power plant in Saudi Arabia, and it has been a continuation of Wärtsilä's successful record in the country. The plant is a landmark power plant in Saudi Arabia because of its combined cycle and dual-fuel capabilities, and it is Saudi Arabia's largest-to-date engine plant installation. The project was achieved through Wärtsilä's emphasis on customer centricity - Where customer interests and satisfaction come first.

The operating conditions in Saudi Arabia's desert climate are harsh, making efficient power usage more difficult. The environment presents its own challenges, with high ambient temperatures, dust and scarce water resources. Usually, cement plants are located in remote areas, and most of the cement industry in Saudi Arabia is powered by captive power plants like Yamama Cement.

While the plant's ability to operate with light fuel oil and crude oil as a backup is nothing new, its real benefit lies in the waste heat recovery system that will use excess heat from the exhaust to power a steam turbine and generate electricity, maximising the plant's efficiency. The solution combines excellent efficiency with complete reliability and availability, providing a great return on investment. Wärtsilä's offer complied with all of the customer prerequisites – technically, economically and operationally.