V35/44G
MAN Diesel & Turbo is the world’s leading designer and manufacturer of low and
medium speed engines. With our range of large stationary gas and diesel engines,
we are a reliable partner for power generating companies, regardless of whether
the energy is fed into the power grid or destined for local supply purposes.
From fuel depot to transformer station, MAN Diesel & Turbo offers one-stop
solu-tions. Our involvement with electrical power generators goes back to 1904 when
we supplied the first ever diesel generator sets to the Kiev Tram System.
Since those early days, MAN Diesel & Turbo has never lost its technological
pre-eminence in the large engine field. Likewise, our engines have never relinquished
their status as the most efficient combustion engines available.
More than ever before, MAN Diesel & Turbo’s development focus is on the
environ-mental performance of our engines. Using our unrivalled grasp of large engine
technology, we aim to make our engines progressively cleaner, more powerful and
more efficient.
With our absolute commitment to reducing emissions while increasing fuel
efficiency and power density and our pro-active involvement in the emissions
law making process, we intend to be part of the global emissions solution.
4 V35/44G – Four-stroke gas engine
Introduction
Driving the stationary use of gas engines
In the near future, the new energy economy will see greater use of fluctuating renewables, such as wind and solar power. This will go hand in hand with the use of highly flexible and efficient decentralised plants, offering combined heat and power (CHP) and provid-ing a fast-operatprovid-ing reserve in a time window of 5-10 minutes.
According to key international organisations such as the International Energy Association (IEA), natural gas will be a cornerstone of this seismic shift on world-wide energy markets. Thanks to its availability and low emissions, natural gas is set to play a significant role in the sustainable energy supply of tomorrow. MAN Diesel & Turbo has developed the single-stage turbocharged Otto gas engine 20V35/44G for
station-ary use in power plants. The engine reaches an out-put of 10.6 MW, has an electrical efficiency of 47.3%, features many innovative technological elements and complies with all current emission limits solely by in-engine measures.
Our portfolio includes solutions for highly efficient electrical power, sustainable heating and cooling, and operating reserve that can be brought on stream at short notice. All of these can be tailored to the needs of customers around the world, delivering maximum return on investment.
MAN Diesel & Turbo SE has a successful track record of highly flexible and innovative energy solutions stretching back 250 years, catering to established and emerging energy markets the world over.
Today, state-of-the-art power generation technology should be designed for
high-est efficiency and lowhigh-est emissions.
5 V35/44G – Four-stroke gas engine
35/44G
A new class of large bore gas engine
Modern and innovative
With its newest gas engine, MAN Diesel & Turbo is now bringing the benefits of gas engines to power and cogeneration plants with electrical outputs of 100 to 200 MW, a category previously dominated by gas turbines.
Highest power density in its class
The 35/44G is offered in a V-type version with 20 cyl-inders and an output of 10,600 kWm. Its rated outputs – 530 kW per cylinder for 50 Hz power generation and 510 kW for 60 Hz power generation – give the 35/44G best-in-class power density among gas engines.
A promising fuel
In addition to a high supply reliability and the poten-tial savings on operating and procurement costs, the advantage of gas-fired power plants lies chiefly in extremely low emissions coupled with a high level of efficiency. Due to the lower carbon content of the fuel, gas engines emit around 25% less CO2 than diesel engines. Nitrogen oxide (NOx) emissions are roughly 80% lower, while emissions of sulfur oxides, soot, and particles are virtually non-existent.
The lean-burn concept
In a lean-burn gas engine, the mixture of air and gas in the cylinder is lean, i.e. more air is present in the cylinder than is needed for complete combustion.
With leaner combustion, the peak temperature is re-duced and less NOx is produced.
Higher output can be reached while avoiding knock-ing and increasknock-ing efficiency, although a too lean mix-ture will cause misfiring.
Advanced Ignition Technology
The ignition system comprises a capacitive discharge system and an ignition coil, which delivers the neces-sary high voltage via an ignition lead to the spark plug. To improve combustion, the spark plug is located in the pre-chamber.
Gas is precisely metered to the pre-chamber by means of a separate valve.
In conjunction with the lean mixture from the main chamber, which is fed into the pre-chamber by the compression cycle, this creates a highly efficient, almost stochiometric mixture. This is ignited using the spark plug, providing an ignition amplifier for the main chamber.
Gas engines are claiming an increasing share of the market for electrical power
generation - thanks to their clean combustion, high efficiencies, comparatively low
carbon dioxide emissions and the attractive price of natural gas.
SaCoS
oneThe 35/44G engine is equipped with the safety and control system SaCoSone. SaCoSone guarantees reli-able engine operation with an optimum operation range between knocking and misfiring. All cylinders are regulated individually.
Cogeneration or combined cycle
In addition to using thermal energy recovered from engine sources for heating or cooling in cogeneration or trigeneration applications, the exhaust heat of the 35/44G engine can also be used to produce steam to drive a steam turbine generator. As a result, the overall output and efficiency of the power plant can be increased without additional fuel costs.
Further major benefits of the 35/44G
Reliable power source: 10,600 kWm rated power Low fuel costs: 47.3% el. efficiency single cycle Heat utilisation: > 90% total efficiency
Short power ramp up time: 100% load within
8 minutes
Ambient temperature compensation: Tair = 40
vin without power derating
Easy maintenance / high availability High safety standards
8 V35/44G – Four-stroke gas engine
Solutions
Electrical power and combined cycle
9 V35/44G – Four-stroke gas engine
Combined cycle
To meet the requirements of high efficiency and en-vironmental friendliness in the production of power, MAN Diesel & Turbo has developed a power cycle process for stationary power plants that utilises heat from the engine exhaust gases for the production of live steam in a bottoming process.
The steam is expanded in a steam turbine, which produces electrical energy via the Clausius-Rankine cycle. This additional electrical energy is produced without consuming additional fuel, which is the strength of the combined cycle.
Powerful performance
A reliable supply of electricity is essential for global economic growth. Given the need for reliability of sup-ply and the environmentally-friendly use of resources, the demands in terms of the energy mix are changing; a flexible range of supply options and efficient, de-centralised production are now more important than ever before.
MAN Diesel & Turbo can help provide this crucial re-source with its highly efficient 20V35/44G gas engine. The newly developed Otto gas engine is suitable for
An example layout of a power station with gas engine combined cycle is shown in the illustration above. The power house contains the engines and the steam turbine with their generators. The hot exhaust gases flow through the heat recovery steam generators be-fore they enter the stacks. The steam is re-cooled by a condenser. The electrical power produced by the engines and the steam turbine is supplied to the grid at the sub-station.
smaller decentralised power plants and can also be deployed in large power plants of up to 150 MW. MAN Diesel & Turbo can draw on its extensive glo-bal expertise in delivering customised turnkey power plants to provide the best solution for your needs. In order to achieve the highest efficiency rates and maximise sustainability, MAN Diesel & Turbo has implemented an integrated gas strategy, which incorporates both the company`s engine and turbine technologies.
Exhaust silencer
MAN Diesel & Turbo 20V35/44G Main stack
Exhaust gas steam boiler
Powerhouse LP steam drum
HP steam drum Air cooled
condenser
MAN steam turbine
District heating water Engine lube oil
Engine jacket + CAC 1&2 Engine exhaust gas Back-up cooling Chimney Electricity Bypass WHRB HT heat recovery District heating network Lube oil heat recovery Back-up cooler HT CAC 1 CAC 2
Solutions
Combined heat and power (CHP)
When electricity is generated in engine-based power plants, waste heat at various temperatures is pro-duced. MAN Diesel & Turbo offers different tech-nologies to convert this waste heat into a useful energy form.
MAN Diesel & Turbo’s engine-based CHP plants are designed to meet end consumers' heating needs and can be used for a wide range of thermal applications – whether at industrial, city-wide or at individual build-ing levels.
The heat extracted from the engine’s exhaust gases can be utilised for steam generation required in the textiles, food, paper and chemicals industries. By in-cluding an exhaust gas or hot water driven absorp-tion chiller, chilled water to run central air condiabsorp-tioning systems in hospitals, hotels and office blocks - can be produced. The heat extracted from the engine lube oil, the engine jacket water and the charge air cool-ing circuits can be utilised for hot water generation, e.g. used in a district heating network for heating pur-poses.
Hot Water Generation
For different applications
Decentralised provision of electricity, hot water, steam and cooling is one of the
most sustainable forms of energy provision. Depending on the heat sinks, CHP can
achieve overall efficiencies of over 90 per cent. Generators driven by gas engines
offer exceptional flexibility, giving them a significant advantage over other power
plant technologies.
Energy flow diagram*
Heat recovery diagram*
* Based on 20V35/44G ISO-3046 conditions; efficiencies valid for return line temperature of 60°C and supply line temperature of 125°C Electricity to grid 45.5% Total CHP efficiency 90% Heat to heat consumers 44.5% Pl an t a ux ili ar ie s, tr af o lo ss es 0 .8 % El ec tr ic al ou tp ut 4 6. 3% Hi gh te m pe ra tu re he at 3 9. 5% Lo w te m pe ra tu re he at 5 % Lo ss es 9 .2 % Fuel input 100%
Benefits
Lower energy costs through more efficient
tion of primary energy
Improved environmental quality through reduced
emissions of pollutants
Recovered waste heat for a wide range of
able thermal applications
Operational flexibility in line with changes in heat
12 V35/44G – Four-stroke gas engine
Solutions
Operating reserve
In addition to rapid start-up, these solutions also need to be extremely efficient when operating under part-load conditions, and capable of accommodating wide variations in load.
These types of applications are set to become in-creasingly attractive for independent power produc-ers (IPPs), local utilities and electricity distributors: the growth of fluctuating energy supplies from renewables
will change the face of electricity markets, adding new capacity markets, where the price of rapidly available short-term operating reserve will rise in line with de-mand.
In contrast to axial flow machines, gas-engine based plants are physically suited to these kinds of applica-tions: they operate efficiently at loads of anything from 20% to 100% of rated load.
Comparison of generation technologies in provision of short-term operating reserve
All plants pre-heated and in normal start-up programme Sample data only
Generation technology providing short-term operating reserve Gas-engine based plants (MAN 20V35/44G) 750 min-1 Large gas-turbine based plants (aeroderivaled turbines) 3,000 min-1 Large gas-turbine combined cycle power plants 3,000 min-1
Coal-fired plants (subcritical) 3,000 min-1
Time (min) to full load incl. synchronisation with grid
8 8 110 > 250
Part-load flexibility / Increase in load (%) in 5 seconds
30 10 5 2
Around the world, energy is increasingly being generated from fluctuating
renewable sources. However, wind turbines and solar power plants require
highly flexible power plant technologies that are able to provide highly efficient
electrical back-up power at extremely short notice in order to stabilise the grid.
Environmental Awareness
Natural gas – the most environmental friendly
fossil energy source
CO2 emitted by various power plant technologies
CO2 emissions from natural gas: 202g/kWh; CO2 emissions from coal: 340g/kWh; Sample data only CO2 emitted by various generation
technologies
Gas-engine based plants (MAN 20V35/44G)
Gas turbine-based plants (industrial gas turbines)
Coal-fired power plants (subcritical)
Electrical efficiency in % (CO2 emissions in g/kWh) 47.3 (427) 33 (612) 38 (895) Thermal efficiency in CHP in % (CO2 emissions in g/kWh) 90 (224) 80 (252) 80 (425)
Being able to scale output to meet consumers’ heat-ing needs is an important consideration when select-ing a power plant technology. The emissions pro-duced by the generation of energy are another key criterion. Gas-engine based plants score extremely well in this regard, due to their high efficiency and use
of natural gas. Recently, CO2 emissions have come under particular scrutiny, given their impact on climate change. In the EU, the majority of CO2 permits will be auctioned from 2013, reshaping cost considerations and ensuring that only the most efficient technologies will remain competitive.
Maximum allowed exhaust gas emission values according to TA-Luft
Nitrogen oxides, NOx in mg/Nm3 1) 500
Carbon monoxides, CO in mg/Nm3 2) 300
Formaldehyde in mg/Nm3 60
Sulphur dioxide, SO2 in mg/Nm3 3) 8.9
Reference oxygen content of exhaust: 5%; 1) Calculated as NO2
2) Compliance with German TA-Luft emissions legislation by means of a catalyst 3) SO2 content in the exhaust gas depends on the H2S content in the natural gas
17 V35/44G – Four-stroke gas engine 16 V35/44G – Four-stroke gas engine
Technical Data
Dimensions and weights
20V35/44G H W B A C Engine type 20V35/44G No. of cyl. 20 A (mm) 9,680 B* (mm) 4,295 C* (mm) 13,975 W (mm) 3,845 H (mm) 4,540 Dry mass gen.* (t) 30.5 Dry mass engine (t) 113.5 * Depending on alternator; nominal generator efficiency: 97.5%
Mean piston speed (m/s) Electrical output (kWel) Lube oil consumption (kg/h) 20V35/44G for power applications Heat rate (kJ/kWhel)
Electrical efficiency (%)
20V35/44G for CHP applications Heat rate (kJ/kWhel)
Electrical efficiency (%)
Output at generator terminals. Nominal efficiency 97.5%. ISO 3046-1 conditions; including attached pumps; MN > 80; 5% tolerance; engine type specific reference charge air temperature before cylinder 43°C; p.f. 0.9;
NOx emissions 500mg/Nm3 @ 5% O2
Four-stroke gas engine 20V35/44G
750 rpm, 50 Hz 11.0 10,335 3.7 7,618 47.3 7,782 46.3 720 rpm, 60 Hz 10.6 9,945 3.5 7,618 47.3 7,782 46.3 Bore 350 mm, stroke 440 mm Engine 20V35/44G
International subsidies for CHP
In many countries, including OECD members, there are fixed prices for the combined generation of heat and power. These represent a highly attractive addi-tional source of income, making investment in these kinds of plants a sound business proposition.
Highly Cost-Effective
Gas-engine based power plant solutions
The decision for a particular power plant
techno-logy is usually based on the following factors:
Type of use – electricity production, CHP, or otherrequirements such as providing short-term operat- ing reserve for stable, reliable grids
Fuel supplies – these need to be readily available
and cost-effective, taking into account local emis- sions regulations and price developments
Local conditions – including at site conditions and
availability of suitable cooling options
Other cost factors, such as price of carbon permits
Fuel is the most significant cost factor for fossil-fuel-driven power plants, accounting for around 80 per cent of the operating costs. This makes maximum efficiency desirable on economic grounds alone.
Gas-engine based plants set the benchmark in this regard: their high efficiency and as a result, low emis-sions, keep the total cost of ownership (TCO) down. To calculate TCO, we can compare the production of electrical energy in terms of cost per MWh over the relevant project lifetime.
Electricity generation costs include not only the tech-nical parameters such as output and consumption but also figures relating to the likely costs of main-tenance, personnel and operating costs. Economic parameters include the initial investment, financing, duration of the construction period and likely costs of carbon credits.
Estimation of electricity generation costs for captive power generation with an output of 20 MW based on 2x20V35/44G engines for an energy-intensive industrial company in the European Union
Cost of electricity generation with an output of 20 MW based on 2x20V35/44G engines, sensitiv-ity analysis with various natural gas supply costs
Wholesale natural gas power prices
Sample data only Scope of services
Gross installed capacity Net output
Electrical efficiency Wholesale gas power price Overall efficiency
Construction period Depreciation period Weighted average cost of capital (WACC) Costs of CO2 emissions Emissions Full-load hours per year 500 h 1,000 h 1,500 h 2,000 h 2,500 h 3,000 h 3,500 h 4,000 h 4,500 h 5,000 h 5,500 h 6,000 h 6,500 h 7,000 h 7,500 h 8,000 h 20 €/ MWh 22 €/ MWh 23 €/ MWh 30 €/ MWh Turnkey delivery, 2x20V35/44G with CHP (water heating) 21.2 MW (2x20V35/44G) 20.8 MW 46.3 % €20/MWh 90 % 1 year 20 years 10 % €15/t Compliant with TA-Luft
(2002) 309.0 168.2 121.2 97.7 83.7 74.3 67.6 62.5 58.6 55.5 52.9 50.8 49.0 47.4 46.1 44.9 311.5 170.7 123.7 100.2 86.1 76.8 70.1 65.0 61.1 58.0 55.4 53.3 51.5 49.9 48.6 47.4 312.7 171.9 124.9 101.5 87.4 78.0 71.3 66.3 62.4 59.2 56.7 54.5 52.7 51.2 49.8 48.7 321.4 180.6 133.6 110.2 96.1 86.7 80.0 75.0 71.0 67.9 65.3 63.2 61.4 59.9 58.5 57.3 Sample data only
Cash Flow Analysis
Gas-engine based power plant solutions
For a complete cost-benefit analysis of the gas-engine based plant in this example, we should con-sider the profitability of the project. In the energy economy, this normally involves an analysis of criteria such as the internal rate of return (IRR) and operating
profits. In the following graph, we shall assume a sales price for electricity generation of € 80/MWh and rev-enue of € 20/MWh for the sale of heat. Let us assume our sample plant is in operation 7,000 hours per year.
25 20 15 10 5 0 -5 -10 -15 -20 0 2 4 6 8 10 12
MAN Diesel & Turbo SE offers specific advice and support for every project, from the initial idea to the implementation, from assistance with obtaining suitable financing to construction and operation of the plant.
Project time (years)
Construction periode Payback periode
Profit
M
io
. €
The economic analysis gives an IRR of 18% and operating profits of € 3 m per year of operation.
MAN PrimeServ – peace of mind for life
With more than 100 PrimeServ service stations and service partners worldwide and our growing network of PrimeServ Academies, the MAN Diesel & Turbo after-sales organisation is committed to maintaining the most efficient, accessible after-sales organisation in the business.
PrimeServ’s aim is to provide:
Prompt, OEM-standard service for the complete
life cycle of an installation
Training and qualification of service personnel at
our PrimeServ Academies to maximise the avail- ability and viability of a plant
Rapid, global availability of genuine, 100%
assured MAN Diesel & Turbo spare parts via local outlets or our 24 hour hotline.
PowerManagement by MAN Diesel & Turbo
Complementing the PrimeServ after-sales offering is the MAN PowerManagement concept.
MAN PowerManagement packages provide integrated support solutions for all aspects of the running of a power or cogeneration plant. Individually negotiated agreements can cover assistance with – or delega-tion of – the management of all mechanical, electrical and thermal equipment. In this way the power plant operator gains comprehensive access to the tech-nology, experience, best practices and professional resources of MAN Diesel & Turbo.
In short: PowerManagement by MAN Diesel & Turbo allows you to benefit from our specialist expertise in running a power plant while you concentrate on your own core business.
World Class Service
MAN Diesel & Turbo 86224 Augsburg, Germany Phone +49 821 322-3897 Fax +49 821 322-1460 [email protected] www.mandieselturbo.com All data pr
ovided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific
individual pr
ojects, the r
elevant data may be subject to changes and will be assessed and determined individually for each pr
oject. This will depend on the particular characteristics of
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oject, especially specific site and operational conditions · Copyright
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