gas engine brochure
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Gas ENgine BrochureTRANSCRIPT
V35/44GFour-stroke gas engine
3V35/44G – Four-stroke gas engine
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
IntroductionDriving 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-operating 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 lowest emissions.
5V35/44G – Four-stroke gas engine
6 V35/44G – Four-stroke gas engine 7V35/44G – Four-stroke gas engine
35/44GA 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 increasing 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.
SaCoSone
The 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 Kel-
vin without power derating Easy maintenance / high availability High safety standards Excellent load response
8 V35/44G – Four-stroke gas engine
SolutionsElectrical power and combined cycle
9V35/44G – 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 silencerMAN Diesel & Turbo
20V35/44G
Main stack
Exhaust gas steam boiler
Powerhouse
LP steam drum
HP steam drum
Air cooled condenser
MAN steam turbine
Air cooled alternator
District heating waterEngine lube oilEngine jacket + CAC 1&2 Engine exhaust gasBack-up cooling
Chimney
ElectricityBypass
WHRB
HT heatrecovery
District heatingnetwork
Lube oilheat recovery
Back-upcooler HT
CAC 1
CAC 2
SolutionsCombined 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 conditioning
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.
10 V35/44G – Four-stroke gas engine 11V35/44G – Four-stroke gas engine
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 togrid 45.5%
Total CHP efficiency 90%
Heat to heatconsumers 44.5%Pl
ant a
uxili
arie
s,tr
afo
loss
es 0
.8%
Elec
tric
al
outp
ut 4
6.3%
High
tem
pera
ture
heat
39.
5%
Low
tem
pera
ture
heat
5%
Loss
es 9
.2%
Fuel input 100%
Benefits Lower energy costs through more efficient utilisa-
tion of primary energy Improved environmental quality through reduced
emissions of pollutants Recovered waste heat for a wide range of sustain-
able thermal applications Operational flexibility in line with changes in heat
and electricity demand
12 V35/44G – Four-stroke gas engine
SolutionsOperating 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.
14 V35/44G – Four-stroke gas engine 15V35/44G – Four-stroke gas engine
Environmental AwarenessNatural 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
17V35/44G – Four-stroke gas engine16 V35/44G – Four-stroke gas engine
Technical DataDimensions and weights
20V35/44G
H
WBA
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-EffectiveGas-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 other
requirements 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 €/
MWhTurnkey 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
19V35/44G – Four-stroke gas engine18 V35/44G – Four-stroke gas engine
Sample data only
Cash Flow AnalysisGas-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
Mio
. €
The economic analysis gives an IRR of 18% and operating profits of € 3 m per year of operation.
20 V35/44G – Four-stroke gas engine
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% quality-
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 ServiceExpert advice and assistance
22 V35/44G – Four-stroke gas engine
MAN Diesel & Turbo
86224 Augsburg, Germany
Phone +49 821 322-3897
Fax +49 821 322-1460
www.mandieselturbo.com
All data provided in this docum
ent is non-binding. This data serves informational purposes only and is especially not guaranteed in any w
ay. Depending on the subsequent specific
individual projects, the relevant data may be subject to changes and w
ill be assessed and determined individually for each project. This w
ill depend on the particular characteristics of
each individual project, especially specific site and operational conditions · Copyright ©
MA
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iesel & Turbo · 2366460E
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