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1< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012

The Gas Engine 20V35/44Gby MAN Diesel & Turbo SE

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All data provided 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 projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.

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The Gas Engine 20V35/44Gby MAN Diesel & Turbo SE

Agenda:

Gas Engine Portfolio of MAN Diesel & Turbo SE

20V35/44G - Main Technical Data

Technical Features and Innovations

Gas Specification andExhaust Emissions

Applications

Operational Behaviour

Summary


Starting of Assembly of new MAN Gas Engine 20V35/44G in Augsburg (Jan. 2011)


20V35/44G – Project Status:Engine on Test bed (10/2011-03/2013)


MAN Diesel & Turbo Stationary Gas Engine Portfolio

2 4 6 8 10 14 16 180 12 20 22 24

Power Output @ 50 Hz [MWm]

18.9 MW51/60G1050 kWm/Cyl. @ 500 rpm

35/44G530 kWm/Cyl. @ 750 rpm

32/40G450 kWm/Cyl. @ 750 rpm

10.6 MW

8.1 MW

8.8 – 17.6 MW51/60DF975 kWm/Cyl. @ 500 rpm

32/40DF400 kWm/Cyl. @ 750 rpm

3.6 – 7.2 MW

Gas

En

gin

es (

Sp

ark

ign

ited

Du

al F

uel

En

gin

es


Properties of Gas Engine20V35/44G

Otto Combustion Processwith Lean Burn Principle(Spark Ignited)

Natural Gas as Fuel(Low Pressure Gas Supply)

Progressive Engine Designwith Newest Methods and Tools

Single Stage Turbochargingwith Variable Turbine Area (VTA)

Waste Heat Utilizationfor Combined Cycle (CC) andCombined Heat and Power (CHP)

Reliable Safety System

High Power Output per Enginefor Low Engine Cost

High Efficienciesfor Low Operating Cost

Low Exhaust EmissionsCompliant to all Relevant Legislations

Low Maintenance Cost

High Maintainability andMAN proven Robustness

High Availability

Results


Main Technical Data20V35/44G

Specification Dimension Value 50 Hz Value 60 Hz

Bore / Stroke mm 350 / 440

Swept Volume litre 42,3

V - angle ° 55

Speed rpm 750 720

Cyl. Output kWm/Cyl. 530 510

bmep bar 20

Engine Output kWm 10.600 10.200

EfficiencyTA-Luft, MN = 80,100 % load, cos = 0,95 % tolerance, ISO Cond. (25 °C, 1 bar)with attached pumps

kJ/kWhel

%el

7,62147.2

Height mm 4.500

Width mm 3.850

Length mm 9.900

Weight (dry) tons 113,5


Key Dimensions Engine 20V35/44G

9.900 mm 4.450 mm

4.50

0 m

m

Mass (dry): 113,5 t


Generator Set Dimensions 20V35/44G

Mass (dry): 145 tons (Engine: 113.5 t, Coupling: 1.0 t, Generator: 30.5 t)


Technical Features and Innovations20V35/44G

Turbocharger Assembly:modular concept,

central exhaust housing,braced on base frame

Safety System:active monitoring,knocking control,

pressure relief valves

Electronics, Cabling:On-Engine-Concept,

cable looms,connectors/clips

Lambda Control:VTA, wastegate,

compressor bypassBase Frame:

integral part of engine,(oil pan, structure stiffness)

Starting System:air pressure starter,slow turn function

Interfaces to Plantgas system,

coolant system,oil system are located

on counter coupling side


Technical Features and Innovations20V35/44G

Combustion Process:lean burn Otto process,

Miller cyclehigh efficiency,

wide operation area

Exhaust Pipe:ceramics foam isolated,

reduced flow losses

Cranktrain:lightweight train

with high efficiencyMAN piston development,

Crankcase:short main tie rods,

high stiffness,V-angle 55 °

Ignition System:gas flushed prechamber,

spark plug,gas admission valves

Ignition Energy Control

Valvetrain:improved gas exchange,

central camshaft,swing and rocker arms


Ignition Process:

1. Main combustion chamber will be filledwith lean mixture of natural gas and air

2. Prechamber will be flushed with natural gas(rich mixture within prechamber)

3. Compression by upward piston motion (checkvalve prevents gas losses)

4. Spark plug initiates the ignitionwithin prechamber

5. Flames coming out of the prechamber start combustion within main combustion chamber

The Gas Engine 20V35/44G Pre-chamber Spark Ignition Principle


20V35/44GEngine Controls “SaCoS_one”

SACOS one

ENGINE CONTROL

- LAMBDA CONTROL

- GVU CONTROL

- LOAD CONTROL

SAFETY SYSTEM ALARM SYSTEM

SACOS one

INJECTION UNIT

SACOS one

IGNITION UNIT

SACOS one

KNOCK CONTROL UNIT

EXHAUST AIR

G

PRECHAMBER GVU GAS VALVE UNIT

MAIN GVU GAS VALVE UNIT


The world-wide strongest 10 MW gas engine from MAN Diesel & Turbo

Length incl. Generator: 14m

High: 4,5m

Width: 4,5m

Weight: 145t

47.2% electrical efficiency


20V35/44GReleased Fuel Gas Specification

LHV [MJ/mN³]

MN [ - ]

1020 30 40 50 60 70 80 90 100 110 1200

20

30

40

50

60

70

80

90

100

110

120

130

Natural Gas H [36/92]Natural Gas L [32/88]

Efficiency Reductionand possibly Power Derating

10

Rated Power

No Operation

Methane [36/100]

Propene C3H6 [88/19]

Biogas [23/133]

Ethene C2H4 [60/15]

Ethane C2H6 [65/44]

Propane C3H8 [93/34]

Butane C4H10 [124/10]

Fuel Specification (Natural Gas):

• Lower Heating Value (LHV):

> 32,4 MJ/mN³

• Sulfur:

< 30 mg/mN³

• H2S:

< 5 mg/mN³

• Fluoride:

< 5 mg/mN³

• Chlorine:

< 10 mg/mN³

• Clean and dry


20V35/44GExhaust Gas Emissions

NOx THC CO HCHO SO2 NMHC Note

[mg/mN³ @ 5 % O2]

TA-Luft(@ 5 % O2)

500 - 300 60 - -

EU Directive (IED / IPPC 1))(@ 15 % O2)

200(75)

- 266(100)

- - - Will come into effect 2013;Exhaust Gas Aftertreatment (SCR) possible for higher effic.

1) Industrial Emissions Directive / Integrated Pollution Prevention and Control

Emission Legislation for Spark Ignited Gas Engines (Excerpt):

Emissions Compared to Diesel HFO Engines:

• CO2: - 25 %

• NOx: - 80 % additional SCR-Catalyst possible, if desired

• CO: + 20 % Oxidation Catalyst

• Particles / SO2: - 99 %


20V35/44GOperational Behaviour



Fuel Gas Specification(Standard Engine Design)

Water Inlet Temp. ofCharge Air Cooler Stage 2

Reference Conditions: - Air Temperature / Pressure: 25 °C / 1.013 mbar(ISO 3046-1) - Relative Humidity: 30 %

- Charge Air Temperature: 43 °C- Exhaust Gas Backpressure: 30 mbar- Methane Number (Natural Gas) ≥ 80

TCA = 43 °C TCA = 50 °C



Load Steps atIsland Mode

20V35/44G

Base Load[kWm]

Load Step[kWm]

0 1.900

(25 %) 2.600 1.900

(50 %) 5.300 1.700

(75 %) 8.000 1.300

(90 %) 9.500 800

Compensation of Ambient TemperatureFluctuations

Example:

Tair,max = + 30 °C

Tair,min = - 10 °C

Full Power Output w/o Derating


20V35/44G for CHP ApplicationsHot water generation, e.g. 60/125°C


20V35/44G for CHP Applications Steam and Hot Water Generation


Heat balance for the 20V35/44G -> case, district heating 60°C/125°C

Fuel input: 22,5 MWth ; Recoverable thermal output: 9,8 MWth (above 60°C)

20V35/44G for CHP ApplicationsThermal Output and Temperature Levels

Tamb: 25°C; pamb : 1000 mbar; Back pressure: 30 mbar; Attached pumps: 1x lube oil, 2x cooling water; Methane number: >80

Exhaust gas

Charge air cooler 1

Charge air cooler 2

Lube oil cooler

Jacket coolingwater

Power in kWth 4,965 1,830 620 1,100 1,400

Temperature level in primary circuit

(in/out °C)

370/120 85/96 73/77 65/76 77/85

Flow in primary circuit

65 t/h 140 m³/h 140 m³/h 200 m³/h 140 m³/h


20V35/44G for CHP Applications CHP – Performance Statement

43.6%

Excellent CO2 statement

In CHP: 225 g/kWh Electricity only: 439 g/kWh Alpha number: 1,1

(“Stromkennzahl”)

Heat balance for the 20V35/44G -> case, hot water 60°C/125°C

- Fuel input: 22,5 MWth

- Recoverable thermal output: 9,8 MWth ; - Electrical Output: 10,34 MWel

46.0%

89.6%

Eff

icie

ncy

Eta Total Eta electrical plus heatBased on 20V35/44G ISO-3046 conditions;

89.6% total efficiency for hot water applications – high efficient gas engine plus efficient waste heat utilisation


20V35/44G for Combined Cycle Engine Combined Cycle - System Overview

25 bar

360 °C

4 bar144 °C

3,6 bar140 °C

4,5 bar

26 bar

370 °C

120 °C

0,16 bar

55 °C

Waste heat potential - exhaust gas - cooling water

Exhaust Gas- ca. 30% of fuel input- ca. 340°C – 370°C- used for steam generation

High temperature cooling water- ca. 13% of fuel input - 90°C- used for condensate preheating, - preheating of aux. consumers


20V35/44G for Combined CycleEngine Combined Cycle - Concept

MAN diesel / gas engines

MAN steam turbine

Boost the efficiency of a power plant with Gas engines by adding heat recovery steam generators and a steam turbine

MAN Diesel & Turbo’s steam turbine family is optimised for CC applications

MAN RENK gearbox

System is modular, easy to commission, easy to operate

Increase of plant efficiency up to 5%

Increase of power output up to 13%

Concept of the Combined Cycle Package

Strong Synergy : In-house Engine and Turbine Technology


Combined Cycle ApplicationsMAN MARC Steam Turbines


20V35/44GSummary – Your Benefits

Reliable Power Source10.600 kWm Rated Power (50Hz)

Low Fuel Cost47.2 % Electrical efficiency Simple cycle

50.4 % Electrical efficiency Combined cycle

Heat Utilization (District heating)~90 % Total CHP efficiency

Short Power Ramp Up Time100 % Load within 5 Minutes

Changing Ambient ConditionsTair = 40 Kelvin without Power Derating

Ease of Maintenance / High AvailabilitySimple & fast exchange of spark plugs

High Safety StandardsActive monitoring, Safety devices, CE conformity


Q&A

1 < >man diesel & turboauthor:gas engine 20v35/44g19.07.2012 the gas engine 20v35/44g by...

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