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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
[Optional] subtitle,referent and location, date
2< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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.
Disclaimer
3< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
4< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
Starting of Assembly of new MAN Gas Engine 20V35/44G in Augsburg (Jan. 2011)
5< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
20V35/44G – Project Status:Engine on Test bed (10/2011-03/2013)
6< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
7< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
8< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
9< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
Key Dimensions Engine 20V35/44G
9.900 mm 4.450 mm
4.50
0 m
m
Mass (dry): 113,5 t
10< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
Generator Set Dimensions 20V35/44G
Mass (dry): 145 tons (Engine: 113.5 t, Coupling: 1.0 t, Generator: 30.5 t)
11< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
12< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
13< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
14< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
15< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
16< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
17< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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 %
18< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
20V35/44GOperational Behaviour
19< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
20< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
20V35/44GOperational Behaviour
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
21< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
20V35/44G for CHP ApplicationsHot water generation, e.g. 60/125°C
22< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
20V35/44G for CHP Applications Steam and Hot Water Generation
23< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
24< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
25< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
26< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
27< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
Combined Cycle ApplicationsMAN MARC Steam Turbines
28< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
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
29< >MAN Diesel & Turbo Author: Gas Engine 20V35/44G 19.07.2012
Q&A