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

powerplant@mandieselturbo.com

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 ©

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