V35/44G

Four-stroke gas engine

MAN Diesel & Turbo is the worlds 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 solutions. 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 preeminence 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 & Turbos development focus is on the environmental 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.

V35/44G Four-stroke gas engine

Introduction Driving the stationary use of gas engines

Today, state-of-the-art power generation technology should be designed for highest efficiency and lowest emissions.
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 providing 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 worldwide 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 stationMAN 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. 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. ary use in power plants. The engine reaches an output 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 inengine measures.

V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine

35/44G A new class of large bore gas engine

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.

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. Higher output can be reached while avoiding knocking and increasing efficiency, although a too lean mixture will cause misfiring. With leaner combustion, the peak temperature is reduced and less NOx is produced.

Highest power density in its class

The 35/44G is offered in a V-type version with 20 cylinders 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.

Advanced Ignition Technology

The ignition system comprises a capacitive discharge system and an ignition coil, which delivers the necessary high voltage via an ignition lead to the spark plug. To improve combustion, the spark plug is located in the pre-chamber.

SaCoSone
The 35/44G engine is equipped with the safety and control system SaCoSone. SaCoSone guarantees reliable engine operation with an optimum operation range between knocking and misfiring. All cylinders are regulated individually.

Further major benefits of the 35/44G

Reliable Low Heat Short

power source: 10,600 kWm rated power

fuel costs: 47.3% el. efficiency single cycle utilisation: > 90% total efficiency power ramp up time: 100% load within temperature compensation: Tair = 40 Kel-

8 minutes
Ambient

A promising fuel
In addition to a high supply reliability and the potential 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. 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 is precisely metered to the pre-chamber by means of a separate valve.

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.

vin without power derating

Easy High

maintenance / high availability safety standards load response

Excellent

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.

V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine

Solutions Electrical power and combined cycle

LP steam drum HP steam drum Air cooled condenser

MAN steam turbine Air cooled alternator

Powerhouse

Main stack

Exhaust gas steam boiler

Exhaust silencer

MAN Diesel & Turbo 20V35/44G

Powerful performance
A reliable supply of electricity is essential for global economic growth. Given the need for reliability of supply 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, decentralised production are now more important than ever before. MAN Diesel & Turbo can help provide this crucial resource with its highly efficient 20V35/44G gas engine. The newly developed Otto gas engine is suitable for MAN Diesel & Turbo can draw on its extensive global 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. smaller decentralised power plants and can also be deployed in large power plants of up to 150 MW.

Combined cycle
To meet the requirements of high efficiency and environmental 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. 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 before 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.

V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine

Solutions Combined heat and power (CHP)

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.
When electricity is generated in engine-based power plants, waste heat at various temperatures is produced. MAN Diesel & Turbo offers different technologies to convert this waste heat into a useful energy form. MAN Diesel & Turbos 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 building levels. The heat extracted from the engines exhaust gases can be utilised for steam generation required in the textiles, food, paper and chemicals industries. By in-

Heat recovery diagram*

Chimney

Electricity CAC 1 CAC 2

Bypass

WHRB

HT heat recovery Back-up cooler HT District heating network Lube oil heat recovery

Benefits
Lower

energy costs through more efficient utilisaenvironmental quality through reduced waste heat for a wide range of sustainflexibility in line with changes in heat
District heating water Engine lube oil Engine jacket + CAC 1&2 Engine exhaust gas Back-up cooling

tion of primary energy

Improved

emissions of pollutants
Recovered

able thermal applications

Operational

and electricity demand

Energy flow diagram*

Fuel input 100%

High temperature heat 39.5%

Electrical output 46.3%

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 ing circuits can be utilised for hot water generation, e.g. used in a district heating network for heating purposes.
Plant auxiliaries, trafo losses 0.8%

oil, the engine jacket water and the charge air cool-

Electricity to grid 45.5%

Heat to heat consumers 44.5%

Total CHP efficiency 90%

* Based on 20V35/44G ISO-3046 conditions; efficiencies valid for return line temperature of 60C and supply line temperature of 125C

10 V35/44G Four-stroke gas engine

Losses 9.2%

cluding an exhaust gas or hot water driven absorp-

Low temperature heat 5%

V35/44G Four-stroke gas engine 11

Solutions Operating reserve

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.
In addition to rapid start-up, these solutions also need to be extremely efficient when operating under partload conditions, and capable of accommodating wide variations in load. These types of applications are set to become increasingly attractive for independent power producers (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 demand. In contrast to axial flow machines, gas-engine based plants are physically suited to these kinds of applications: 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

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 > 250 2 110 5 8 10 8 30 Time (min) to full load incl. synchronisation with grid Part-load flexibility / Increase in load (%) in 5 seconds

All plants pre-heated and in normal start-up programme Sample data only

12 V35/44G Four-stroke gas engine

Environmental Awareness Natural gas the most environmental friendly fossil energy source

Being able to scale output to meet consumers heating needs is an important consideration when selecting a power plant technology. The emissions produced 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.

CO2 emitted by various power plant technologies

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) 33 (612) 38 (895) 80 (252) 80 (425) 47.3 (427) 90 (224) Electrical efficiency in % (CO2 emissions in g/kWh) Thermal efficiency in CHP in % (CO2 emissions in g/kWh)

CO2 emissions from natural gas: 202g/kWh; CO2 emissions from coal: 340g/kWh; Sample data only

Maximum allowed exhaust gas emission values according to TA-Luft

Nitrogen oxides, NO x in mg/Nm3 1) Carbon monoxides, CO in Formaldehyde in mg/Nm3 Sulphur dioxide, SO2 in mg/Nm3 3) mg/Nm3 2) 500 300 60 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

14 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 15

Technical Data Dimensions and weights

20V35/44G

A C

Engine 20V35/44G
Dry mass 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 engine (t) 113.5 Dry mass gen.* (t) 30.5

Four-stroke gas engine 20V35/44G

Bore 350 mm, stroke 440 mm Mean piston speed (m/s) Electrical output (kWel) Lube oil consumption (kg/h) 750 rpm, 50 Hz 11.0 10,335 3.7 720 rpm, 60 Hz 10.6 9,945 3.5

* Depending on alternator; nominal generator efficiency: 97.5%

20V35/44G for power applications Heat rate (kJ/kWh el) Electrical efficiency (%) 20V35/44G for CHP applications Heat rate (kJ/kWh el) Electrical efficiency (%) 7,782 46.3 7,782 46.3 7,618 47.3 7,618 47.3

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 43C; p.f. 0.9; NOx emissions 500mg/Nm3 @ 5% O2

16 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 17

Highly Cost-Effective Gas-engine based power plant solutions

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, sensitivity analysis with various natural gas supply costs
Wholesale natural gas power prices Full-load hours 20 / MWh 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 22 / MWh 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 23 / MWh 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 30 / MWh 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

Scope of services

Turnkey delivery, 2x20V35/44G with CHP (water heating)

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
Sample data only

Gross installed capacity Net output Electrical efficiency Wholesale gas power price Overall efficiency Construction period

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)

The decision for a particular power plant technology is usually based on the following factors:
n

Depreciation period

Gas-engine based plants set the benchmark in this regard: their high efficiency and as a result, low emissions, 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 technical parameters such as output and consumption but also figures relating to the likely costs of maintenance, personnel and operating costs. Economic parameters include the initial investment, financing, duration of the construction period and likely costs of carbon credits.

Weighted average cost of capital (WACC) Costs of CO2 emissions Emissions

Type of use electricity production, CHP, or other

requirements such as providing short-term operat ing reserve for stable, reliable grids
n

Fuel supplies these need to be readily available

and cost-effective, taking into account local emis sions regulations and price developments
n

Sample data only

Local conditions including at site conditions and Other cost factors, such as price of carbon permits

availability of suitable cooling options

n

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 additional source of income, making investment in these kinds of plants a sound business proposition.

Fuel is the most significant cost factor for fossil-fueldriven power plants, accounting for around 80 per cent of the operating costs. This makes maximum efficiency desirable on economic grounds alone.

18 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 19

Cash Flow Analysis Gas-engine based power plant solutions

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.

For a complete cost-benefit analysis of the gasengine based plant in this example, we should consider 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 revenue of 20/MWh for the sale of heat. Let us assume our sample plant is in operation 7,000 hours per year.

The economic analysis gives an IRR of 18% and operating profits of 3 m per year of operation.
25 20 15 10 Mio. 5 0 -5 -10 -15 -20 0 2 4 6 Project time (years) 8 10 12
Profit Construction periode Payback periode

20 V35/44G Four-stroke gas engine

World Class Service Expert advice and assistance

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. PrimeServs aim is to provide:
Prompt,

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 delegation of the management of all mechanical, electrical and thermal equipment. In this way the power plant operator gains comprehensive access to the technology, 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.

OEM-standard service for the complete and qualification of service personnel at

life cycle of an installation

Training

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.

22 V35/44G Four-stroke gas engine

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 CopyrightMAN Diesel & Turbo 2366460EN-N3 Printed in Germany GMC-AUG-05122

MAN Diesel & Turbo 86224 Augsburg, Germany Phone +49 821 322-3897 Fax +49 821 322-1460 powerplant@mandieselturbo.com www.mandieselturbo.com