Thermo Efficiency System

for Reduction of Fuel Consumption and

CO2 Emission

Contents

Introduction.................................................................................................. 5
Description of the Thermo Efficiency System.................................................. 6
Power concept and arrangement............................................................. 6
Main engine performance data...................................................................... 7
Exhaust gas boiler and steam systems.......................................................... 8
Obtainable Electric Power Production of the Thermo Efficiency System........ 10
Exhaust gas turbine output.................................................................... 10
Exhaust gas and steam turbine generator output single pressure............... 10
Exhaust gas and steam turbine generator output dual pressure................. 12
Payback time of the Thermo Efficiency System............................................ 12
Summary.................................................................................................... 15
References................................................................................................. 15

MAN B&W Diesel

Thermo Efficiency System

Thermo Efficiency System (TES)

for Reduction of Fuel Consumption and CO2 Emission

Introduction

demand for installation of a Thermo Ef-

of the total waste heat, i.e. about 25%

Following the trend of required higher

ficiency System is that the reliability and

of the total fuel energy. In the standard

overall ship efficiency since the first oil

safety of the main engine/ship operation

highefficiency engine version, the ex-

crisis in 1973, the efficiency of the main

must not be jeopardised.

haust gas temperature after the turbo-

engines has increased and, today, the

charger is relatively low, and just high

fuel energy efficiency is about 50%. This

As an example, the heat balance dia-

enough for production of the necessary

high efficiency has, among others, led

gram for the nominally rated 12K98ME/

steam for a ships heating purposes by

to a correspondingly lower exhaust gas

MC engine (18.2 bar) of the standard

means of the exhaust gas fired boiler.

temperature after the turbochargers.

highefficiency version is shown in Fig.

1a. Fig. 1b shows an example based

However, a main engine with changed

Even though a main engine fuel energy

on the Thermo Efficiency System, valid

timing and exhaust gas bypass which

efficiency of 50% is relatively high, the

for a singlepressure steam system,

redistributes the exhaust gas heat from

primary objective for the shipowner is

together with the corresponding fig-

high amount/low temperature to low

still to lower the total fuel consumption

ures for a dualpressure steam system

amount/high temperature increases

of the ship and, thereby, to reduce the

shown in parenthesis.

the effect of utilising the exhaust gas

CO2 emission of his ship.

heat, but at the same time may slightly

The primary source of waste heat of a

reduce the efficiency of the main engine

Today an even lower CO2 emission can

main engine is the exhaust gas heat dis-

itself. Such a system is called a Thermo

be achieved by installing a Thermo Ef-

sipation, which accounts for about half

Efficiency System (TES).

ficiency System. However, the main

12K98ME/MC with TES
SMCR : 68,640 kW at 94.0 r/min
ISO ambient reference conditions
TES : Single pressure (Dual pressure)

Shaft power
output 49.3%

12K98ME/MC Standard engine version

SMCR : 68,640 kW at 94.0 r/min
ISO ambient reference conditions

Total power output 54.2% (54.8%)

Shaft power
output 49.3%

El. power production of

TES 4.9% (5.5%)
Gain = 9.9% (11.2%)

Lubricating oil
cooler 2.9%
Lubricating oil
cooler 2.9%

Jacket water
cooler 5.2%

Jacket water
cooler 5.2%

Exhaust gas
25.5%

Exhaust gas and

condenser
22.9% (22.3%)

Air cooler
16.5%

Fuel 100%
(171 g/kWh)

Air cooler
14.2%

Heat radiation
0.6%
Fuel 100%
(171 g/kWh)

Heat radiation
0.6%

Fig. 1a: Heat balance diagram of the nominally rated 12K98ME/MC Mk 6

Fig. 1b: Heat balance diagram of the nominally rated 12K98ME/MC Mk 6 engine

engine (18.2 bar) of the standard engine version operating at ISO ambient

(18.2 bar) with Thermo Efficiency System (TES) operating at ISO ambient

reference conditions and at 100% SMCR

reference conditions and at 100% SMCR

MAN B&W Diesel

Thermo Efficiency System

Description of the Thermo Efficiency

System

When a part of the exhaust gas flow is

The total electric power output of the

bypassed the turbocharger, the total

TES which reduces the ships fuel costs

Power concept and arrangement

amount of air and gas will be reduced,

is only a gain provided that it can re-

The Thermo Efficiency System (TES)

and the exhaust gas temperature after

place the power output of other electric

consists of an exhaust gas fired boiler

the turbocharger and bypass will in-

power producers on board the ship.

system, a steam turbine (often called a

crease. This will increase the obtainable

Otherwise, a shaft power motor con-

turbo generator), an exhaust gas tur-

steam production from the exhaust gas

nected to the main engine shaft could

bine (often called a power turbine) and

fired boiler.

be an option, as also shown in Fig. 2a,

a common generator for electric power

but this extra system is rather expensive.

production. The turbines and the gen-

The exhaust gas bypass valve will be

erator are placed on a common bed-

closed for engine loads lower than about

In general (without a shaft power mo-

plate. The system is shown schemati-

50% SMCR, which means that the ex-

tor installed), when producing too much

cally in Fig. 2a, and the arrangement of

haust gas temperature will be reduced

electric power, the (high pressure) su-

the complete turbine generating set is

when operating below 50% SMCR.

perheated steam to the steam turbine

shown in Fig. 2b.

is controlled by a speed control govThe power output from the exhaust

ernor through a single throttle valve,

The exhaust gas turbine is driven by a

gas turbine is transmitted to the steam

which means that the surplus steam

part of the exhaust gas flow, which by-

turbine via a reduction gear (see Figs.

is dumped via a dumping condenser.

passes the turbochargers. The exhaust

2a and 2b) with an overspeed clutch,

When the generator is operating in par-

gas turbine produces extra output pow-

which is needed in order to protect the

allel with the auxiliary diesel generators,

er for electric power production, which

exhaust gas turbine from overspeeding

the governor operates in the normal

depends on the bypassed exhaust gas

in case the generator drops out.

way to give correct load sharing.

flow amount.

Fig. 2a: Power concept for the Thermo Efficiency System

Thermo Efficiency System

Generator, AC alternator
Reduction gear
Steam turbine

Exhaust gas turbine

Reduction gear

Approx. dimensions
referring to a 12K98ME/MC:
Length: 10 metres
Breadth: 3.5 metres
Weight:

58 tons without
condenser

Weight: 75 tons with

condenser

Fig. 2b: Arrangement of the complete turbine generating set

Main engine performance data

The mixed exhaust gas temperature be-

peratures, the exhaust gas temperature

The exhaust gas bypass and turbine

fore the exhaust gas boiler, and valid for

will be higher (about +1.6C per +1C

are available with the following ap-

the TES and based on ISO ambient ref-

air), and vice versa for lower ambient air

prox. effects, compared with a stand-

erence conditions, is shown as a func-

temperatures.

ard highefficiency main engine version

tion of the engine load in Fig. 3. When

without an exhaust gas bypass:

operating under higher ambient air tem-

Parameters
Power output
of exhaust gas
turbine at 100%
SMCR, up to

Open exhaust gas

bypass for exhaust gas turbine

Exhaust gas temperature

after exh. gas bypass

Ambient reference conditions:

Tropical 45C air/36C c.w.
ISO
25C air/25C c.w.
Winter
15C air/36C c.w.

C
350

Tropical

4.6% SMCR
+
power

300

Reduction of total exhaust gas

amount, approx.

-13%

250

Total increase of
mixed exhaust gas
temperature after
bypass, up to

+50C

200

Increased fuel
consumption

from 0.0% to
+1.8%

ISO
Winter

40

60

Exh. gas bypass

closed

MAN B&W Diesel

50

70

80

90

100 % SMCR

Mainengine shaft power

open

Fig. 3: Exhaust gas temperature after exhaust gas bypass for a main engine with TES

Thermo Efficiency System

The increased fuel consumption of the

Exh. gas boiler
sections:

main engine depends on the actual

maximum firing pressure (Pmax) used.

Steam
drum

Preheater

The Pmax used for TES will normally be

increased compared with a standard

Evaporator

engine and thereby an increase of the

specific fuel oil consumption can be

Circ. pump

Superheater

avoided when using TES.

Exhaust gas
Surplus
valve

Exhaust gas boiler and steam systems

Sat. steam
for heating
services

Steam
turbine

The exhaust gas boiler and steam turbine systems analysed in this paper are
Feedwater
pump

Condenser

based on the two types below:

1. Single-pressure steam system
The simple singlepressure steam
system is only utilising the exhaust

Hot well

gas heat. See the process diagram

in Fig. 4 and the corresponding tem

Fig. 4: Process diagram for the Thermo Efficiency System singlepressure exhaust gas boiler system

perature/heat transmission diagram

with a singlepressure steam turbine

in Fig. 5. The steam drum from the

oil fired boiler can also be used in
stead of a separate steam drum.
Exh. gas boiler sections:
A. Superheater
B. Evaporator
C. Preheater

Temperature
C
300
Superheated
steam
250

Exh. gas

200
Saturated
steam

Steam/water

100

min 20 C

Exh. gas

7 bar abs/165 C

150

50

Feedwater
Ambient air

0
04

20

60

100%
80
Heat transmission

Fig. 5: Temperature/heat transmission diagram of an exhaust gas boiler with singlepressuresteam

system valid for a main engine with TES and operating at 85% SMCR/ISO

Thermo Efficiency System

2. Dualpressure steam system

When using the dualpressure steam

Alternative WHR
sources for feedwater
preheating

system, it is not possible to install an

exhaust gas lowpressure preheater
section in the exhaust gas boiler, because the exhaust gas boiler outlet
temperature otherwise would be too
low and increase the risk of wet (oily)
soot deposits on the boiler tubes.

Exh. gas boiler

sections:

LP-steam drum

LP

LP-Evaporator
LP-circ. pump

HP-Preheater
LP-Superheater

The more complex dualpressure

steam

system,

therefore,

needs

supplementary waste heat recovery

HP

HP-steam drum

HP-Evaporator
HP-circ. pump

HP-Superheater

(WHR) sources (jacket water and

HP

scavenge air heat) for preheating of

Exhaust
gas

the feedwater which, of course, will

increase the obtainable steam and

Surplus
valve

LP
HP-steam
for heating
services

Steam
turbine

electric power production of TES.

See the process diagram in Fig. 6

Feedwater
pump

Condenser

and the corresponding temperature/

heat transmission diagram in Fig. 7.

Hot well

If no alternative waste heat recovery sources are used to preheat the

feedwater, the low pressure (LP)

Fig. 6: Process diagram for the Thermo Efficiency System dualpressure exhaust gas boiler system

steam may be used to preheat the

with a dualpressure steam turbine

feedwater, involving an about 16%

reduction of the total steam produc-

Temperature
C
300

tion.
The available superheated steam used

Superheated
HP steam 250

Exh. gas boiler sections:

A. HP-superheater
B. HP-evaporator
C. HP-preheater
D. Possible LP-superheater
E. LP-evaporator

Exh. gas

for the steam turbine is equal to the

Superheated LP steam

surplus steam after deduction of the

saturated steam needed for heating
services.
The exhaust gas boiler has to be designed in such a way that the risk of
soot deposits and fires is minimised,
Ref. [1].

200
Saturated
HP steam

Steam/water min 20C

10 bar abs/180C

min 15C

150

4 bar abs/144C
100

Exh. gas
Feedwater
preheated
by alternative
WHR sources

50
Ambient air
0
04

20

60

80
100%
Heat transmission

Fig. 7: Temperature/heat transmission diagram of an exhaust gas boiler with dualpressure steam system
valid for a main engine with TES and operating at 85% SMCR/ISO

MAN B&W Diesel

Thermo Efficiency System

Obtainable Electric Power Production

of the Thermo Efficiency System

Exhaust gas and steam turbine generator output single pressure

As an example valid for the nominally

Exhaust gas turbine output

The singlepressure steam system is a

operating at ISO ambient reference con-

The exhaust gas bypass for the ex-

system where all heat recovered comes

ditions, we have calculated the steam

haust gas turbine has a bypass gas

from the exhaust gas heat only, which

production and the electric power pro-

amount of approx. 12% of the total ex-

makes it relatively simple, see Figs. 4

duction of TES, see Figs. 10 and 11.

haust gas amount at 100% SMCR. This

and 5.

rated 12K98ME/MC (18.2 bar) engine

bypassgas amount led through the

The total electric power production in %

exhaust gas turbine will typically pro-

As low gas temperatures (risk of con-

of the main engine shaft power output is

duce an available power output of max.

densed sulphuric acid) and low gas ve-

also shown as a function of the engine

4.6% of the SMCR power when running

locities (risk of soot deposits) through

load, see Fig. 9.

at 100% SMCR. The corresponding

the exhaust gas boiler may have a dete-

electric power output will be somewhat

riorating effect on the boiler, Ref. [1], we

The results for operation at 85% SMCR

lower because of generator and gear

have, in our studies, selected an exhaust

are shown in Fig. 14, together with the

losses.

gas boiler designed for a singlepressure

calculated ISO ambient temperature

steam system of minimum 7 bar abs

based results for three other main en-

At part load running of the main engine,

(6 bar g) steam pressure (165C),

gine types. The corresponding results

the power output will be reduced by ap-

and minimum 20C pinch point. The

based on tropical ambient temperature

proximately the square root of the en-

superheated

is

conditions are shown in Fig. 15. How-

gine load.

about 270C. The steam turbine is a

ever, it should be emphasised that it is

steam

temperature

multistage singlepressure condensing

probably more realistic to use the ISO

As an example, the maximum available

type. The alternator/generator is driven

ambient temperatures as the average

power output of the exhaust gas turbine

both by the steam turbine and the ex-

ambient temperatures in worldwide op-

valid for a nominally rated 12K98ME/

haust gas turbine.

eration. In Fig. 16, the ISO based total

MC (18.2 bar) engine is shown in Fig. 8,

electric power production at 85% SMCR

as a function of the engine load.

is also shown as a function of the main

engine size measured in SMCR power.

Available power output of exhaust gas turbine

kW
3,500
3,000

Electric power production of TES

relative to the main engine power output
%
13
Main engine 12K98ME/MC
12

SMCR = 68,640 kW at 94 r/min

11

ISO amb. cond.

10

2,500

Dual press.
Single press.

9
8

2,000

7
1,500

Steam turbine

6
5

1,000

Exhaust
gas turbine

500

4
3
2

0
30

40 50 60 70 80 90 100 % SMCR
Exh. gas bypass
Main engine shaf t power
closed
open

Exhaust
gas turbine

1
0

Fig. 8: Expected available power output of exhaust gas turbine for a

80
90
100 % SMCR
Main engine shaft power
Fig. 9: Expected electric power production in % of the main engine shaft power

12K98ME/MC with SMCR = 68,640 kW x 94 r/min

output valid for a 12K98ME/MC with Thermo Efficiency System (TES) and

50

60

70

based on ISO ambient reference conditions

10 Thermo Efficiency System

Obtainable steam production

Electric power production

kW
8,000

kg/h
35,000
12K98ME/MC with TES (single press.)
SMCR = 68,640 kW at 94 r/min
ISO amb. cond.

30,000
25,000

7,000

Total steam
pr oduction

12K98ME/MC with TES (single press.)

SMCR = 68,640 kW at 94 r/min
ISO amb. cond.

Total el.
production

6,000
5,000

20,000

4,000

15,000
Superheated steam
for steam turbine

10,000

Exhaust
gas turbine

3,000
2,000

5,000

Steam turbine

1,000

40

50

60

70

80

Exh. gas bypass

closed
open

90
100 % SMCR
Main engine shaft power

40
50
60
Exh. gas bypass
closed

70

80
90
100 % SMCR
Main engine shaft power

open

Fig. 10: Expected steam production of an exhaust gas boiler with

Fig. 11: Expected electric power production of the Thermo Efficiency System

singlepressure steam system valid for main engine 12K98ME/MC with TES

(TES) with a singlepressure steam system valid for main engine 12K98ME/

and based on ISO ambient reference conditions

MC and based on ISO ambient reference conditions

Obtainable steam production

kg/h
40,000
35,000
30,000
25,000

Electric power production

kW
8,000

12K98ME/MC with TES (dual press.)

SMCR = 68,640 kW at 94 r/min
ISO amb. cond.

Total steam
production

Superheated
LP-steam for
steam turbine

7,000

5,000
4,000

15,000

3,000
Superheated
for steam turbine

5,000
0

50

60

70

Exh. gas bypass

closed
open

80
90
100 % SMCR
Main engine shaft power

Exhaust
gas turbine

2,000
Steam turbine
1,000
0

40

Total el.
production

6,000

20,000

10,000

12K98ME/MC with TES (dual press.)

SMCR = 68,640 kW at 94 r/min
ISO amb. cond.

40
50
60
Exh. gas bypass
closed
open

70

80
90
100 % SMCR
Main engine shaft power

Fig. 12: Expected steam production of an exhaust gas boiler with a

Fig. 13: Expected electric power production of the Thermo Efficiency System

dualpressure steam system valid for main engine 12K98ME/MC with TES and

(TES) with a dualpressure steam system valid for main engine 12K98ME/MC

based on ISO ambient reference conditions

and based on ISO ambient reference conditions

MAN B&W Diesel

Fig. 11
Expected steam production of an exhaust gas boiler with a dual-pressure
steam system valid for main engine 12K98ME/MC with TES and based
on ISO ambient reference conditions

Thermo Efficiency System 11

Exhaust gas and steam turbine generator output dual pressure

The feedwater, therefore, has to be

The results for operation at 85% SMCR

preheated by means of alternative heat

are shown in Fig. 14, together with the

Besides the singlepressure steam system,

sources such as the jacket water and

calculated ISO ambient temperature

a more complex and more expensive

scavenge air cooler heat.

based results for three other main en-

dualpressure steam system is also

gine types. The corresponding results

available, see Figs. 6 and 7. The high

Furthermore, the pinch point should

based on tropical ambient temperature

and low steam pressures used are

not be too low (giving low gas veloci-

conditions are shown in Fig. 15. How-

about 1011 and 45 bar abs (910 and

ties through the boiler) in order to pro-

ever, it should be emphasised that it is

34 bar g), respectively.

tect the exhaust gas boiler against soot

probably more realistic to use the ISO

deposits and fires.

ambient temperatures as the average

The steam turbine is a multistage dual

ambient temperatures in worldwide op-

pressure condensing type. The alternator/

As an example valid for the nominally

eration. In Fig. 16, the ISO based total

generator is driven both by the steam

rated 12K98ME/MC (18.2 bar) en-

electric power production at 85% SMCR

turbine and the exhaust gas turbine.

gine operating at ISO ambient refer-

is also shown as a function of the main

ence conditions, we have calculated

engine size measured in SMCR power.

Because of the low steam pressure and

the steam production and the elec-

corresponding low saturated steam tem

tric power production of the TES, see

perature (144C/4.0 bar abs), there is no

Figs. 12 and 13.

room for an LPpreheater section in the

Payback time of the Thermo

Efficiency System
The payback time of TES depends very

exhaust gas boiler for feedwater preheat-

The total electric power production in %

much on the size of the main engine

ing, because the exhaust gas boiler

of the main engine shaft power output is

and the trade pattern (main engine load

outlet temperature has to be higher than

also shown as a function of the engine

and ambient temperatures) of the ship.

about 160165C in order to avoid sulphu

load, see Fig. 9.

ric acid corrosion of the boiler outlet.

Main engines operating at 85% SMCR and ISO ambient reference conditions
ME = Main engine
EGT = Exh. gas turbine
ST1 = Steam turbine
Single steam pressure
7.0 bar abs
ST2 = Steam turbine
Dual steam pressure
4.0 bar abs/10.0 bar abs
Additional feed water
preheating required
TES1 = EGT+ST1
TES2 = EGT+ST2
In normal service at
85% SMCR per year:
280 days

Ship type
Main engine type
Specied MCR (L1)

kW

VLCC
6S90ME-C
29,340

4,500 teu
7K98ME-C
39,970

6,000 teu
12K90ME
54,840

8,000 teu
12K98ME
68,640

% SMCR
kW

85
24,939

85
33,975

85
46,614

85
58,344

Steam consumption for heating services

EGT electric power production, approx.
in % of ME output

kg/h
kW
%

1,400
920
3.7

1,800
1,260
3.7

2,400
1,730
3.7

3,000
2,180
3.7

ST1 electric power production

in % of ME output

kW
%

1,110
4.5

1,640
4.8

2,250
4.8

2,840
4.9

ST2 electric power production

in % of ME output

kW
%

1,360
5.4

2,020
5.9

2,800
6.0

3,520
6.0

Total TES1 electric power production

in % of ME output
Annual fuel savings
payback time

kW
%
USD/year
year

2,030
8.2
374,000
8.8

2,900
8.5
528,000
7.0

3,980
8.5
724,000
5.8

5,020
8.6
917,000
5.0

Total TES2 electric power production

in % of ME output
Annual fuel savings
Payback time

kW
%
USD/year
year

2,280
9.1
415,000
8.8

3,280
9.6
596,000
7.0

4,530
9.7
818,000
5.8

5,700
9.8
1,045,000
5.0

Main engine load

Main engine power output

Fig. 14: Steam and electric power production and payback time of the Thermo Efficiency System (TES) when operating at 85% SMCR and ISO ambient
reference conditions

12 Thermo Efficiency System

Main engines operating at 85% SMCR and tropical ambient conditions

ME = Main engine
EGT = Exh. gas turbine
ST1 = Steam turbine
Single steam pressure
7.0 bar abs
ST2 = Steam turbine
Dual steam pressure
4.0 bar abs/10.0 bar abs
Additional feed water
preheating required
TES1 = EGT+ST1
TES2 = EGT+ST2

Ship type
Main engine type
Specied MCR (L1)

kW

VLCC
6S90ME-C
29,340

4,500 teu
7K98ME-C
39,970

6,000 teu
12K90ME
54,840

8,000 teu
12K98ME
68,640

% SMCR
kW

85
24,939

85
33,975

85
46,614

85
58,344

Steam consumption for heating services

EGT electric power production, approx.
in % of ME output

kg/h
kW
%

900
880
3.5

1,200
1,200
3.5

1,600
1,650
3.5

2,000
2,070
3.5

ST1 electric power production

in % of ME output

kW
%

1,600
6.4

2,300
6.8

3,150
6.8

4,000
6.9

ST2 electric power production

in % of ME output

kW
%

1,950
7.8

2,800
8.2

3,830
8.2

4,850
8.3

Total TES1 electric power production

in % of ME output

kW
%

2,480
9.9

3,500
10.3

4,800
10.3

6,070
10.4

Total TES2 electric power production

in % of ME output

kW
%

2,830
11.3

4,000
11.8

5,480
11.8

6,920
11.9

Main engine load

Main engine power output

Fig. 15: Steam and electric power production of the Thermo Efficiency System (TES) when operating at 85% SMCR and tropical ambient conditions

When for example operating at tropical

Based on the average operation in serv-

and a fuel price of 160 USD/t the annual

ambient conditions, the electric power

ice at 85% SMCR = 58,344 kW in 280

main engine fuel costs of the standard

output of the TES is higher than for ISO

days a year, SFOC = 0.00017 t/kWh

12K98ME/MC engine are as follows:

ambient conditions, which again has a

higher TES output compared with winter ambient conditions.
Furthermore, the investment costs per
installed kWe output of a TES plant are
relatively cheaper the bigger the plant is.
A simple estimation of the average saved

Possible annual savings of fuel costs

mill. USD/year
kW Electric power production
7,000
Normal service : 85% SMCR in 280 days/year
1.2
Fuel consumption : 0.17 kg/kWh
Fuel price : 160 USD/t
6,000
1.0

0.8
4,000

with TES (for single or dual pressure)

compared to a standard 12K98ME/MC

0.6

engine can be found by means of the

already estimated relative TES1/TES2

0.4

gain of 8.6%/9.8% of the main engine

output, see Fig. 14.

Single press.

ISO ambient reference conditions

5,000

fuel costs in service at ISO ambient tem

perature conditions for a 12K98ME/MC

Dual press.

0.2

Steam turbine

3,000
2,000
1,000
0
20,000

Exhaust gas turbine

40,000

60,000
80,000 kW
Size of main engine, SMCR power

Fig. 16: Expected total electric power production and possible annual fuel cost savings of the Thermo
Efficiency System (TES) based on ISO ambient reference conditions and 85% SMCR, shown as a

MAN B&W Diesel

function of the main engine size, SMCR power

Thermo Efficiency System 13

Fuel costs = 280 days/y x 24 h/day

In Fig. 17, the estimated payback time

It has been assumed that the increased

x 0.00017 t/kWh

of the TES plant is shown as a function

specific fuel consumption of the TES

x 58,344 kW

of the main engine size. The payback

main engine has been avoided by using

x 160 USD/t

time is only valid provided all electric

an increased firing pressure, Pmax.

= 10,664,000 USD/year

power production savings are used on

board the ship.

For the single and dualpressure systems, respectively, the TES gain in
saved fuel consumptions will then be as
follows:

Payback time of TES

Year
13

10

Normal service : 85% SMCR

In service per year : 280 days/year
Fuel consumption : 0.17 kg/kWh
Fuel price : 160 USD/t

ISO ambient reference conditions

TES1 savings = 0.086 x 10,664,000

12

11

= 917,000 USD/year

TES2 savings = 0.098 x 10,664,000

= 1,045,000 USD/year

as shown in Fig. 14.

The similar fuel cost savings valid for the
other three cases with smaller main engines are also stated in Fig. 14, and in
curve form in Fig. 16 as a function of the
main engine size, SMCR power.

8
7
6
5
4
3
2
1
0
20,000

Based on the extra investment costs of

40,000

60,000

80,000 kW

Size of main engine, SMCR power

the TES plant (without installation of a

shaft power motor on the main engine

Fig. 17: Estimated payback time of the Thermo Efficiency System (TES) valid for both a single and a

shaft and minus the investment cost of

dualpressure steam system

a normal exhaust gas boiler system) for

the four main engine cases compared
to a standard main engine installation,
the estimated payback time found is
as stated in Fig. 14, i.e. in principle the
same for the single and dualpressure
systems. For the 12K98ME/MC engine,
the calculated payback time is about
five years.

14 Thermo Efficiency System

Summary

dualpressure systems, because the

References

Our calculations indicate that for ISO

increased electric power production

[1] Soot Deposits and Fires in Ex-

ambient reference conditions, a reduc-

gain of the dualpressure system might

haust Gas Boilers, MAN B&W Die-

tion of the fuel consumption of 810%

correspond to about the same relative

sel A/S, Copenhagen, Denmark,

for a singlepressure system is possible

increase of the investment costs com-

p.280,March 2004.

in the normal service range of the main

pared to the singlepressure system.

engine. The larger the engine load, the

greater the possible reduction.

When selecting the type of Thermo Efficiency System, the correspondingly

For the more complex dualpressure

involved higher risks for soot deposits

system, the corresponding reduction is

and fires of the exhaust gas boiler has

about 911%.

to be considered, see Ref. [1].

All calculations presume unchanged

Because of this, but also because of the

MTBOs (maintenance time between

more simple singlepressure steam boil-

overhauls) compared to todays expec-

er system, MAN Diesel & Turbo recom-

tations.

mends using the singlepressure steam

system, when installing TES.

However, if the ship sails frequently in

cold weather conditions, the electric

Of course, the more complex and more

power production of the steam turbine

expensive dualpressure steam system,

will be reduced, and the abovestated

which gives a somewhat higher elec-

reduction of fuel consumption and cor-

tric power output, may also be used in

responding reduction of CO2 emission

connection with MAN B&W twostroke

might not be met.

main engine types.

The extra investment costs of the Thermo

The TES is rather expensive, and relatively

Efficiency System and the payback

more expensive the smaller the main

of the investment can be obtained by

engine and the TES are, giving a rela-

means of lower fuel/lube oil costs and,

tively higher payback time. Therefore,

not to forget, the possibility of obtaining

the installation of the TES is normally

additional freight charters and higher

only relevant for the large merchant ships,

freight rates, thanks to the green ship

such as the large container vessels.

image!
The TES may be delivered as a packThe payback time calculations based

age by MAN Diesel & Turbo (turbines)

on a large container vessel with a

in cooperation with Aalborg Industries

12K98ME/MC as main engine and as

(boiler) and Siemens (generator) or by

average operating at 85% SMCR and

other makers.

at ISO ambient reference conditions in

normal service during 280 days/year
indicate a payback time of about 5 years
for the TES. The payback time is valid
for both the singlepressure and the

MAN B&W Diesel

Thermo Efficiency System 15

Copyright MAN Diesel & Turbo Subject to modification in the interest of technical progress.
5510-0030-02ppr Aug10 Printed in Denmark

MAN Diesel & Turbo

Teglholmsgade 41
2450 Copenhagen SV, Denmark
Phone +45 33 85 11 00
Fax +45 33 85 10 30
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