Académique Documents
Professionnel Documents
Culture Documents
October 2009
Carsten Dommermuth
Senior Manger Sales Support Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 <1>
Table of content
MAN Diesel as a sole provider of all ranges MAN Diesel engines in comparsion MAN Diesel at the worldwide power plant market Environmental policy and engine based power generation Two stroke vs. four-stroke Maintenance cost- comparison two-stroke vs. four-stroke Reference two-stroke power plants back-up Biofuel for two-stroke engines
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MAN Diesel
2009/04/01
<2>
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MAN Diesel
2009/04/01
MAN Group
Transport-Related Engineering 2008: Revenue 14.9 billion; Operating Profit 1.7 billion; 51,300 Employees
Commercial Vehicles Trucks Buses Engines Services Diesel Engines Marine applications / power plants Turbochargers Services Turbo Machinery Compressors Turbines Services RENK (76% stake) Gear systems Slide bearings Testing systems Services
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
<5>
Frederikshavn
Copenhagen Holeby
Shanghai Aurangabad
Denmark
MAN Diesel, Two- and four-stroke engines, propellers and propulsion Copenhagen packages, after-sales services Holeby
Villepinte/Paris
France
Saint-Nazaire MAN Diesel SAS Four-stroke engines, aftersales services
Augsburg
Czech Republic
Velk Bte PBS Turbo s.r.o. Turbochargers
Germany
Status: 12/05
up to 80 080 kW
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MAN Diesel
2009/04/01
<8>
Japan
Diesel United J.F.E. Engineering Hitachi Kawasaki Mitsubishi Mitsui Niigata 1963 1964 1951 1911 1929 1926 1973
Korea
Doosan Engine Hyundai Heavy Industries STX Heavy Industry, STX Engine STX Enpaco 1983 1976 1977 1995
Poland
H. Cegielski Poznan 1959
Russia
Bryansk 1959
Spain Croatia
Adriadiesel Brodosplit Uljanik 1998 1967 1984 Navantia 1965
U.S.A.
Fairbanks Morse Engine 1995
India
Kirloskar 1977
Vietnam
Vinashin 2004
Low-Speed
Medium-Speed
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High-Speed
Turbocharger
CP-Propeller
MAN Diesel 2009/04/01 <9>
Mitsubishi 2%
Sulzer (Wrtsil) 6%
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
50,000 40,000
Two-stroke
Four-stroke
Low speed
30,000
Medium speed
20,000
10,000
0 100
200 300 400
500
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MAN Diesel
2009/04/01
Two-Stroke Licensees
1954 1984
Russia Bryansk
1959
1941
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
up to 80 080 kW
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MAN Diesel
2009/04/01
< 15 >
Carsten Dommermuth
Senior Manger Sales Support Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01
Operation conditions: Gas turbines: (according to ISO 3977) Diesel engines: (according to ISO 3046) *Type: MAN Diesel SE Reference of Graphic: Article from Mr. H. W. Khler, MAN Diesel SE: Diesel engines and gas turbines in cruise vessel propulsion a technical and commercial comparison, 1999
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MAN Diesel
2009/04/01
Gas turbine 80
Base Load
% Power 100
20
25
30
90
80
46 25 35 Min. [current topic] 35 42 Design 45 52 Max. Air inlet temperature C o Cooling water temperature C Ambient conditions MAN Diesel 2009/04/01
o
Part Load
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MAN Diesel
2009/04/01
Carsten Dommermuth
Senior Manger Sales Support Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01
Examples of Liquid Fuels Burned in MAN B&W Two-stroke Low Speed Diesel Engines
Fuel No Viscosity Density Flash point Conradson Carbon Asphalt Sulphur Water Ash Aluminium Vanadium Sodium CCAI
I 560
J 690
K 710
Units cSt/50C kg/m3 at 15C C % weight % weight % weight % weight % weight mg/kg mg/kg mg/kg -
1200 50,000
1,010 1,008 1,030 90 17.3 14.6 2.22 0.00 0.04 122 22 868 79 22.1 19.3 3.52 0.00 0.07 300 24 864 84 24.7 29.0 3.30 0.00 0.09 370 50 885
0.065 0.025
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MAN Diesel
2009/04/01
MAN B&W Two-Stroke Dual Fuel Low Speed Diesel, Fuel Type Mode
Fuel 100% Fuel-oil-only mode Fuel 100% Minimum fuel mode
Gas Fuel
8%
Fuel
100% load
Fuel 100%
100% load
Gas
8%
Fuel
100% load
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MAN Diesel
2009/04/01
Power Plant at CHIBA Power Plant in Japan Engine: MAN B&W 12K80MC-GI
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MAN Diesel
2009/04/01
Examples of Gaseous Fuels Burned in MAN B&W Two-Stroke Low Speed Diesel Engines
Composition
CH4 C2H6 C3H8 C4H10 C5+ CO2 N2 Molar mass Lower calorific value Lower calorific value Density: at 25 oC/ 1 bar abs at 25 oC/ 200 bar abs
kg/kmol 18.83
kg/m 3 kg/m 3
0.76 194
0.73 179
1.43 487
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MAN Diesel
2009/04/01
Carsten Dommermuth
Senior Manger Sales Support Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01
Turbo generator Exhaust gas energy A) Steam boiler B) Heat exchanger (230-260 C)
o
Electrical energy
o (60-65 C)
o (80-85 C)
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MAN Diesel
2009/04/01
MAN B&W 2-stroke diesel engines are well known for their low specific fuel oil consumption, overall efficiency, and long-term reliability. The recent dramatic increase in fuel oil costs has revived interest in methods for maximising fuel economy in 2-stroke engine systems, while ensuring continued high system reliability.
55
53
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MAN Diesel
2009/04/01
600 kW MAN B&W TCS Unit for Exhaust Gas Energy Recovery
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MAN Diesel
2009/04/01
A Sankey diagram is a specific type of flow diagram, in which the width of the arrows is shown proportionally to the flow quantity. Is shows exactly the well known first law of
Engine shaft generator thermodynamics output 47.7%
22.5% 1.2%
Total energy utilisation: Electrical energy = 50.0% Thermal energy = 1.2% Total energy utilisation = 51.2%
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MAN Diesel
2009/04/01
Carsten Dommermuth
Senior Manager Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 30 >
(GMD12/ACJ)
MAN Diesel
2009/04/01
3/3
Western Pacific Ocean: 80 MW (12K80-MC-S) Greece: 100 MW Tender (12K90MC-S) North America: 50 MW Tender (12K90MC-S) Italia: 20 MW Private Project (12K60MC-S) Albania 120 MW Private Project (12K80MC-S) Southwest Asia 600 MW governmental project (12K90MC-S) Several enquiries for Bio projects (range from 4-max. 20 MW) L35MC-S
[current topic] MAN Diesel 2009/04/01 < 32 >
Environmental policy
The new driver for modern power plant solutions
Carsten Dommermuth
Senior Manager Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 33 >
Emission facts
The emission issue will become more and more important in the future. In local areas, regulations will be even stricter than they are today. The main driver for sophisticated MAN Diesel two-stroke environmental technology is the
market dominance of MANs two-stroke engines in the marine business.
Our two and four-stroke power plant solutions fulfill high standards of international regulations
like World Bank and IFC.
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MAN Diesel
2009/04/01
< 34 >
Emission facts
Emissions from diesel and heavy fuel oil engines NOx (Nitrogen Oxides): Function of peak combustion temperatures and oxygen concentration. Reduction: Primary or secondary methods SOx (Sulphur Oxides): Function of fuel oil sulphur content. Reduction: The most effective means is to lower the sulphur content in the fuel. CO2 (Carbon dioxide): Function of the thermal effienecy of the complete generating process. Particulate emissions: A result of: Ash content in fuel/cylinder and lube oil. Partly burned lube oil dosage.
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MAN Diesel
2009/04/01
< 35 >
Environmental policy and regulations are the main driver for modern power plant solutions
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MAN Diesel
2009/04/01
< 36 >
HFO 380cSt
(3230/JH)
MAN Diesel
2009/04/01
Exhaust Emissions
Heat Exhaust gas 13.00% O2 75.80% N2 5.20% CO2 5.35% H2O 1500 vppm NOx 600 vppm SOx 60 vppm CO 180 vppm HC 120 mg/Nm3 Part
Exhaust Emissions
World Bank (2008) Guideline for thermal power plants > 300 MWth
NOx
[mg/m3]
SOx [mg/m3]
580
PM
[mg/m3]
WB 2008
740
30-50
Measurements with 15%O2 in dry Exhaust Gas 1% S in fuel and non degraded air shed
How can we meet the current World Bank or the local emission rules?
[current topic] MAN Diesel 2009/04/01
2-stroke engines
350 C
270 C
Engine
SCR
T/C
Boiler
4-stroke engines
350 C
Engine
T/C
SCR
Boiler
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MAN Diesel
2009/04/01
Exhaust Emissions
Two stroke solution for reduction the SOx (SO2)- Main driver for this emissions is the available fuel
3000
NOx
[mg/m3]
SOx [mg/m3]
580*
PM
[mg/m3]
2500
2000
WB 2008
740
50
1500
1000
500
To meet minimum World Bank without secondary method a low sulphur content is the driver
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MAN Diesel
2009/04/01
40MW 38 MW 60 MW 40 MW
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
Stationary Applications
Liquid fuel two-stroke diesel engine emission control status Emission Control method CO2 Efficiency NOx Engine adjustment Water emulsification SCR EGR Particulates Fuel selection Engine adjustment Precipitators SOx Fuel selection DeSOx X X up up up up X X X up up up X X X X up up up up up up up up Tested technology Proven technology Influence on 1st cost Influence on running cost Influence on maintenance effort
up
down
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MAN Diesel
2009/04/01
Carsten Dommermuth
Senior Manger Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 45 >
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MAN Diesel
2009/04/01
Maintenance 6%
Two stroke has a lower specific Fuel Oil consumption than four
stroke.
The equity pay back time for a two stroke solution is under ceteris paribus nearly the same with 4,5 years under a NPV Analysis. Reasons are the higher thermal efficiency, lower fuel and spare part consumption
[current topic] MAN Diesel 2009/04/01
7 x 12K90MC-S
With TCS and steam turbine 328,9 MW net
18 x 18V48/60
With steam turbine 303 MW net
SFOC Fuel oil costs per year (230 US$/MT) System oil consumption (per unit) Cylinder oil consumption (per unit) Lube and cylinder oil costs System oil costs (plant) Cylinder oil costs (plant) Maintanance costs (7200h/a) Total operating costs per year Specific operating costs per year
based on 7000 h/a*
172,3 g/kWh 91,6 Mio.US$ 4,8 kg/h 1,0 g/kWh 3,8 US$/kg 1,1 Mio.US$ 8,9 Mio.US$ 7,0 Mio.US$/year
(3,0 US$/MWh)
192 g/kWh 93,8 Mio.US$ 11,5 kg/h ----3,8 US$/kg 5,66 Mio.US$ ---18,59 Mio.US/year
(7,8 US$ /MWh)
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MAN Diesel
2009/04/01
Electricity generating costs based on a ~330 MW base load power plant solution
Power Plant Solution Capital costs
7 x 12K90MC-S
With TCS and steam turbine 328,9 MW net
18 x 18V48/60
With steam turbine 303 MW net
Construction time Equity ratio Tax rate Equity costs Loan costs Weighted costs of capital
56 US$/MWh
60,2 US$/MWh
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MAN Diesel
2009/04/01
Results of comparison two stroke vs. four stroke in annual running costs for ~330 MW
Lub oil costs per plant in Mio.US$/a
Four stroke
5,66
Two stroke
1,1
Four stroke
Two stroke
10
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MAN Diesel
2009/04/01
Results of comparison two stroke vs. four stroke in annual running costs ~330 MW
Maintenance costs (7200h/a) Mio.US$/a
Four stroke
18,59
High price differences are caused by 2 main servicing at 15.000 operating hours and 30.000 operating hours for 4-stroke engine. First main servicing for 2-stroke engine at 32.000 operating hours
Two stroke
10
15
20
Four stroke
126
Two stroke
115,6
110
120
125
130
Source: B. Jacobsen and P.G. Povelsen, MAN Diesel A/S, -G. Ambrasas, MAN Diesel SE
MAN Diesel
2009/04/01
The focus for IPP power plant investment decisions is more financial orientated
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MAN Diesel
2009/04/01
The focus for public owned power plant investments is more orientated at save and steady energy supply
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MAN Diesel
2009/04/01
* EPC package incl. 2x 9K80 MC-S engines, 1x Steam Turbine and 2x TCS Systems
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MAN Diesel
2009/04/01
- Installed capacity: 62.000kW Net - 115 Mio. US$ - Specific price: 1850US$/kW
Electrical Equipment 8%
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MAN Diesel
2009/04/01
Carsten Dommermuth
Senior Manger Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 56 >
2,40
Two-stroke
Four-stroke
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MAN Diesel
2009/04/01
< 57 >
48,02
Two-stroke
Four-stroke
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MAN Diesel
2009/04/01
< 58 >
Different engine designs a the main reason for high different in maintenance pricing
*based on 7000 h/a: Estimated maintenance costs for a 12K90 MC-S engine. Exhaust valve-TBO 16.000 h pricing 12.000 plus blue colar costs (7 h x 7/h) in total 12.100
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MAN Diesel
2009/04/01
< 59 >
2,40
Two-stroke
Four-stroke
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MAN Diesel
2009/04/01
< 60 >
48,02
Two-stroke
Four-stroke
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MAN Diesel
2009/04/01
< 61 >
Different engine designs are the main reason for high differences in maintenance pricing
*based on 7000 h/a: Estimated maintenance costs for a 12K90 MC-S engine. Exhaust valve-TBO 16.000 h pricing 12.000 plus blue colar costs (7 h x 7/h) in total 12.100
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MAN Diesel
2009/04/01
< 62 >
MAN Diesel SE
Two-stroke reference plants
Carsten Dommermuth
Senior Manager Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 63 >
(GMD12/ACJ)
MAN Diesel
2009/04/01
3/3
As at 2002.10.16
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MAN Diesel
2009/04/01
Alstom Power S.A., Spain - Main contractor - Generator - Mechanical and electrical aux. systems - Logistics - Site erection - Commissioning
Manises Diesel Engine Co. S.A., Spain - Diesel engine supply - Site erection - Commissioning
MAN B&W Diesel A/S, Denmark - Diesel engine design Foundation design Conceptual plant engineering Commissioning assistance
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MAN Diesel
2009/04/01
As at 2002.10.16
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MAN Diesel
2009/04/01
The world largest Power Barge- 95 Meters long, 45 Meters Wide, 50 Meters high, 22000 Ton
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
Olachea (San Carlos) Location: Mexico Operator: Comision Federal de Electricidade Configuration: 2 X 32-MW, 1 X 42-MW 12K90MC-S engine. Fuel: Heavy Fuel Oil EPC: MHI, Hyundai, MAN B&W, ABB
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
Ibiza-Holiday Island in the Mediterranen SeaBase and Midle load powered by MAN Diesel two- and four stroke engines
[current topic] MAN Diesel 2009/04/01
Ibiza- Location: Baleares, Operator: Endesa Spain Configuration: 4 X 8.5-MW 6K74ES engines, 2 X 15.4-MW 10K67GSCA engines Operation: 1973-1981 Fuel: HFO E/G supplier: MAN B&W
[current topic] MAN Diesel 2009/04/01
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
1999 2000 1999 2000 D8 Availability Reliability Scheduled outage % % hrs. 96.3 99.0 234 84 82 93.1 98.3 272 95 94 D9 95.1 93.6 97.6 94.0 217 207 83 274 138 94
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MAN Diesel
2009/04/01
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MAN Diesel
2009/04/01
MAN Diesel SE Business Unit Power Plants Phone: +49 821 322-3184 Mobil: +49 171 7645070 carsten.dommermuth@man.eu
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MAN Diesel
2009/04/01
< 80 >
Carsten Dommermuth
Senior Manager Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01
Scope of delivery: Turnkey CHP (Combined Heat and Power) plant to a site in
the city of Brake, near Bremen, Germany.
Engine: MAN B&W 7L35MC-S engine, supplying 4.2 MWel to the national grid
and 3.6 MWth to a palm-oil refinery situated nearby. The engine is a two stroke, low-speed, crosshead uniflow diesel engine.
Fuel: Crude palm oil with a Total Acid Number (TAN) of up to 15 mg/KOH/g. Heat rate: 7,400 kJ/kWh at site ambient conditions, corresponding to an efficiency
of 49%; plant total efficiency in CHP-mode 87%.
Exhaust gas cleaning: The plant is equipped with an SCR (Selective Catalytic
Reduction) catalyst, an oxidation catalyst and an electrostatic precipitator
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MAN Diesel
2009/04/01
< 82 >
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MAN Diesel
2009/04/01
< 83 >
Brake
Emden Italy
Danish
Din.EN-ISO 660 mg KOH/g ASTM D 240 ASTM D 4052 ASTM D 445 IP 336 ASTM D 482 MJ/kg g/ml cSt ppm % wt
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MAN Diesel
2009/04/01
Viscosity/50 C Cetane number Coke residue Sediment content Oxidation stability (110 C) Phosphorus content Na + K content Ash content Iodine Number Water content TAN (total acid number) Cold Filter Plugging Point
Source: Dr. Gehring MAN Diesel SE
DIN EN ISO 3104 FIA DIN EN ISO 10370 DIN EN 12662 ISO 6886 ASTM D3231 DIN 51797-3 DIN EN ISO 6245 DIN EN 14111 EN ISO 12537 DIN EN ISO 660 EN 116
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MAN Diesel
2009/04/01
< 85 >
Modified components
Reinforced camshaft Introduced
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MAN Diesel
2009/04/01
No remarkable SOx
emissions.
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MAN Diesel
2009/04/01
< 87 >
CO
mg/Nm3
NOX
mg/Nm3
HC
mg/Nm3
PM
mg/Nm3
90 60 80
35 45 55
80 70 65
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MAN Diesel
2009/04/01
< 88 >
http://www.manbw.com/engines/TwoStrokeLowSpeedEngines.asp?model=L35MC-S
[current topic] MAN Diesel 2009/04/01 <1>
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MAN Diesel
2009/04/01
< 90 >
Two-stroke Bio SCR Arrangement MAN B&W Low Speed Biofuel Engine
Chimney
TC Silencer Generator
Cyl.1
Suction blower
[current topic]
MAN Diesel
2009/04/01
Two-stroke Bio project investment costs for 4,5 MWmech in a CHP mode
E&M turnkey pricing approx. 1100 /kW
incl, SCR, Oxicat and ESP (4,95 Mio. )
Electrical Equipment 8%
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MAN Diesel
2009/04/01
< 92 >