Insight in the Development of MAN s Game Changing 45/60CR Engine Portfolio Alexander Knafl, PhD Head of Advanced Engineering & Exhaust Aftertreatment MAN Diesel & Turbo, Germany < 1 >
Disclaimer 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. < 2 >
Agenda 1 Introduction 2 Specifications 3 Development Insight 4 Summary < 3 >
Introduction 1 gram liquid fuel results in ~ 3.1 gram CO 2 Increasing thermal efficiency by 1%, lowers CO 2 emissions by 2,200 tons / year based on a 25MW plant @ 8,000 hrs / year Equivalent of annual CO 2 emissions of 2,000 cars @ 95g/km Efficiency very much matters < 4 >
Introduction Definition of requirements for new developments Customer Requirements INNOVATION SERVICEABILITY POWER NOISE APPEARANCE RELIABILITY MANUFACTURING AVAILABILITY PROCESS SAFETY RETROFITABILITY TCO* QUALITY PERFORMANCE DESIGN EFFICIENCY IDENTIFICATION Blank sheet of paper Regulatory Boundaries PUBLIC AWARENESS RISE IN FUEL PRICES ENVIRONMENT LOGISTICS EEDI LNG AVAILABILITY OF GAS STANDARDS MARKETING BUDGET DF EMISSION REGULATIONS INDUSTRY POLITICS CERTIFICATION ACCEPTANCE Design of a new engine family Centerline-new engine with proven design approach and components < 5 >
Agenda 1 Introduction 2 Specifications 3 Development Insight 4 Summary < 6 >
Main Engine Data Configurations, Dimensions, Performance Specification Bore / Stroke (mm) 450 / 600 Minimum centerline distance between two engines (mm) Cylinder configuration: Marine Cylinder configuration: Power V: 5,050 6L, 7L, 8L, 9L, 10L, 12V, 14V 12V, 20V rpm (min -1 ) 600 Power output per cyl. (kw m ) 1,300 Power range: Marine (kw m ) Power range: Power (kw m ) L: 7,800 13,000 V: 15,600 18,200 15,600 26,000 Break mean eff. pressure p me (bar) 27.2 SFOC*: Marine (g/kwh) Efficiency*: Power (% m ) Application: Marine Application: Power Emission: Marine Emission: Power L: 167 V: 166 >50% DM (CPP), DE SC, CC IMO Tier II IMO Tier III** WB 2007 / 2008 * ISO conditions. For detailed boundary conditions, ref. to respective project guides ** With exhaust gas aftertreatment system < 7 >
Main Engine Data Marine application MAN 12V45/60CR vs. MAN 12V48/60CR *Drawing & dimensions without flywheel seating. MAN 12V45/60CR MAN 12V48/60CR (14,400 kw) MAN 12V45/60CR (15,600 kw) 12V48/60CR Dry mass* (t) 204 189 Spec. weight (kg/kw) 13.1 13.1 SFOC (g/kwh) 166 173 At comparable dimensions, the MAN 45/60CR provides significantly improved SFOC & power output < 8 >
Main Engine Data Power plant application TUMO 20V45/60 48/60 TS w/o Alt. 7,400 5,500 H ALT * W ALT * 4,600 5,700 6,500 12,600 L ALT * Dimensions and Weight 20V engine 20V TUMO L mm 12,600 (L1) 6,500 (L2) W mm 4,600 (W1) 5,700 (W2) H mm 5,500 (H1) 7,400 (H2) Dry Mass t 303 90 @ 26MW, highest power output of any 4-stroke engine on the market < 9 >
Design Feature Two-stage turbocharging Benefits of two-stage turbocharging Two-stage turbocharging in combination with Miller timing for SFOC and emission reduction Higher pressure ratio to achieve higher power density Tolerance towards ambient conditions Compact design: double the amount of turbochargers yet similar dimensions Reduced complexity for continued ease of maintenance Fully integrated wet and dry cleaning systems Reduced noise emissions due to improved silencer Two-stage turbocharging is key for highest efficiency < 10 >
Design Features Load Application 100 90 80 Engine load [%] 70 60 50 40 30 20 10 0 0 60 120 180 240 300 30 40 Time [sec] Emergency loading (with Jet Assist) Emergency loading (without Jet Assist) Short loading Normal loading Although MAN 45/60CR is two-stage turbocharged, the load pick-up behavior is the same as for MAN 48/60CR < 11 >
Design Feature Fit for EGA* systems New MAN 45/60CR engine permits high exhaust gas backpressure SOx scrubber Gas flow in a monolith filter (Courtesy of Coming Inc.) *Exhaust gas aftertreatment Fully compliant Tier III system; prepared for future emissions requirements without derating or fuel economy penalty < 12 >
Agenda 1 Introduction 2 Specifications 3 Development Insight 4 Summary < 13 >
Development Insight Latest simulation tools Latest simulation methodology using multi-criteria optimization Example: concept design of the crankshaft No. of possible solutions max. & min. values for friction and damping Safety factor Equal air distribution over all cylinders 12,000 1st Selection 50 2nd Selection 20 1D Calculation 5 Minimum vibrations over entire engine Vibration simulation 1 Robust and low friction design leading to high product reliability and efficiency < 14 >
Development Insight Approach to combustion & performance 0D / 1D Simulation CFD Simulation Single-Cylinder Engine Full-Scale Engine Turbocharger setup Compression ratio Valve lift curves Injection nozzle design Piston bowl shape Validation completed Confirmation of efficiency and engine-out emissions Optimization of the combustion setup Proven development process enables mature products right from the start < 15 >
Development Insight Combustion optimization on single cylinder engine Steep injection angle Longest combustion Lowest NOx Emissions at cylinder pressure limit Highest smoke emission Highest SFOC 2459 hours of single cylinder engine combustion development: Setups for Marine, Power, SC, CC, CHP applications defined 11 piston bowls ~50 injector configuration 8 cam shaft configurations 3 swirl variants 4968 Measurements Best trade-off between performance, emissions @ maximum durability < 16 >
Development Insight Utilization of proven technologies and suppliers Proven key technologies 2 4 1 5 6 6 Common rail injection system MAN turbocharger technology MAN SaCoS technology 3 5 6 MAN SCR System Key components in-house 7 Established key suppliers Development & validation processes The centerline-new 45/60CR features well-known MAN technologies < 17 >
Validation Procedure Component test rigs Single cylinder engine 12V and 20V test engines 4 step approach: Component test rigs with extreme condition tests > 6,000 hrs. Single cylinder engine with 2,500 hrs. 12V prototype ~1,000 hrs. 20V 26MW power plant serial engine Supplying a fully validated product < 18 >
Agenda 1 Introduction 2 Specifications 3 Development Insight 4 Summary < 19 >
Summary Achievements in the development of the 45/60 engine family Low life cycle costs best efficiency, high power density Compact design Low emissions including World Bank 2007/2008, IMO Tier II / Tier III with SCR High permissible backpressure for exhaust gas aftertreatment systems No derating / insensitive to ambient conditions High reliability Easy installation / reduced interfaces Retrofitability < 20 >
MAN kann Thank you for your attention! Alexander Knafl, PhD Vice President Head Advanced Development & Exhaust Aftertreatment alexander.knafl@man.eu +49 (0)821 322 1254 < 21 >
Movie < 22 >