MAN has revealed the latest addition to the company’s 4x line of high-performance diesel engines: the MAN 20V45/60 comes with a limit-pushing power output of 26 MW. Furthermore, the company was able to considerably reduce fuel consumption compared to its predecessor, the MAN 48/60.
The 20V45/60 expands the current performance range of MAN’s 4x family of diesel engines by more than 4 MW, while offering a best-in-class fuel efficiency of more than 50%. Hence, it allows customers to save both investment and operational costs.
Next to a frontloading approach, using thermodynamic engine process calculations, MAN used computational fluid dynamics to simulate and optimize the combustion process. Also finite elements analysis was used to optimize the engine’s mechanical strength and vibration behavior. Then, MAN put the power unit to the test on the world’s largest four-stroke, single-cylinder test bed and started the experimental optimization and validation phase.
The new engine is also a new centerpiece of MAN’s extended systems approach which reflects in the company’s latest generation digital Safety and Control System, SaCoS 5000. Following a decentralized design concept, SaCoS 5000 offers unprecedented data availability and optimized alarm visualization and diagnosis.
The two-stage turbocharger module rounds off the MAN 20V45/60’s superior profile. MAN Diesel & Turbo is the pioneer in developing and operating two-stage turbocharging for large-bore engines, a concept which achieves excellent efficiency thanks to a low-pressure and a high-pressure turbocharger arranged in series.
Perfect fit for power generation in remote locations
The 20V45/60 is a perfect fit for power generation in remote locations and islands where a gas supply is not available. Its sturdy design and construction withstands extreme site conditions like hot ambient temperatures and high altitudes, and makes the engine an excellent solution for captive power applications in climatically-demanding locations. The two-stage turbocharging prevents derating even at 2,500 meters above sea level and the engine shows no decrease in output even in ambient temperatures of up to 53 ºC.
Plant operators benefit from the engine’s high power-density, which significantly reduces capital expenses, as fewer engines and less space are needed to reach a plant’s desired overall output. An extremely competitive fuel-oil consumption adds to the sustainability of the engine’s environmental footprint, which meets the World Bank 2 (2007/2008) emission standard for heavy fuel oil (HFO), marine gas oil (MGO), and marine diesel oil (MDO). A solution with integrated selective catalytic reduction (SCR) is under preparation and will further reduce NOx emissions by up to 80%.
The worldwide rise of decentralized energy generation and renewable energy has significantly changed the capability profile that thermal power plants need to match. Consequently, the new 45/60 is ideally suited for base load as well as peak-shaving applications. Operational flexibility has become essential for power plant operators these days, and state-of-the-art plants need to be able to master repeated and rapid startups and the ability for load-following operation. The 45/60 reaches full load in a short time, effortlessly handles load reversals, and allows for high fuel-efficiency even when operated in partial load.
Gas and dual-fuel versions of the engine are currently under preparation. Also, more cylinder configurations will be added to the 45/60 engine family in the future.