MAN 18 V- 48/60 TS - Co-generation is possible?

REMARKS ON 18V 48/60 TS SERIES

MAN

our understanding is as below referring to this video and earlier inputs as below.

1.     This is a 18 cylinder engine with power @ 1050 kw/ cylinder.

2.     In earlier one ( MAN 18V 40/60), the fuel consumption is 185.7g/kwh. This is a single stage turbo charging unit.

3.     In new  one ( MAN 18V 40/60 TS), the fuel consumption is 171g/kwh as seen in  the video for power output per cylinder at 1050kw/cylinder. This is a two stage turbo charging unit.

4.     Thus with new model the fuel consumption is less by 8%.

5.     This less fuel consumption  ultimately reduce the energy( heat energy) in engine exhaust gas proportionately which is used to generate steam in EGB,

6.     This reduction in energy in exhaust gas can be due to reduced gas quantity , reduced gas temperature or combination of both. The exact revision to flue gas parameters can be only said by the manufactures. hence please get the details.

7.     The other aspect is: due to the additional turbo charging unit, the back pressure of the exhaust gas available for EGB will be less. Earlier it was 30mbar ( 300mmwc). We don't know what's it now for the new model. Please get this data from manufacturer. This is required to size the EGB as the EGB sizing will be based on the back pressure available. We hope you are asking the engine supplier, the guarantees of performance for engines ( specific fuel consumption, power output) considering the back pressure of EGBs.

8.     In nutshell, with 8% less energy available and considering that a back pressure of around 250mmwc ( 25mbar), the cogeneration is still possible . The power output may fall by approx 10-12%. expected power from 3 EGBs for 3 engines at full load may be 3.9mwe instaed of 4.5mwe. But this has to be finally verified after redesigning the EGBs and STGs based on your revised inputs with new engines ( Man 18V 40/60 TS)

Consultant Expert

MAILING ON MAN 18 V 48/60 TS SERIES
Thanks for your mail. From your mail, we have understood that in spite of low gas quantity and low temperature, co-generation is still  possible. For this, investment ( boiler, turbine, fuel) is required. Please find technical booklet of 18 V 48/60 TS as received from MAN. We are going to IPP Project for a duration of 15 year and 55 MW Capacity plant. We need following clarification:

 a. Earlier one ( 18 V 48/60) fuel consumption was 185.7gm/Kwhr. New one ( 18 V 48/60 TS) has consumption 171 gm/ Kwhr. So save is 14.7 gm/Kwhr. If I consider a 18 MW engine running at 80% load in a month then total save of fuel is 14.7 X 1000 X 18 X 30 X 24 X 0.8 = 1524 ton. Is it correct? What will be the cost of this HFO fuel?

b. Exhaust quality will be reduced due to low consumption of fuel. You are considering new design of EGB. Is it HFO fired? What will be the fuel consumption of this EGB? We have a concept that to make the exhaust saturated, we need oil fired boiler. Please clarify this.

c. Can you give a rough idea that what will be the estimated cost of New co-generation system ?

d. Can you give me a comparison that what will be fuel save ( Gain) and co-generation investment with this TS series?

We appreciate your quick response, because we are in contract phase with MAN. CUSTOMER

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FURTHER OPINION

Thanks for your mail. Basically we are going with MAN 48/60 TS series for our new 02 projects (55 MW X 2).  Still the engine is in  monitoring phase.  However as per MAN, The main technical data of this engine is as below:

a.     Fuel consumption: 171 – 177 g/Kwhr (load varies from 18.9 MW – 21.6 MW).

b.     Heat rate:  7305 Kj/ Kwhr – 7560 Kj/ Kwhr

c.      Exhaust: for the ambient temperature of 40°C, MAN experienced a reduction of 10°C in exhaust gas temperatures and 10 t/h in exhaust gas mass flow rate in comparison to MAN 48/60 B. ( for MAN 48/60 B: exhaust gas flow 130 t/h, temperature after turbine 350 deg C, pressure behind turbine 30 mbar).

Basis on above data, please confirm following:

a.     Co-generation is still possible. (EGB, turbine from SIEMENS or Dresser Rand).

b.     3- 3.5 MW generation possible. ( out of 55 MW full load)

c.      In EGB no oil will be required.( if required, mention)

d.     Design and Technical support can be provided

  

You can add any suggestion, comments in relation with this.

We appreciate your kind support.

CUSTOMER

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OPINION OF MAN REP 

thanks for your Email and for the discussions we had on the phone; as already mentioned we have not considered our 48/60TS for your  Project due to several reasons. As we have no reference yet, we are not offering such engine for applications for which a certain track record is required. Also technically, we are at the moment developing a standard to use that engine type for future applications, but as your project is a fast track project, also the delivery time would not be suitable at the moment.

With regard to your questions, please find attached our reply:

a)     What is the exhaust gas temperature of  MAN Diesel & Turbo 48/60TS?
For similar ambient conditions, the 18V48/60TS engine will yield considerably lower exhaust temperatures and exhaust gas mass flow rate. From another project on which we have worked on we could notice, that for the ambient temperature of 40°C we experience a reduction of 10°C in exhaust gas temperatures and 10 t/h in exhaust gas mass flow rate. The exhaust gas temperatures which can be achieved with our  18V48/60B engines were submitted in the first offer and also are attached herewith.

b)    Is there any possibility to use this exhaust in co-generation?
Possibility…Yes. But it makes more sense to use 18V48/60B engines for co-generation for obviously higher exhaust gas temp and more mass flow rate.

c)     We have an idea that by adding HFO fired boiler in exhaust, we can make saturated steam and can use in co-generation. What is your comments?

You can use a HFO fired exhaust gas boiler for co-generation with 18V48/60B engines (TS as well), but it is up to you  if you want that to have such system for a 3-engine plant. There will definitely be additional costs for boiler, turbine and other equipments etc. And for the relative increase in output with co-generation, the investment costs will be too high.

d)    This engine (48/60TS) has fixed capacity alternator( 18.9 MW) or having a range (18.9 - 21.6 MW)?
the Engine is designed with a cylinder output of 1,050 – 1,200, whatever is required. Fuel consumption will change  as higher the cylinder output will be. Please refer to our attached brochure for ISO figures. 

e)     Is there a test bench of this engine for observing technical details?
We have this engine at our test bench, but not for clients to visit. We are testing several operating modes etc. and such confidential information are only for internal use. 

f)     What is the weight of this engine?
approx. 300 tons – as package around 407 tons (dry)

g)    Can I get a technical manual of this engine?
our brochure is attached - Brochure_18V4860TS

As mentioned, we have selected the 48/60B as the most suitable and economical package for your application considering the requirement of site services, experience and the installation.

We hope for your understanding, that we won’t be able to consider the 48/60TS for your application.

Kindly feel free to contact me for any further details.

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