Two-stroke- Sales introduction course

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>

Without any comment.

50% of World Trade is Powered by Engines from MAN Diesel

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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

MAN Latin America Trucks Buses Services

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MAN Diesel

2009/04/01

Sole Provider of a Diesel Engine Programme from 450 kW to 97,300 kW

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MAN Diesel

2009/04/01

<5>

Development and Production Locations

Frederikshavn

Copenhagen Holeby

Shanghai Aurangabad

St. Nazaire Augsburg Velk Bte

China P.R. Germany India Denmark France Czech Republic

[current topic] MAN Diesel 2009/04/01 <6>

MAN Diesel Group Locations in Europe

Employees worldwide: 7,700 Great Britain
MAN Diesel Ltd. After-sales services Frederikshavn

Denmark
MAN Diesel, Two- and four-stroke engines, propellers and propulsion Copenhagen packages, after-sales services Holeby

Stockport Colchester Rostock Hamburg

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

MAN Diesel SE Headquarters, four-stroke engines, turbochargers, after-sales services

[current topic] MAN Diesel 2009/04/01 <7>

MAN Diesel Copenhagen, Denmark

up to 80 080 kW

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MAN Diesel

2009/04/01

<8>

MAN Diesel Licensees

China P.R.
Shanghai Xinzhong Power Mach. Plant (CXZ),CSIC Shaanxi Diesel Engine Heavy Ind., (SXD) CSIC Henan Diesel Engine Heavy Industry, (HND) CSIC Wuhan Marine Machinery Plant, (WMMP) CSIC Dalian Marine Diesel, CSIC Yichang Marine Diesel, CSIC Zhenjiang CME, CSSC Hudong, CSSC MES Diesel, CSSC Dalian Locomotive (DLRC) Hangzhou Zhonggao Engine (ZGPT) STX Dalian, STX Fushun Jiangsu Antai (JAD) Shandong Juli Jiangsu Guotai Marine Diesel CSR Ziyang Locomotive Zhongji Hitachi Zosen Diesel Engine (ZHD) Rong An Yungpu Zhejiang Yungpu Heavy Machinery 1980 2004 2007 2006 1980 1989 1980 1980 2007 2004 2006 2007 2007 2008 2008 2008 2008 2008 2008 2008

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
[current topic]

High-Speed

Turbocharger

CP-Propeller
MAN Diesel 2009/04/01 <9>

MAN Diesel Leading Position on the two stroke market

Mitsubishi 2%

Sulzer (Wrtsil) 6%

MAN Diesel 92%

Source: BRL Shipping Consultants Lloyds Ship Manager June 2007

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MAN Diesel

2009/04/01

MAN Diesel Engine Program

Sole Provider of a Diesel Engine Program from 500 kW to 97,300 kW

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MAN Diesel

2009/04/01

MAN B&W Diesel Engine Programme

Engine output Pmech (kW) 80,000 70,000 60,000

50,000 40,000

Two-stroke

Four-stroke

Low speed
30,000

Medium speed

20,000
10,000

0 100
200 300 400

500

600 700 Engine speed (r/min)

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MAN Diesel

2009/04/01

Two-Stroke Licensees

China HHM DMD YMD

1980 1980 1989

Croatia Uljanik Split

1954 1984

Japan Mitsui Makita Hitachi Kawasaki

1926 1981 1951 1981

Korea Hyundai HSD STX

Poland 1976 1983 1984 Cegielski 1959

Russia Bryansk

1959

Spain IZAR Manises

1941

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MAN Diesel

2009/04/01

6S35MC and 10K98MC-C on Testbed

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MAN Diesel

2009/04/01

Two stroke engine 10K98MC-C

up to 80 080 kW

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MAN Diesel

2009/04/01

< 15 >

Comparison IC engine vs. gas turbine

Carsten Dommermuth
Senior Manger Sales Support Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01

Power Efficiency Comparison at ISO 3046

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

[current topic]

MAN Diesel

2009/04/01

Influence of Ambient Conditions on Rating of Internal Combustion Engines

% Power 100 Power restriction Low speed diesel Medium speed diesel 90

Gas turbine 80

Base Load
% Power 100

20

25

30

35 45 40 o Ambient temperature C (%) Overall efficiency 50 49 48 47

Low speed diesel

90

Efficiency, low speed diesel

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

Influence of flexibel load profile on Rating

Part Load

Output Reduction Two stroke Engine

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MAN Diesel

2009/04/01

Fuel flexibility for a better economical performance

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

A 3.8 968 98 0.3 0.78 0.10 0.01 0.00 0 0 912

B 84 995 84 17.2 15.1 2.72 0.01 220 27 874

C 85 970 80 12.1 8.9 1.16 0.01 20 23 849

D 141 993 103 13.3 9.2 0.91 0.00 0.03 23 24 866

E 198 938 100 9.4 3.7 0.83 0.01 0.03 12 25 807

F 255 977 106 14.5 10.0 0.87 0.02 0.025 17 40 843

G 470 985 90 16.8 11.3 0.90 0.02 0.03 24 35 844

H 520 983 95 14.8 12.8 1.18 0.01 0.035 45 22 841

I 560

J 690

K 710

L 800 935 >40 9.4 1.02 0.37 0.043 415 9 -

M 998 80 14,1 12 4 0,65 12 312 -

N 1,040 >60 24.2 4.8 0.05 0.035 2.0 149 -

O 1.01 >70 11.7 2.8 0.18 1 -

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%

30 - 40% Specified gas mode

100% load

Gas

8%

Fuel
100% load

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MAN Diesel

2009/04/01

40 MW Plant, Chiba, Japan

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

Units Natural gas types

vol.% vol.% vol.% vol.% vol.% vol.% vol.% 88.5 4.6 5.4 1.5 91.1 4.7 1.7 1.4 0.5 0.6 17.98 26.1 2.5 0.1 64.0 7.3 35.20

VOC fuel types

1.1 65.5 23.9 6.5 6.3 5.0 88.7 6.1 93.9 -

kg/kmol 18.83

kJ/kg 49170 48390 7050 kJ/Nm3 41460 38930 11120

kg/m 3 kg/m 3

0.76 194

0.73 179

1.43 487

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MAN Diesel

2009/04/01

Waste Energy Utilisation

Environmental friendly and a chance for optimising also economical efficiency of the electrical generation process

Carsten Dommermuth
Senior Manger Sales Support Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01

Low Speed Diesels Waste Energy Utilisation

Air cooler energy A) Hot water => 100 C B) Hot water => 100 C (80-130 C)
o

Turbo generator Exhaust gas energy A) Steam boiler B) Heat exchanger (230-260 C)
o

Pressurised Process heat District heating

Process steam District heating Process heating

Electrical energy

TCS unit A) Power turbine

o (60-65 C)

o (80-85 C)

Process water District heating

Energy from lubricating oil cooling A) Heat exchanger

Energy from jacket cooling A) Heat exchanger B) Direct use

Turbo generator Process steam District heating

[current topic]

MAN Diesel

2009/04/01

Two-stroke Low Speed Diesel Combined Cycle

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.

Thermal efficiency [%]

57

55

53

51 50 60 70 80 90 100 110 Load [%]

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MAN Diesel

2009/04/01

600 kW MAN B&W TCS Unit for Exhaust Gas Energy Recovery

Generator Coupling Gear box Exhaust gas turbine

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MAN Diesel

2009/04/01

Typical Utility Installation (Macao)

Heat balance data: Energy in fuel: 100% Generator cooling: Radiation: Lub. oil cooling: Unutilised Utilised energy energy Low temp. High temp. 1.5% 0.5% 4.1% 7.0%

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%

Jacket water cooling:

Charge air cooling: 22.5%

Exhaust gas: Heat exchanger

22.5% 1.2%

Total energy utilisation: Electrical energy = 50.0% Thermal energy = 1.2% Total energy utilisation = 51.2%
[current topic]

Turbo TCS generator generator 1.3% 1.0%

MAN Diesel

2009/04/01

MAN Diesel SE Power Market

Carsten Dommermuth
Senior Manager Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 30 >

Two-stroke Low Speed Engines for Stationary Applications

Range from 20-50 MW

33363416 [current topic]

(GMD12/ACJ)

MAN Diesel

2009/04/01

3/3

2009 and 2010

Stationary two-stroke projects

Actual and upcoming projects only two-stroke (as of 09-2009)

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.

[current topic]

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

[current topic]

MAN Diesel

2009/04/01

< 36 >

CO2 Emission as function of plant efficiency

CO2 CO2 g/kWh g/kWh 800

HFO 380cSt

750 700 650 600 550 500 450 400 35 40 45 50 55 60 % efficiency

[current topic] 3334790.2007.03.28

(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

Air 8.5 kg/kWh 21% O2 79% N2

Two stroke Engine air and exhaust gas flow

Fuel 175 g/kWh 97% HC 3% S

Lube 1 g/kWh 97% HC 2.5% Ca 0.5% S Work

[current topic] MAN Diesel 2009/04/01

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

or local requirements, or values defined by an Environmental Assessment Study

How can we meet the current World Bank or the local emission rules?
[current topic] MAN Diesel 2009/04/01

Schematic SCR Flow Chart Exhaust Emissions

2-stroke engines

350 C

270 C

Engine

SCR

T/C

Boiler

4-stroke engines

350 C

Engine

T/C

SCR

Boiler

[current topic]

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]

SOx Emissions mg/Nm @ 15% O2

2500

2000

WB 2008

740

50

1500

Measurements with 15%O2 in dry Exhaust Gas *1% S in fuel

1000

500

0 0 1 2 3 S-Content in Fuel Oil %w t. 4 5

or local requirements, or values defined by an Environmental Assessment Study

To meet minimum World Bank without secondary method a low sulphur content is the driver

[current topic]

MAN Diesel

2009/04/01

Electrostatic Precipitator Reference List

1 x MAN 12K80MC-S engines (40 MW) Engines in Korea

1990 1997 2004 2005

40MW 38 MW 60 MW 40 MW

4 x 7K60MC-S 3 x 7K60MC-S 2 x 9K80MC-S 1 x 12K80MC-S

Cheju, Korea DCM, India BLPC, Barbados Komipo, Korea

[current topic]

MAN Diesel

2009/04/01

Jeju Island, South Korea

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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

[current topic]

MAN Diesel

2009/04/01

Two-stroke vs. four-stroke

Carsten Dommermuth
Senior Manger Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 45 >

Economics in power generation

Comparison of pricing in power generation for 2-stroke and 4-stroke

[current topic]

MAN Diesel

2009/04/01

Comparison two stroke vs. four stroke

Investors view
Typical Cost Distribution for running costs in Electricity Generation
Lube Oil 4%

Driver for a two stroke Solution

Two stroke Engine with a higher thermal efficiency.

(Net Heat Rate)

Maintenance 6%

Two stroke has a lower specific Fuel Oil consumption than four
stroke.

Two stroke with longer Time between overhaul (TBO) in service.

Two stroke engine with lower mean piston velocity (MPV) as

indicator for lower maintenance costs.
Fuel Oil 90%

*Without cost of capital

Two stroke is very flexible in fuel share.

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

Comparison of annual running cost for ~330 MW base load power

Power Plant Solution
Calculations without capital costs- capital costs for equity and debt are depending on customers business case

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)

108,6 Mio.US$ 0,049 US$/kWh net*

121,85 Mio.US$ 0,057 US$/kWh net*

[current topic]

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

2,5 40% 30% 15% 5% 8,1%

1,5 40% 30% 15% 5% 8,1%

Full eletricity generation costs

56 US$/MWh

60,2 US$/MWh

[current topic]

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

Cylinder oil costs (plant) Mio.US$/a *

Four stroke

Two stroke

10

*Four stroke engines without a cylinder oil system

[current topic]

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

Total operating costs per year in Mio.US$

Four stroke

126

Two stroke

115,6

110

115 [current topic]

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 main drivers for power plant investment decisions

Ranking for Independent Power Producer (IPP)

1. Heat Rate. 2. High electricity market prices. 3. Best financial case under Net Present Value - The net added $-value of cash flow/investment in todays money- adjusted by the discount rate 4. Return on investment attainable for investors. 5. The internal rate of return of an investment. (IRR) 6. Project implementation time (project development/financing, engineering, construction, etc.). 7. Interest rate/loan tenor. 8. Flexible operation, short start and easy shutdowns. 9. Comparatively low operation and maintenance (O&M) costs.

The focus for IPP power plant investment decisions is more financial orientated

[current topic]

MAN Diesel

2009/04/01

The main drivers for power plant investment decisions

Ranking for Publicly Owned power projects

1. High Reliability. 2. High Availability 3. Long and steady operation up to first major overhaul. 4. Heat Rate. 5. Comparatively low operation and maintenance (O&M) costs. 6. Best financial case under Net Present Value - The net added $-value of cash flow/investment in todays money- adjusted by the discount rate 7. Return on investment. 8. The internal rate of return of an investment. (IRR) 9. Project implementation time (project development/financing, engineering, construction, etc.). 10. Interest rate/loan tenor.

The focus for public owned power plant investments is more orientated at save and steady energy supply

[current topic]

MAN Diesel

2009/04/01

The main drivers for power plant investment decisions

* EPC package incl. 2x 9K80 MC-S engines, 1x Steam Turbine and 2x TCS Systems

[current topic]

MAN Diesel

2009/04/01

The main drivers for power plant investment decisions

Typical cost distribution of a EPC two stroke project (in %)

Full EPC turnkey price:
Errection and Comissioning 10% Engineering 3% Engines 20% Generators 11%

- Installed capacity: 62.000kW Net - 115 Mio. US$ - Specific price: 1850US$/kW

Transport and Logistic 4%

Balance of Plant/Civil 20%

Electrical Equipment 8%

Mechanical Equipment 24%

[current topic]

MAN Diesel

2009/04/01

Two-stroke vs. four-stroke

Maintenance costs

Carsten Dommermuth
Senior Manger Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01 < 56 >

Comparison of maintenance costs ~330 MW

Specific Maintenance costs

Two-stroke 7,3 /kW/year Four-stroke 21 /kW/year

Annual maintenance costs in Mio.

6,36

2,40

Two-stroke

Four-stroke

[current topic]

MAN Diesel

2009/04/01

< 57 >

Comparison of maintenance costs ~330 MW

Accumulated maintenance costs for 20 years

Two-stroke 48,02 Mio. Four-stroke 127,26 Mio.

127,26

48,02

Two-stroke

Four-stroke

[current topic]

MAN Diesel

2009/04/01

< 58 >

Comparison of maintenance costs ~330 MW

Main influence factors for maintenance costs: Number of cylinders and cylinder heads, number of moving parts and mean piston velocity

Example: Number of Valves

Engine Cylinder Valves Spare part costs only for valves in 20 years (140.000h) 7 x12K90MC-S Two-stroke 84 84 8,89 Mio. 18 x18V48/60 Four-stroke 324 648 27 Mio.

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

[current topic]

MAN Diesel

2009/04/01

< 59 >

Comparison of maintenance costs

~330 MW

Specific Maintenance costs

Two-stroke 7,3 /kW/year Four-stroke 21 /kW/year

Annual maintenance costs in Mio.

6,36

2,40

Two-stroke

Four-stroke

[current topic]

MAN Diesel

2009/04/01

< 60 >

Comparison of maintenance costs

~330 MW

Accumulated maintenance costs for 20 years

Two-stroke 48,02 Mio. Four-stroke 127,26 Mio.

127,26

48,02

Two-stroke

Four-stroke

[current topic]

MAN Diesel

2009/04/01

< 61 >

Comparison of maintenance costs

~330 MW
Main influence factors for maintenance costs: Number of cylinders and cylinder heads, number of moving parts and mean piston velocity

Example: Number of Valves

Engine Cylinder Valves Spare part costs only for valves in 20 years (140.000h) 7 x12K90MC-S Two-stroke 84 84 8,89 Mio. 18 x18V48/60 Four-stroke 324 648 27 Mio.

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

[current topic]

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 >

Two-stroke Low Speed Engines for Stationary Applications

Range from 20-50 MW

33363416 [current topic]

(GMD12/ACJ)

MAN Diesel

2009/04/01

3/3

Clifton Pier Power Plant, the Bahamas

As at 2002.10.16

[current topic]

MAN Diesel

2009/04/01

Bahamas, 2 x 33 MW Project Organisation

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

[current topic]

MAN Diesel

2009/04/01

Clifton Pier Power Plant, the Bahamas

Clifton Pier Power Station: Location: Bahamas Operator: Bahamas Electricity Corp

Fuel: Heavy Fuel Oil

As at 2002.10.16

[current topic]

MAN Diesel

2009/04/01

24x 100 MW HFO Barges for the Phillipines x 12K90MC-S 4 x 12K90MC-S

2 x 100 MW HFO Barges for the Phillipines

The world largest Power Barge- 95 Meters long, 45 Meters Wide, 50 Meters high, 22000 Ton

[current topic]

MAN Diesel

2009/04/01

Mindanao Plant Performance

Engine data Engine type Number of cylinders MCR r/min Bore Stroke Mean piston velocity Mean effective pressure Length Width Height Total weight Heaviest weight for maintenance kW rpm cm cm m/s bar m m m t t 12K90MC-S 12 51.240 102.9 90 230 7.89 17,0 23 7,9 14,9 1830 10

[current topic]

MAN Diesel

2009/04/01

12K90MC-S, San Carlos, Mexico

[current topic]

MAN Diesel

2009/04/01

12K90MC-S, San Carlos, Mexico

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

[current topic]

MAN Diesel

2009/04/01

200 MW GMR Plant at Chennai, India

[current topic]

MAN Diesel

2009/04/01

125 MW, Ibiza, Spain

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

125 MW, Ibiza, Spain

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

90 MW Plant at Fort George, Mauritius 3 x 9K80MC-S

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MAN Diesel

2009/04/01

90 MW Plant at Fort George, Mauritius 3 x 9K80MC-S

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MAN Diesel

2009/04/01

90 MW Power Plant, Guam

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MAN Diesel

2009/04/01

90 MW Power Plant, Guam

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

Unscheduled outage hrs. Load factor %

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MAN Diesel

2009/04/01

Many Thanks for your attention.

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MAN Diesel

2009/04/01

MAN Diesel Contacts Power Plants Sales

Carsten Dommermuth Senior Manager Two-stroke, stationary power plants

MAN Diesel SE Business Unit Power Plants Phone: +49 821 322-3184 Mobil: +49 171 7645070 carsten.dommermuth@man.eu

Postal address: Stadtbachstr. 1 86153 Augsburg, Germany

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MAN Diesel

2009/04/01

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MAN Diesel SE Two-stroke engine bio fuel application

Carsten Dommermuth
Senior Manager Business Unit Power Plants
[current topic] MAN Diesel 2009/04/01

Two-stroke Bio Project under the German EEG in Brake

Customer: PBB GmbH, cogeneration IPPC (Independent Power Producer
Company) based in Oldenburg,

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

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Two-stroke Bio Project under the German EEG in Brake

Power Plant site from PBB GmbH in Brake, Germany

MAN Diesel B&W 7L35MC-S engine with 4,5 KWmech

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MAN Diesel

2009/04/01

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Two-stroke Bio Crude Palm Oil Specifications

Name of project
Test Free fat acid Conradson carbon residue Water content fuel max. Flash point, PMcc Phosphorus Total acid number Calorific value, net Density at 15C Viscosity at 50C Sulphur Ash ASTM D 189 ASTM D 95 ASTM D 93 ISO 10478 Method Unit % % wt % vol C mg/kg 7 0.5 0.5 200 100 14 36 930 kg/m3 32 10 0.01 6.5 2 <1 >60 13 37-39 5.56 0.52 0.11 239 15 11.2 36.9 12.48 0.74 0.1 24.96 35.5

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

0,89-0,92 0.8888 0.9142 40 <50 <0.1 28.3 1 <0.01 28 0.005

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MAN Diesel

2009/04/01

MAN Diesel four-stroke Biofuel Specification

Density/15 C Flash point Lower calorific value 900 930 kg/m > 60 C > 35 MJ/kg (typical: 37 MJ/kg) < 40 cSt (corresponds to viscosity/ 40 C < 60 cSt) > 40 < 0,4 % < 200 ppm >5h < 15 ppm < 15 ppm < 0,01 % < 125 g/100g < 0,5 % < 4 mgKOH/g < 10 C below lowest temperature in fuel system DIN EN ISO 3675, EN ISO 12185 DIN EN 22719 DIN 51900-3

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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2009/04/01

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Two-stroke Bio Conversion of Standard Stationary HFO Engine to CPO Engine

Larger fuel valves Introduced (coated)

Larger fuel pumps introduced; modified Materials (coated)

Modified components
Reinforced camshaft Introduced

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MAN Diesel

2009/04/01

Two-stroke Bio Project with Crude Palm Oil

The emission levels are based
on the ISO 8178 measurement method, except for PM values, which are stated according to EPA 17.

NOx level assumes to fuel

bound nitrogen. The emissions are recalculated to 15% of O2 at dry exhaust gas at ISO 3046 ambient conditions.

No remarkable SOx
emissions.

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MAN Diesel

2009/04/01

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Two-stroke Bio Project with Crude Palm Oil

Emissions measured at the test bed without exhaust gas cleaning (15% O2)

CO
mg/Nm3

NOX
mg/Nm3

HC
mg/Nm3

PM
mg/Nm3

100% MCR 75% MCR 50% MCR

90 60 80

2600 2600 2400

35 45 55

80 70 65

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2009/04/01

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Two-stroke Bio MAN B&W twostroke engine L35MC-S at test bed

http://www.manbw.com/engines/TwoStrokeLowSpeedEngines.asp?model=L35MC-S
[current topic] MAN Diesel 2009/04/01 <1>

Two-stroke Bio Brake fulfil the strict German TA Luft

The MAN Diesel reference Palm Oil plant in Brake is equipped with an SCR, Oxi-cat and an electrostatic precipitator*

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MAN Diesel

2009/04/01

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Two-stroke Bio SCR Arrangement MAN B&W Low Speed Biofuel Engine

Total back pressure to be below 350 mmWC

Chimney

Power house SCR Exhaust gas boiler Electrostatic precipitator

TC Silencer Generator
Cyl.1

Suction blower

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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. )

CHP installation 100 /kW (450 T)

Errection and Comissioning 10% Engineering 3%

Transport and Logistic 4%

Engines 20% Generators 11%

Balance of Plant/Civil 20%

Electrical Equipment 8%

Mechanical Equipment 24%

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MAN Diesel

2009/04/01

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