V35/44G

Four-stroke gas engine

MAN Diesel & Turbo is the worlds leading designer and manufacturer of low and
medium speed engines. With our range of large stationary gas and diesel engines,
we are a reliable partner for power generating companies, regardless of whether
the energy is fed into the power grid or destined for local supply purposes.
From fuel depot to transformer station, MAN Diesel & Turbo offers one-stop solutions. Our involvement with electrical power generators goes back to 1904 when
we supplied the first ever diesel generator sets to the Kiev Tram System.
Since those early days, MAN Diesel & Turbo has never lost its technological preeminence in the large engine field. Likewise, our engines have never relinquished
their status as the most efficient combustion engines available.
More than ever before, MAN Diesel & Turbos development focus is on the environmental performance of our engines. Using our unrivalled grasp of large engine
technology, we aim to make our engines progressively cleaner, more powerful and
more efficient.
With our absolute commitment to reducing emissions while increasing fuel
efficiency and power density and our pro-active involvement in the emissions
law making process, we intend to be part of the global emissions solution.

V35/44G Four-stroke gas engine

Introduction
Driving the stationary use of gas engines

Today, state-of-the-art power generation technology should be designed for highest efficiency and lowest emissions.
In the near future, the new energy economy will see

ary use in power plants. The engine reaches an out-

greater use of fluctuating renewables, such as wind

put of 10.6 MW, has an electrical efficiency of 47.2%,

and solar power. This will go hand in hand with the

features many innovative technological elements and

use of highly flexible and efficient decentralised plants,

complies with all current emission limits solely by in-

offering combined heat and power (CHP) and provid-

engine measures.

ing a fast-operating reserve in a time window of 5-10

minutes.

Our portfolio includes solutions for highly efficient

electrical power, sustainable heating and cooling, and

According to key international organisations such as

operating reserve that can be brought on stream at

the International Energy Association (IEA), natural gas

short notice. All of these can be tailored to the needs

will be a cornerstone of this seismic shift on world-

of customers around the world, delivering maximum

wide energy markets. Thanks to its availability and low

return on investment.

emissions, natural gas is set to play a significant role

in the sustainable energy supply of tomorrow.

MAN Diesel & Turbo SE has a successful track record

of highly flexible and innovative energy solutions

MAN Diesel & Turbo has developed the single-stage

stretching back 250 years, catering to established

turbocharged Otto gas engine 20V35/44G for station-

and emerging energy markets the world over.

V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine

V35/44G
A new class of large bore gas engine

Gas engines are claiming an increasing share of the market for electrical power
generation - thanks to their clean combustion, high efficiencies, comparatively low
carbon dioxide emissions and the attractive price of natural gas.

Modern and innovative

With its newest gas engine, MAN Diesel & Turbo is

With leaner combustion, the peak temperature is re-

now bringing the benefits of gas engines to power

duced and less NOx is produced.

and cogeneration plants with electrical outputs of 100

to 200 MW, a category previously dominated by gas

Higher output can be reached while avoiding knock-

turbines.

ing and increasing efficiency.

Highest power density in its class

Advanced Ignition Technology

The 35/44G is offered in a V-type version with 20

The ignition system comprises a capacitive discharge

SaCoSone

Further major benefits of the 35/44G

cylinders and an output of 10,600 kWm, respectively

system and an ignition coil, which delivers the neces-

The 35/44G engine is equipped with the safety and

Reliable

10,200 kWm. Its rated outputs 530 kW per cylin-

sary high voltage via an ignition lead to the spark plug.

control system SaCoSone. SaCoSone guarantees reli-

Low

der for 50 Hz power generation and 510 kW for 60

To improve combustion, the spark plug is located in

able engine operation with an optimum operation

Heat

utilisation: > 90% total efficiency

Hz power generation give the 35/44G best-in-class

the pre-chamber.

range between knocking and misfiring. All cylinders

Short

power ramp up time: 100% load within

power density among gas engines.

are regulated individually.

A promising fuel

means of a separate valve.

In addition to a high supply reliability and the poten-

8 minutes
Ambient

Gas is precisely metered to the pre-chamber by

power source: 10,600 kWm rated power

fuel costs: 47.3% el. efficiency single cycle

temperature compensation:

Cogeneration or combined cycle

In addition to using thermal energy recovered from

Easy

maintenance / high availability

safety standards

Tair = 40 Kelvin without power derating

tial savings on operating and procurement costs, the

In conjunction with the lean mixture from the main

engine sources for heating or cooling in cogeneration

High

advantage of gas-fired power plants lies chiefly in

chamber, which is fed into the pre-chamber by the

or trigeneration applications, the exhaust heat of the

Excellent

extremely low emissions coupled with a high level of

compression cycle, this creates a highly efficient,

35/44G engine can also be used to produce steam

efficiency. Due to the lower carbon content of the fuel,

almost stochiometric mixture. This is ignited using

to drive a steam turbine generator. As a result, the

gas engines emit around 25% less CO2 than diesel

the spark plug, providing an ignition amplifier for the

overall output and efficiency of the power plant can be

engines. Nitrogen oxide (NOx) emissions are roughly

main chamber.

increased without additional fuel costs.

load response

80% lower, while emissions of sulfur oxides, soot, and

particles are virtually non-existent.

The lean-burn concept

In a lean-burn gas engine, the mixture of air and gas
in the cylinder is lean, i.e. more air is present in the
cylinder than is needed for complete combustion.

V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine

LP steam drum

Solutions
Electrical power and combined cycle

MAN steam turbine

HP steam drum
Air cooled
condenser

Air cooled alternator

Powerhouse

Main stack

Exhaust gas steam boiler

Powerful performance

Exhaust silencer

MAN Diesel & Turbo

20V35/44G

Combined cycle

A reliable supply of electricity is essential for global

smaller decentralised power plants and can also be

To meet the requirements of high efficiency and en-

An example layout of a power station with gas engine

economic growth. Given the need for reliability of sup-

deployed in large power plants of up to 150 MW.

vironmental friendliness in the production of power,

combined cycle is shown in the illustration above. The

ply and the environmentally-friendly use of resources,

MAN Diesel & Turbo has developed a power cycle

power house contains the engines and the steam

the demands in terms of the energy mix are changing;

MAN Diesel & Turbo can draw on its extensive glo-

process for stationary power plants that utilises heat

turbine with their generators. The hot exhaust gases

a flexible range of supply options and efficient, de-

bal expertise in delivering customised turnkey power

from the engine exhaust gases for the production of

flow through the heat recovery steam generators be-

centralised production are now more important than

plants to provide the best solution for your needs.

live steam in a bottoming process.

fore they enter the stacks. The steam is re-cooled by

ever before.

In order to achieve the highest efficiency rates and

a condenser. The electrical power produced by the

maximise sustainability, MAN Diesel & Turbo has

The steam is expanded in a steam turbine, which

engines and the steam turbine is supplied to the grid

MAN Diesel & Turbo can help provide this crucial re-

implemented an integrated gas strategy, which

produces electrical energy via the Clausius-Rankine

at the sub-station.

source with its highly efficient 20V35/44G gas engine.

incorporates both the company`s engine and turbine

cycle. This additional electrical energy is produced

The newly developed Otto gas engine is suitable for

technologies.

without consuming additional fuel, which is the

strength of the combined cycle.

V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine

Solutions
Combined heat and power (CHP)

Hot Water Generation

For different applications

Decentralised provision of electricity, hot water, steam and cooling is one of the

Heat recovery diagram*

Chimney

most sustainable forms of energy provision. Depending on the heat sinks, CHP can
achieve overall efficiencies of over 90 per cent. Generators driven by gas engines

Bypass

Electricity

offer exceptional flexibility, giving them a significant advantage over other power

CAC 1

plant technologies.
Benefits

plants, waste heat at various temperatures is pro-

Lower

Back-up
cooler HT

energy costs through more efficient utilisa-

duced. MAN Diesel & Turbo offers different tech-

tion of primary energy

nologies to convert this waste heat into a useful

Improved

energy form.

emissions of pollutants

District heating water

Engine lube oil
Engine jacket + CAC 1&2
Engine exhaust gas
Back-up cooling

environmental quality through reduced

Recovered

waste heat for a wide range of sustain-

MAN Diesel & Turbos engine-based CHP plants are

able thermal applications

designed to meet end consumers heating needs and

Operational

can be used for a wide range of thermal applications

and electricity demand

whether at industrial, city-wide or at individual build-

HT heat
recovery

CAC 2

When electricity is generated in engine-based power

WHRB

District heating
network
Lube oil
heat
recovery

flexibility in line with changes in heat

Energy flow diagram*

ing levels.
The heat extracted from the engines exhaust gases

Fuel input 100%

can be utilised for steam generation required in the

systems in hospitals, hotels and office blocks can be

oil, the engine jacket water and the charge air cooling circuits can be utilised for hot water generation,
e.g. used in a district heating network for heating purposes.

Plant auxiliaries,
trafo losses 0.8%

produced. The heat extracted from the engine lube

Electricity to
grid 45.5%

Losses 9.2%

tion chiller, chilled water to run central air conditioning

Low temperature
heat 5%

Electrical
output 46.3%

cluding an exhaust gas or hot water driven absorp-

High temperature
heat 39.5%

textiles, food, paper and chemicals industries. By in-

Heat to heat
consumers 44.5%

Total CHP efficiency 90%

* Based on 20V35/44G ISO-3046 conditions; efficiencies valid for return line temperature of 60C and supply line temperature of 125C

10 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 11

Solutions
Operating reserve

Around the world, energy is increasingly being generated from fluctuating

renewable sources. However, wind turbines and solar power plants require
highly flexible power plant technologies that are able to provide highly efficient
electrical back-up power at extremely short notice in order to stabilise the grid.
In addition to rapid start-up, these solutions also need

will change the face of electricity markets, adding new

to be extremely efficient when operating under part-

capacity markets, where the price of rapidly available

load conditions, and capable of accommodating wide

short-term operating reserve will rise in line with de-

variations in load.

mand.

These types of applications are set to become in-

In contrast to axial flow machines, gas-engine based

creasingly attractive for independent power produc-

plants are physically suited to these kinds of applica-

ers (IPPs), local utilities and electricity distributors: the

tions: they operate efficiently at loads of anything from

growth of fluctuating energy supplies from renewables

20% to 100% of rated load.

Comparison of generation technologies in provision of short-term operating reserve

Generation technology providing
short-term operating reserve

Time (min) to full load incl.

Part-load flexibility /

synchronisation with grid

Increase in load (%) in 5 seconds

30

10

110

> 250

Gas-engine based plants

(MAN 20V35/44G) 750 min -1
Large gas-turbine based plants
(aeroderivaled turbines) 3,000 min -1
Large gas-turbine combined cycle
power plants 3,000 min -1
Coal-fired plants (subcritical)
3,000 min -1

All plants pre-heated and in normal start-up programme

Sample data only

12 V35/44G Four-stroke gas engine

Environmental Awareness
Natural gas the most environmental friendly
fossil energy source

Being able to scale output to meet consumers heat-

of natural gas. CO2 emissions are under particular

ing needs is an important consideration when select-

scrutiny, given their impact on climate change. In the

ing a power plant technology. The emissions pro-

EU, the majority of CO2 permits will be auctioned from

duced by the generation of energy are another key

2013, reshaping cost considerations and ensuring

criterion. Gas-engine based plants score extremely

that only the most efficient technologies will remain

well in this regard, due to their high efficiency and use

competitive.

CO2 emitted by various power plant technologies

CO2 emitted by various generation

Electrical efficiency in %

Thermal efficiency in CHP in %

(CO2 emissions in g/kWh)

(CO2 emissions in g/kWh)

47.3 (427)

90 (224)

(industrial gas turbines)

33 (612)

80 (252)

Coal-fired power plants (subcritical)

38 (895)

80 (425)

technologies
Gas-engine based plants
(MAN 20V35/44G)
Gas turbine-based plants

CO2 emissions from natural gas: 202g/kWh; CO2 emissions from coal: 340g/kWh; Sample data only

Maximum allowed exhaust gas emission values according to TA-Luft

Nitrogen oxides, NO x in mg/Nm3 1)
Carbon monoxides, CO in

mg/Nm3

500
2)

Formaldehyde in mg/Nm3
Sulphur dioxide, SO2 in

mg/Nm3

300
60

3)

10

Reference oxygen content of exhaust: 5%;

1) Calculated as NO2
2) Compliance with German TA-Luft emissions legislation by means of a catalyst
3) SO2 content in the exhaust gas depends on the H2S content in the natural gas

14 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 15

Technical Data
V35/44G

Dimensions and Weights

V35/44G

20V35/44G

Four-stroke gas engine 20V35/44G

Bore 350 mm, stroke 440 mm

Engine 20V35/44G
750 rpm, 50 Hz

Mean piston speed (m/s)

Electrical output (kWel)
Lube oil consumption (kg/h)

720 rpm, 60 Hz

11.0

10.6

10,335

9,945

3.7

3.7

Engine type
20V35/44G

Dry mass

Dry mass

No. of cyl.

A (mm)

B* (mm)

C* (mm)

W (mm)

H (mm)

engine (t)

gen.* (t)

20

9,680

4,295

13,975

3,845

4,540

113.5

30.5

* Depending on alternator; nominal generator efficiency: 97.5%

20V35/44G for power applications

Heat rate (kJ/kWh el)
Electrical efficiency (%)

7,621

7,621

47.2

47.2

7,832

7,832

46.0

46.0

20V35/44G for CHP applications

Heat rate (kJ/kWh el)
Electrical efficiency (%)

Output at generator terminals. Nominal efficiency 97.5%. ISO 3046-1 conditions; including attached pumps; MN > 80; 5% tolerance;
engine type specific reference charge air temperature before cylinder 43C; p.f. 0.9;
NOx emissions 500mg/Nm3 @ 5% O2

16 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 17

Highly Cost-Effective
Gas-engine based power plant solutions

Estimation of electricity generation costs for

Cost of electricity generation with an output of

captive power generation with an output of

20 MW based on 2x20V35/44G engines, sensitiv-

20 MW based on 2x20V35/44G engines for

ity analysis with various natural gas supply costs

an energy-intensive industrial company in the

European Union

Wholesale natural gas power prices

Full-load hours
Turnkey delivery,

Scope of services

2x20V35/44G with CHP

171.9

180.6
133.6

20.8 MW

2,000 h

97.7

100.2

101.5

110.2

46.3 %

2,500 h

83.7

86.1

87.4

96.1

20/MWh

3,000 h

74.3

76.8

78.0

86.7

90 %

3,500 h

67.6

70.1

71.3

80.0

Construction period

1 year

4,000 h

62.5

65.0

66.3

75.0

Depreciation period

20 years

4,500 h

58.6

61.1

62.4

71.0

Weighted average cost of

capital (WACC)

relevant project lifetime.

5,000 h

55.5

58.0

59.2

67.9

10 %

5,500 h

52.9

55.4

56.7

65.3

15/t

6,000 h

50.8

53.3

54.5

63.2

Compliant with TA-Luft

6,500 h

49.0

51.5

52.7

61.4

(2002)

7,000 h

47.4

49.9

51.2

59.9

7,500 h

46.1

48.6

49.8

58.5

8,000 h

44.9

47.4

48.7

57.3

Costs of CO2 emissions

Emissions

sions regulations and price developments

321.4

124.9

regard: their high efficiency and as a result, low emis-

electrical energy in terms of cost per MWh over the

MWh

312.7

170.7

Gas-engine based plants set the benchmark in this

To calculate TCO, we can compare the production of

MWh

311.5
123.7

Fuel supplies these need to be readily available

MWh

309.0
121.2

The decision for a particular power plant technology is usually based on the following factors:

and cost-effective, taking into account local emis-

MWh

500 h

168.2

Overall efficiency

per year

1,500 h

Wholesale gas power price

sions, keep the total cost of ownership (TCO) down.

30 /

1,000 h

Electrical efficiency

ing reserve for stable, reliable grids

23 /

(water heating)
Net output

requirements such as providing short-term operat-

22 /

21.2 MW (2x20V35/44G)

Gross installed capacity

Type of use electricity production, CHP, or other

20 /

Sample data only

Local conditions including at site conditions and

availability of suitable cooling options

Electricity generation costs include not only the tech-

nical parameters such as output and consumption

International subsidies for CHP

Other cost factors, such as price of carbon permits

Sample data only

but also figures relating to the likely costs of main-

In many countries, including OECD members, there

Fuel is the most significant cost factor for fossil-fuel-

tenance, personnel and operating costs. Economic

are fixed prices for the combined generation of heat

driven power plants, accounting for around 80 per

parameters include the initial investment, financing,

and power. These represent a highly attractive addi-

cent of the operating costs. This makes maximum

duration of the construction period and likely costs of

tional source of income, making investment in these

efficiency desirable on economic grounds alone.

carbon credits.

kinds of plants a sound business proposition.

18 V35/44G Four-stroke gas engine

V35/44G Four-stroke gas engine 19

Cash Flow Analysis

Gas-engine based power plant solutions

MAN Diesel & Turbo SE offers specific advice and support for every project,
from the initial idea to the implementation, from assistance with obtaining
suitable financing to construction and operation of the plant.

For a complete cost-benefit analysis of the gas-

profits. In the following graph, we shall assume a sales

engine based plant in this example, we should con-

price for electricity generation of 80/MWh and rev-

sider the profitability of the project. In the energy

enue of 20/MWh for the sale of heat. Let us assume

economy, this normally involves an analysis of criteria

our sample plant is in operation 7,000 hours per year.

such as the internal rate of return (IRR) and operating

The economic analysis gives an IRR of 18% and operating profits of 3 m per year of operation.
25
20
15

Mio.

10

Construction periode

Payback periode

5
0
-5
Profit

-10
-15
-20

6
Project time (years)

20 V35/44G Four-stroke gas engine

10

12

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in the business.

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PrimeServs aim is to provide:

tion of the management of all mechanical, electrical

Prompt,

and thermal equipment. In this way the power plant

OEM-standard service for the complete

life cycle of an installation

operator gains comprehensive access to the tech-

Training

nology, experience, best practices and professional

and qualification of service personnel at

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resources of MAN Diesel & Turbo.

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In short: PowerManagement by MAN Diesel & Turbo

assured MAN Diesel & Turbo spare parts via local

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22 V35/44G Four-stroke gas engine

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. CopyrightMAN Diesel & Turbo.
2366460EN-N4 Printed in Germany GMC-AUG-08121

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Phone +49 821 322-3897
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