Thermo Efficiency System

Thermo Efficiency System
for Reduction of Fuel Consumption and

CO2 Emission
Contents
Introduction.................................................................................................. 5
Description of the Thermo Efficiency System.................................................. 6
Power concept and arrangement............................................................. 6
Main engine performance data...................................................................... 7
Exhaust gas boiler and steam systems.......................................................... 8
Obtainable Electric Power Production of the Thermo Efficiency System........ 10
Exhaust gas turbine output.................................................................... 10
Exhaust gas and steam turbine generator output single pressure............... 10
Exhaust gas and steam turbine generator output dual pressure................. 12
Payback time of the Thermo Efficiency System............................................ 12
Summary.................................................................................................... 15
References................................................................................................. 15
Thermo Efficiency System (TES)

for Reduction of Fuel Consumption and CO2 Emission
Introduction
demand for installation of a Thermo Ef
of the total fuel energy. In the standard
Following the trend of required higher
ficiency System is that the reliability and
highefficiency engine version, the ex
overall ship efficiency since the first oil
safety of the main engine/ship opera
haust gas temperature after the turbo
crisis in 1973, the efficiency of the main
tion must not be jeopardised.
charger is relatively low, and just high
engines has increased and, today, the
enough for production of the necessary
fuel energy efficiency is about 50%.
As an example, the heat balance dia
steam for a ships heating purposes by
This high efficiency has, among others,
gram for the nominally rated 12K98ME/
means of the exhaust gas fired boiler.
led to a correspondingly lower exhaust
MC engine (18.2 bar) of the standard
gas temperature after the turbochargers.
highefficiency version is shown in Fig.
However, a main engine with changed
1a. Fig. 1b shows an example based
timing and exhaust gas bypass which
Even though a main engine fuel energy
on the Thermo Efficiency System, valid
redistributes the exhaust gas heat from
efficiency of 50% is relatively high, the
for a singlepressure steam system,
high amount/low temperature to low
primary objective for the shipowner is
together with the corresponding fig
amount/high temperature increases
still to lower the total fuel consumption
ures for a dualpressure steam system
the effect of utilising the exhaust gas
of the ship and, thereby, to reduce the
shown in parenthesis.
heat, but at the same time may slightly
CO2 emission of his ship.
reduce the efficiency of the main engine

The primary source of waste heat of a
itself. Such a system is called a Thermo
Today an even lower CO2 emission can
main engine is the exhaust gas heat dis
Efficiency System (TES).
be achieved by installing a Thermo Ef
sipation, which accounts for about half
ficiency System. However, the main
of the total waste heat, i.e. about 25%

12K98ME/MC with TES
SMCR : 68,640 kW at 94.0 r/min
ISO ambient reference conditions
TES : Single pressure (Dual pressure)
Shaft power
output 49.3%
12K98ME/MC Standard engine version

SMCR : 68,640 kW at 94.0 r/min
Total power output 54.2% (54.8%)

Shaft power
output 49.3%
El. power production of

TES 4.9% (5.5%)
Gain = 9.9% (11.2%)
Lubricating oil
cooler 2.9%
Lubricating oil
cooler 2.9%
Jacket water
cooler 5.2%
Jacket water
cooler 5.2%
Exhaust gas
25.5%
Exhaust gas and

condenser
22.9% (22.3%)
Air cooler
16.5%
Fuel 100%
(171 g/kWh)
Air cooler
14.2%
Heat radiation
0.6%
Fuel 100%
(171 g/kWh)
Fig. 1a: Heat balance diagram of the nominally rated 12K98ME/MC Mk 6

engine (18.2 bar) of the standard engine version operating at ISO ambient
reference conditions and at 100% SMCR
Heat radiation
0.6%
Fig. 1b: Heat balance diagram of the nominally rated 12K98ME/MC Mk 6 engine
(18.2 bar) with Thermo Efficiency System (TES) operating at ISO ambient
reference conditions and at 100% SMCR
Thermo Efficiency System (TES) for Reduction of Fuel Consumption and CO2 Emission
Description of the Thermo Efficiency

System
When a part of the exhaust gas flow is
The total electric power output of the
bypassed the turbocharger, the total
TES which reduces the ships fuel costs
Power concept and arrangement
amount of air and gas will be reduced,
is only a gain provided that it can re
The Thermo Efficiency System (TES)
and the exhaust gas temperature after
place the power output of other electric
consists of an exhaust gas fired boiler
the turbocharger and bypass will in
power producers on board the ship.
system, a steam turbine (often called a
crease. This will increase the obtainable
Otherwise, a shaft power motor con
turbo generator), an exhaust gas tur
steam production from the exhaust gas
nected to the main engine shaft could
bine (often called a power turbine) and
fired boiler.
be an option, as also shown in Fig. 2a,
a common generator for electric power
but this extra system is rather expensive.
production. The turbines and the gen
The exhaust gas bypass valve will be
erator are placed on a common bed
closed for engine loads lower than about
In general (without a shaft power motor
plate. The system is shown schemati
50% SMCR, which means that the ex
installed), when producing too much
cally in Fig. 2a, and the arrangement of
haust gas temperature will be reduced
electric power, the (high pressure) su
the complete turbine generating set is
when operating below 50% SMCR.
perheated steam to the steam turbine
shown in Fig. 2b.
is controlled by a speed control gov

The power output from the exhaust
ernor through a single throttle valve,
The exhaust gas turbine is driven by
gas turbine is transmitted to the steam
which means that the surplus steam
a part of the exhaust gas flow, which
turbine via a reduction gear (see Figs.
is dumped via a dumping condenser.
bypasses the turbochargers. The ex
2a and 2b) with an overspeed clutch,
When the generator is operating in par
haust gas turbine produces extra out
which is needed in order to protect the
allel with the auxiliary diesel generators,
put power for electric power produc
exhaust gas turbine from overspeeding
the governor operates in the normal
tion, which depends on the bypassed
in case the generator drops out.
way to give correct load sharing.
exhaust gas flow amount.
Fig. 2a: Power concept for the Thermo Efficiency System
Steam turbine
Reduction gear
Generator, AC alternator
Reduction gear Exhaust gas turbine
Approx. dimensions
referring to a 12K98ME/MC:
Length: 10 metres
Breadth: 3.5 metres
Weight: 58 tons without
condenser
Weight: 75 tons with
condenser
Fig. 2b: Arrangement of the complete turbine generating set
Main engine performance data
The mixed exhaust gas temperature
air temperatures, the exhaust gas tem
The exhaust gas bypass and turbine
before the exhaust gas boiler, and valid
perature will be higher (about +1.6C
are available with the following ap
for the TES and based on ISO ambi
per +1C air), and vice versa for lower
prox. effects, compared with a stand
ent reference conditions, is shown as
ambient air temperatures.
ard highefficiency main engine version
a function of the engine load in Fig. 3.
without an exhaust gas bypass:
When operating under higher ambient
Parameters
Power output
of exhaust gas
turbine at 100%
SMCR, up to
Open exhaust gas

bypass for exhaust gas turbine
Exhaust gas temperature

after exh. gas bypass
Ambient reference conditions:

Tropical 45C air/36C c.w.
ISO
25C air/25C c.w.
Winter
15C air/36C c.w.
C
350
Tropical
+4.6% SMCR
power
300
ISO
Winter
Reduction of to
tal exhaust gas
amount, approx.
-13%
250
Total increase of
mixed exhaust gas
temperature after
bypass, up to
+50C
200
Increased fuel
consumption
from 0.0% to
+1.8%
40
50
60
Exh. gas bypass

closed
70
80
90
100 % SMCR
Mainengine shaft power
open
Fig. 3: Exhaust gas temperature after exhaust gas bypass for a main engine with TES
The increased fuel consumption of the

Exh. gas boiler
sections:
main engine depends on the actual

maximum firing pressure (Pmax) used.
Steam
drum
Preheater
The Pmax used for TES will normally be
Evaporator
increased compared with a standard

engine and thereby an increase of the
Circ. pump
Superheater
specific fuel oil consumption can be

avoided when using TES.
Exhaust gas
Surplus
valve
Sat. steam
for heating
services
Steam
turbine
Exhaust gas boiler and steam systems

The exhaust gas boiler and steam tur
Feedwater
pump
Condenser
bine systems analysed in this paper are

based on the two types below:
1. Single-pressure steam system
The simple singlepressure steam
Hot well
system is only utilising the exhaust

gas heat. See the process diagram
Fig. 4: Process diagram for the Thermo Efficiency System singlepressure exhaust gas boiler system
with a singlepressure steam turbine
in Fig. 4 and the corresponding tem

perature/heat transmission diagram
in Fig. 5. The steam drum from the
oil fired boiler can also be used in
stead of a separate steam drum.
Exh. gas boiler sections:

A. Superheater
B. Evaporator
C. Preheater
Temperature
C
300
Superheated
steam
250
Exh. gas
200
Saturated
steam
Steam/water
100
min 20 C
Exh. gas
7 bar abs/165 C
150
50
Feedwater
Ambient air
0
04
20
60
100%
80
Heat transmission
Fig. 5: Temperature/heat transmission diagram of an exhaust gas boiler with singlepressuresteam

system valid for a main engine with TES and operating at 85% SMCR/ISO
2. Dualpressure steam system

When using the dualpressure steam
Alternative WHR
sources for feedwater
preheating
system, it is not possible to install an

exhaust gas lowpressure preheater
section in the exhaust gas boiler, be
cause the exhaust gas boiler outlet
temperature otherwise would be too
low and increase the risk of wet (oily)
soot deposits on the boiler tubes.
Exh. gas boiler

sections:
LP-steam drum
LP
LP-Evaporator
LP-circ. pump
HP-Preheater
LP-Superheater
The more complex dualpressure

steam
system,
therefore,
needs
supplementary waste heat recovery
HP
HP-steam drum
HP-Evaporator
HP-circ. pump
HP-Superheater
(WHR) sources (jacket water and
HP
scavenge air heat) for preheating of
Exhaust
gas
the feedwater which, of course, will

increase the obtainable steam and
Surplus
valve
LP
HP-steam
for heating
services
Steam
turbine
electric power production of TES.

See the process diagram in Fig. 6
Feedwater
pump
Condenser
and the corresponding temperature/

heat transmission diagram in Fig. 7.
Hot well
If no alternative waste heat recov

ery sources are used to preheat the
feedwater, the low pressure (LP)
steam may be used to preheat the
Fig. 6: Process diagram for the Thermo Efficiency System dualpressure exhaust gas boiler system
with a dualpressure steam turbine
feedwater, involving an about 16%

reduction of the total steam produc
Temperature
C
300
tion.
The available superheated steam used
Superheated
HP steam 250
Exh. gas boiler sections:

A. HP-superheater
B. HP-evaporator
C. HP-preheater
D. Possible LP-superheater
E. LP-evaporator
Exh. gas
for the steam turbine is equal to the
Superheated LP steam
surplus steam after deduction of the

saturated steam needed for heating
services.
The exhaust gas boiler has to be de
signed in such a way that the risk of
soot deposits and fires is minimised,
Ref. [1].
200
Saturated
HP steam
Steam/water min 20C

10 bar abs/180C
min 15C
150
4 bar abs/144C
100
Exh. gas
Feedwater
preheated
by alternative
WHR sources
50
Ambient air
0
04
20
60
80
100%
Heat transmission
Fig. 7: Temperature/heat transmission diagram of an exhaust gas boiler with dualpressure steam system
valid for a main engine with TES and operating at 85% SMCR/ISO
Obtainable Electric Power Production

of the Thermo Efficiency System
Exhaust gas and steam turbine generator output single pressure
gine operating at ISO ambient refer
Exhaust gas turbine output
The singlepressure steam system is a
the steam production and the electric
The exhaust gas bypass for the ex
system where all heat recovered comes
power production of TES, see Figs. 10
haust gas turbine has a bypass gas
from the exhaust gas heat only, which
and 11.
amount of approx. 12% of the total
makes it relatively simple, see Figs. 4
exhaust gas amount at 100% SMCR.
and 5.
ence conditions, we have calculated
The total electric power production in
This bypassgas amount led through
% of the main engine shaft power out
the exhaust gas turbine will typically
As low gas temperatures (risk of
put is also shown as a function of the
produce an available power output of
condensed sulphuric acid) and low
engine load, see Fig. 9.
max. 4.6% of the SMCR power when
gas velocities (risk of soot depos
running at 100% SMCR. The corre
its) through the exhaust gas boiler
The results for operation at 85% SMCR
sponding electric power output will be
may have a deteriorating effect on
are shown in Fig. 14, together with the
somewhat lower because of generator
the boiler, Ref. [1], we have, in our
calculated ISO ambient temperature
and gear losses.
studies,
gas
based results for three other main en
boiler designed for a singlepressure
selected
an
gine types. The corresponding results
At part load running of the main engine,
steam system of minimum 7 bar abs
based on tropical ambient temperature
the power output will be reduced by
(6 bar g) steam pressure (165C),
conditions are shown in Fig. 15. How
approximately the square root of the
and minimum 20C pinch point. The
ever, it should be emphasised that it is
engine load.
superheated
is
probably more realistic to use the ISO
steam
exhaust
temperature
about 270C. The steam turbine is a
ambient temperatures as the average
As an example, the maximum available
multistage singlepressure condensing
ambient temperatures in worldwide
power output of the exhaust gas turbine
type. The alternator/generator is driven
operation. In Fig. 16, the ISO based
valid for a nominally rated 12K98ME/
both by the steam turbine and the ex
total electric power production at 85%
MC (18.2 bar) engine is shown in Fig. 8,
haust gas turbine.
SMCR is also shown as a function
as a function of the engine load.
of the main engine size measured in

As an example valid for the nominally
SMCR power.
rated 12K98ME/MC (18.2 bar) en
Available power output of exhaust gas turbine

kW
3,500
3,000
2,500
Electric power production of TES

relative to the main engine power output
%
13
Main engine 12K98ME/MC
12
SMCR = 68,640 kW at 94 r/min
11
ISO amb. cond.
Single press.
2,000
1,500
7
Steam turbine
1,000
Exhaust
gas turbine
500
4
3
0
30
40 50 60 70 80 90 100 % SMCR
Exh. gas bypass
Main engine shaf t power
closed
open
Fig. 8: Expected available power output of exhaust gas turbine for a

12K98ME/MC with SMCR = 68,640 kW x 94 r/min
10
Dual press.
10
Exhaust
gas turbine
1
0
50
60
70
80
90
100 % SMCR
Main engine shaft power
Fig. 9: Expected electric power production in % of the main engine shaft power
output valid for a 12K98ME/MC with Thermo Efficiency System (TES) and
based on ISO ambient reference conditions
Electric power production

kW
8,000
Obtainable steam production

kg/h
35,000
12K98ME/MC with TES (single press.)
ISO amb. cond.
30,000
25,000
7,000
Total steam
pr oduction
12K98ME/MC with TES (single press.)

ISO amb. cond.
Total el.
production
6,000
5,000
20,000
4,000
15,000
Superheated steam
for steam turbine
10,000
Exhaust
gas turbine
3,000
2,000
5,000
Steam turbine
1,000
40
50
60
70
80
Exh. gas bypass

closed
open
90
100 % SMCR
40
50
60
Exh. gas bypass
closed
Fig. 10: Expected steam production of an exhaust gas boiler with

singlepressure steam system valid for main engine 12K98ME/MC with TES
and based on ISO ambient reference conditions
30,000
25,000
12K98ME/MC with TES (dual press.)

ISO amb. cond.
Total steam
production
Superheated
LP-steam for
steam turbine
7,000
3,000
Superheated
Steam turbine
for steam turbine
1,000
0
60
Exh. gas bypass

closed
open
70
Exhaust
gas turbine
2,000
5,000
50
Total el.
production
5,000
15,000
10,000
12K98ME/MC with TES (dual press.)

ISO amb. cond.
6,000
4,000
40
open
Fig. 11: Expected electric power production of the Thermo Efficiency System
(TES) with a singlepressure steam system valid for main engine 12K98ME/
MC and based on ISO ambient reference conditions
20,000
80
90
100 % SMCR
Electric power production

kW
8,000
Obtainable steam production

kg/h
40,000
35,000
70
80
90
100 % SMCR
Fig. 12: Expected steam production of an exhaust gas boiler with a

dualpressure steam system valid for main engine 12K98ME/MC with TES
40
50
60
Exh. gas bypass
closed
open
70
80
90
100 % SMCR
Fig. 13: Expected electric power production of the Thermo Efficiency System
(TES) with a dualpressure steam system valid for main engine 12K98ME/MC
Fig. 11
Expected steam production of an exhaust gas boiler with a dual-pressure
steam system valid for main engine 12K98ME/MC with TES and based
on ISO ambient reference conditions
11
Exhaust gas and steam turbine generator output dual pressure
The feedwater, therefore, has to be
The results for operation at 85% SMCR
preheated by means of alternative heat
are shown in Fig. 14, together with the
Besides the singlepressure steam system,
sources such as the jacket water and
calculated ISO ambient temperature
a more complex and more expensive
scavenge air cooler heat.
based results for three other main en
dualpressure steam system is also
gine types. The corresponding results
available, see Figs. 6 and 7. The high
Furthermore, the pinch point should
based on tropical ambient temperature
and low steam pressures used are
not be too low (giving low gas veloci
conditions are shown in Fig. 15. How
about 1011 and 45 bar abs (910 and
ties through the boiler) in order to pro
ever, it should be emphasised that it is
34 bar g), respectively.
tect the exhaust gas boiler against soot
probably more realistic to use the ISO
deposits and fires.
ambient temperatures as the average
The steam turbine is a multistage dual
ambient temperatures in worldwide
pressure condensing type. The alternator/
As an example valid for the nominally
operation. In Fig. 16, the ISO based
generator is driven both by the steam
rated 12K98ME/MC (18.2 bar) en
total electric power production at 85%
turbine and the exhaust gas turbine.
gine operating at ISO ambient refer
SMCR is also shown as a function
ence conditions, we have calculated
of the main engine size measured in
Because of the low steam pressure and
the steam production and the elec
SMCR power.
corresponding low saturated steam tem
tric power production of the TES, see
perature (144C/4.0 bar abs), there is no
Figs. 12 and 13.
Payback time of the Thermo

Efficiency System
exhaust gas boiler for feedwater preheat
The total electric power production in
The payback time of TES depends very
ing, because the exhaust gas boiler
% of the main engine shaft power out
much on the size of the main engine
outlet temperature has to be higher than
put is also shown as a function of the
and the trade pattern (main engine load
about 160165C in order to avoid sulphu
engine load, see Fig. 9.
and ambient temperatures) of the ship.
room for an LPpreheater section in the
ric acid corrosion of the boiler outlet.
Main engines operating at 85% SMCR and ISO ambient reference conditions
ME = Main engine
EGT = Exh. gas turbine
ST1 = Steam turbine
Single steam pressure
7.0 bar abs
ST2 = Steam turbine
Dual steam pressure
4.0 bar abs/10.0 bar abs
Additional feed water
preheating required
TES1 = EGT+ST1
TES2 = EGT+ST2
In normal service at
85% SMCR per year:
280 days
Ship type
Main engine type
Specied MCR (L1)
kW
VLCC
6S90ME-C
29,340
4,500 teu
7K98ME-C
39,970
6,000 teu
12K90ME
54,840
8,000 teu
12K98ME
68,640
% SMCR
kW
85
24,939
85
33,975
85
46,614
85
58,344
Steam consumption for heating services

EGT electric power production, approx.
in % of ME output
kg/h
kW
%
1,400
920
3.7
1,800
1,260
3.7
2,400
1,730
3.7
3,000
2,180
3.7
ST1 electric power production

in % of ME output
kW
%
1,110
4.5
1,640
4.8
2,250
4.8
2,840
4.9

in % of ME output
kW
%
1,360
5.4
2,020
5.9
2,800
6.0
3,520
6.0
Total TES1 electric power production

in % of ME output
Annual fuel savings
payback time
kW
%
USD/year
year
2,030
8.2
374,000
8.8
2,900
8.5
528,000
7.0
3,980
8.5
724,000
5.8
5,020
8.6
917,000
5.0

in % of ME output
Annual fuel savings
Payback time
kW
%
USD/year
year
2,280
9.1
415,000
8.8
3,280
9.6
596,000
7.0
4,530
9.7
818,000
5.8
5,700
9.8
1,045,000
5.0
Main engine load

Main engine power output
Fig. 14: Steam and electric power production and payback time of the Thermo Efficiency System (TES) when operating at 85% SMCR and ISO ambient
reference conditions
12
Main engines operating at 85% SMCR and tropical ambient conditions

ME = Main engine
EGT = Exh. gas turbine
ST1 = Steam turbine
Single steam pressure
7.0 bar abs
ST2 = Steam turbine
Dual steam pressure
4.0 bar abs/10.0 bar abs
Additional feed water
preheating required
TES1 = EGT+ST1
TES2 = EGT+ST2
Ship type
Main engine type
Specied MCR (L1)
kW
VLCC
6S90ME-C
29,340
4,500 teu
7K98ME-C
39,970
6,000 teu
12K90ME
54,840
8,000 teu
12K98ME
68,640
% SMCR
kW
85
24,939
85
33,975
85
46,614
85
58,344
Steam consumption for heating services

EGT electric power production, approx.
in % of ME output
kg/h
kW
%
900
880
3.5
1,200
1,200
3.5
1,600
1,650
3.5
2,000
2,070
3.5

in % of ME output
kW
%
1,600
6.4
2,300
6.8
3,150
6.8
4,000
6.9

in % of ME output
kW
%
1,950
7.8
2,800
8.2
3,830
8.2
4,850
8.3

in % of ME output
kW
%
2,480
9.9
3,500
10.3
4,800
10.3
6,070
10.4

in % of ME output
kW
%
2,830
11.3
4,000
11.8
5,480
11.8
6,920
11.9
Main engine load

Main engine power output
Fig. 15: Steam and electric power production of the Thermo Efficiency System (TES) when operating at 85% SMCR and tropical ambient conditions
When for example operating at tropical
Based on the average operation in ser
main engine fuel costs of the standard
ambient conditions, the electric power
vice at 85% SMCR = 58,344 kW in 280
12K98ME/MC engine are as follows:
output of the TES is higher than for ISO
days a year, SFOC = 0.00017 t/kWh
ambient conditions, which again has a
and a fuel price of 160 USD/t the annual
higher TES output compared with win

ter ambient conditions.
Furthermore, the investment costs per
installed kWe output of a TES plant are
relatively cheaper the bigger the plant
is.
Possible annual savings of fuel costs

mill. USD/year
kW Electric power production
7,000
Normal service : 85% SMCR in 280 days/year
1.2
Fuel consumption : 0.17 kg/kWh
Fuel price : 160 USD/t
6,000
1.0
Dual press.
Single press.

5,000
A simple estimation of the average saved

fuel costs in service at ISO ambient tem
perature conditions for a 12K98ME/MC
with TES (for single or dual pressure)
compared to a standard 12K98ME/MC
engine can be found by means of the
already estimated relative TES1/TES2
gain of 8.6%/9.8% of the main engine
output, see Fig. 14.
0.8
4,000
0.6
0.4
0.2
Steam turbine
3,000
2,000
1,000
0
20,000
Exhaust gas turbine
40,000
60,000
80,000 kW
Size of main engine, SMCR power
Fig. 16: Expected total electric power production and possible annual fuel cost savings of the Thermo
Efficiency System (TES) based on ISO ambient reference conditions and 85% SMCR, shown as a
function of the main engine size, SMCR power
13
Fuel costs = 280 days/y x 24 h/day
In Fig. 17, the estimated payback time
It has been assumed that the increased
x 0.00017 t/kWh
of the TES plant is shown as a function
specific fuel consumption of the TES
x 58,344 kW
of the main engine size. The payback
main engine has been avoided by using
x 160 USD/t
time is only valid provided all electric
an increased firing pressure, Pmax.
= 10,664,000 USD/year
power production savings are used on

board the ship.
For the single and dualpressure sys

tems, respectively, the TES gain in
saved fuel consumptions will then be
as follows:
Payback time of TES

Year
13
TES1 savings = 0.086 x 10,664,000
12
11
= 917,000 USD/year
TES2 savings = 0.098 x 10,664,000

= 1,045,000 USD/year
as shown in Fig. 14.

The similar fuel cost savings valid for
the other three cases with smaller main
engines are also stated in Fig. 14, and
in curve form in Fig. 16 as a function of
the main engine size, SMCR power.
10
Normal service : 85% SMCR

In service per year : 280 days/year
Fuel consumption : 0.17 kg/kWh
Fuel price : 160 USD/t
8
7
6
5
4
3
2
1
0
20,000
40,000
Based on the extra investment costs of
60,000
80,000 kW
Size of main engine, SMCR power
the TES plant (without installation of a

shaft power motor on the main engine
shaft and minus the investment cost of
Fig. 17: Estimated payback time of the Thermo Efficiency System (TES) valid for both a single and a
dualpressure steam system
a normal exhaust gas boiler system) for

the four main engine cases compared
to a standard main engine installation,
the estimated payback time found is
as stated in Fig. 14, i.e. in principle the
same for the single and dualpressure
systems. For the 12K98ME/MC engine,
the calculated payback time is about
five years.
14
Summary
increased electric power production
References
Our calculations indicate that for ISO
gain of the dualpressure system might
[1] Soot Deposits and Fires in Exhaust
ambient reference conditions, a reduc
correspond to about the same relative
Gas Boilers, MAN B&W Diesel A/S,
tion of the fuel consumption of 810%
increase of the investment costs com
Copenhagen,
for a singlepressure system is possible
pared to the singlepressure system.
March 2004.
Denmark,
p.280,
in the normal service range of the main

engine. The larger the engine load, the
When selecting the type of Thermo Ef
greater the possible reduction.
ficiency System, the correspondingly

involved higher risks for soot deposits
For the more complex dualpressure
and fires of the exhaust gas boiler has
system, the corresponding reduction is
to be considered, see Ref. [1].
about 911%.
Because of this, but also because of
All calculations presume unchanged
the more simple singlepressure steam
MTBOs (maintenance time between
boiler system, MAN Diesel & Turbo
overhauls) compared to todays expec
recommends using the singlepressure
tations.
steam system, when installing TES.
However, if the ship sails frequently in
Of course, the more complex and more
cold weather conditions, the electric
expensive dualpressure steam system,
power production of the steam turbine
which gives a somewhat higher elec
will be reduced, and the abovestated
tric power output, may also be used in
reduction of fuel consumption and cor
connection with MAN B&W twostroke
responding reduction of CO2 emission
main engine types.
might not be met.

The TES is rather expensive, and relative
The extra investment costs of the Thermo
ly more expensive the smaller the main
Efficiency System and the payback
engine and the TES are, giving a rela
of the investment can be obtained by
tively higher payback time. Therefore,
means of lower fuel/lube oil costs and,
the installation of the TES is normally
not to forget, the possibility of obtaining
only relevant for the large merchant ships,
additional freight charters and higher
such as the large container vessels.
freight rates, thanks to the green ship

image!
The TES may be delivered as a pack

age by MAN Diesel & Turbo (turbines)
The payback time calculations based
in cooperation with Aalborg Industries
on a large container vessel with a
(boiler) and Siemens (generator) or by
12K98ME/MC as main engine and as
other makers.
average operating at 85% SMCR and

at ISO ambient reference conditions in
normal service during 280 days/year
indicate a payback time of about 5 years
for the TES. The payback time is valid
for both the singlepressure and the
dualpressure systems, because the
15
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.
5510-0030-03ppr Oct 2014 Printed in Denmark
MAN Diesel & Turbo

Teglholmsgade 41
2450 Copenhagen SV, Denmark
Phone +45 33 85 11 00
Fax +45 33 85 10 30
info-cph@mandieselturbo.com
www.mandieselturbo.com
MAN Diesel & Turbo a member of the MAN Group

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Thermo Efficiency System

for Reduction of Fuel Consumption and

Thermo Efficiency System (TES)

demand for installation of a Thermo Ef

of the total fuel energy. In the standard

Following the trend of required higher

ficiency System is that the reliability and

highefficiency engine version, the ex

overall ship efficiency since the first oil

safety of the main engine/ship opera

haust gas temperature after the turbo

crisis in 1973, the efficiency of the main

tion must not be jeopardised.

charger is relatively low, and just high

engines has increased and, today, the

enough for production of the necessary

fuel energy efficiency is about 50%.

As an example, the heat balance dia

steam for a ships heating purposes by

This high efficiency has, among others,

gram for the nominally rated 12K98ME/

means of the exhaust gas fired boiler.

led to a correspondingly lower exhaust

MC engine (18.2 bar) of the standard

gas temperature after the turbochargers.

highefficiency version is shown in Fig.

However, a main engine with changed

1a. Fig. 1b shows an example based

timing and exhaust gas bypass which

Even though a main engine fuel energy

on the Thermo Efficiency System, valid

redistributes the exhaust gas heat from

efficiency of 50% is relatively high, the

for a singlepressure steam system,

high amount/low temperature to low

primary objective for the shipowner is

together with the corresponding fig

amount/high temperature increases

still to lower the total fuel consumption

ures for a dualpressure steam system

the effect of utilising the exhaust gas

of the ship and, thereby, to reduce the

heat, but at the same time may slightly

CO2 emission of his ship.

reduce the efficiency of the main engine

itself. Such a system is called a Thermo

Today an even lower CO2 emission can

main engine is the exhaust gas heat dis

Efficiency System (TES).

be achieved by installing a Thermo Ef

sipation, which accounts for about half

ficiency System. However, the main

of the total waste heat, i.e. about 25%

12K98ME/MC Standard engine version

Total power output 54.2% (54.8%)

ISO ambient reference conditions

El. power production of

Exhaust gas and

Fig. 1a: Heat balance diagram of the nominally rated 12K98ME/MC Mk 6

Description of the Thermo Efficiency

When a part of the exhaust gas flow is

The total electric power output of the

bypassed the turbocharger, the total

TES which reduces the ships fuel costs