World’s Most Powerful Four-Stroke Engine Revealed

MAN has revealed the latest addition to the company’s 4x line of high-performance diesel engines: the MAN 20V45/60 comes with a limit-pushing power output of 26 MW. Furthermore, the company was able to considerably reduce fuel consumption compared to its predecessor, the MAN 48/60. “26 MW in output is unprecedented – this is the most powerful four-stroke engine in the market”, said Wayne Jones, Chief Sales Officer of MAN Diesel & Turbo.
Game-changing power density and efficiency
“The 20V45/60 expands the current performance range of MAN’s 4x family of diesel engines by more than 4 MW, while offering a best-in-class fuel efficien-cy of more than 50%”, added Jones. “Hence, it allows our customers to save both investment and operational costs. With this engine, innovative engineer-ing meets the vast experience of a world market-leader in four-stroke engine design. MAN’s 4x family has accumulated millions of operating hours all over the world and we have listened closely to the needs of our customers. Accord-ingly, we knew exactly where we wanted to go in engineering the next genera-tion of this global success story: We were aiming for a game-changing level in power density and efficiency, and we accomplished that mission.”
“Next to a frontloading approach, using thermodynamic engine process calcu-lations, we used computational fluid dynamics to simulate and optimize the combustion process. Also finite elements analysis was used to optimize the engine’s mechanical strength and vibration behavior. We then put the power unit to the test on the world’s largest four-stroke, single-cylinder test bed and started the experimental optimization and validation phase”, said Dr. Gunnar Stiesch, Head of Engineering Engines at MAN Diesel & Turbo.
The new engine is also a new centerpiece of MAN’s extended systems ap-proach which reflects in the company’s latest generation digital Safety and Control System, SaCoS 5000. Following a decentralized design concept, Sa-CoS 5000 offers unprecedented data availability and optimized alarm visuali-zation and diagnosis. “Thanks to the new SaCoS, the MAN 45/60 is not only online-ready but also equipped for the digital future of power generation”, stat-ed Stiesch.
The two-stage turbocharger module rounds off the MAN 20V45/60’s superior
profile. MAN Diesel & Turbo is the pioneer in developing and operating twostage
turbocharging for large-bore engines, a concept which achieves excellent
efficiency thanks to a low-pressure and a high-pressure turbocharger arranged
in series. “We are the only company in the market that develops both
engine and turbochargers”, says Stiesch. “This unique, in-house competence
allows us to truly tailor-design this engine for optimized two-stage turbocharging
and to unleash its full potential. Operators thus profit from maximized peak
pressure and optimal utilization of the Miller Cycle.”
Perfect fit for power generation in remote locations
Adding MAN’s outstanding track record in designing particularly robust and
reliable engines, the 20V45/60 is a perfect fit for power generation in remote
locations and islands where a gas supply is not available. Its sturdy design
and construction withstands extreme site conditions like hot ambient temperatures
and high altitudes, and makes the engine an excellent solution for captive
power applications in climatically-demanding locations. “The two-stage
turbocharging prevents derating even at 2,500 meters above sea level and
the engine shows no decrease in output even in ambient temperatures of up
to 53° Celsius”, said Alexander Stöckler, Global Head of Sales for the power
plants business at MAN Diesel & Turbo.
Plant operators benefit from the engine’s high power-density, which significantly
reduces capital expenses, as fewer engines and less space are needed
to reach a plant’s desired overall output. An extremely competitive fuel-oil
consumption adds to the sustainability of the engine’s environmental footprint,
which meets the World Bank 2 (2007/2008) emission standard for heavy fuel
oil (HFO), marine gas oil (MGO), and marine diesel oil (MDO). A solution with
integrated selective catalytic reduction (SCR) is under preparation and will
further reduce NOx emissions by up to 80%. Here, MAN Diesel & Turbo will
once more bring to bear its extensive in-house competence regarding integrated
SCR solutions.
The worldwide rise of decentralized energy generation and renewable energy
has significantly changed the capability profile that thermal power plants need
to match. Consequently, the new 45/60 is ideally suited for base load as well
as peak-shaving applications. “Operational flexibility has become essential for
power plant operators these days”, Stöckler said. “State-of-the-art plants need
to be able to master repeated and rapid startups and the ability for loadfollowing
operation. The 45/60 reaches full load in a short time, effortlessly
handles load reversals, and allows for high fuel-efficiency even when operated
in partial load.”
Gas and dual-fuel versions of the engine are currently under preparation. Also,
more cylinder configurations will be added to the 45/60 engine family in the
future.