prof. nikolaos kyrtatos, director of the laboratory of marine

Efficient engines with ultra-low emissions for ships:

The HERCULES project

Nikolaos P. Kyrtatos

Professor of Marine Engineering NTU Athens Hercules Coordinator

Presentation at Ship Efficiency: The Event – London 8-9th September 2015

HERCULES is developing new technologies for marine diesel engines:

• Increase engine reliability

• Reduce emissions gaseous particulate

• Increase engine efficiency Reduce fuel consumption Reduce CO2 emissions Reduce lifecycle cost

HERCULES timeline

I.P. HERCULES – Consortium

WARTSILA Finland Oy. WARTSILA Schweiz AG

MAN DIESEL SAS WARTSILA NEDERLANDS BV

32 Partners. Industrial 60% - Universities/Research Inst. 40%

External Associates Group

MAN Diesel & Turbo SE (DE, DK)

HERCULES - B Consortium

HERCULES Management

TaskTechnical

Boards<Quarterly>

Task1.1Leader

HERCULES-B TECHNICAL BOARD

PROJECT COORDINATOR

is chair of

HERCULES-B STEERING COMMITTEE

is member of

QUALITY ASSURANCE & INTERNAL AFFAIRS COMMITEE

coor

dina

tes

withCOMMERCIAL EXPLOITATION & DISSEMINATION

COMMITTEE

coor

dina

tes

with

reports toreports to

Secretariat & Assistantssupport

Financial & Legalsupport

Task 1.2Leader

Task 2.1 Leader

is member of

Task 2.2 Leader

Task 3.1Leader

Task 3.2Leader

SubProject 5.1.3

Leader

SubProject 5.1.2

Leader

SubProject 5.1.1

Leader

Task 5.1 Technical BoardSub

Project 5.2.3

Leader

SubProject 5.2.2

Leader

SubProject 5.2.1

Leader

Task 5.2 Technical Board

Project SteeringCommittee<Annually>

ProjectTechnical

Board<Semi-annually>

PartnersForum

<Annually>

Task 5.1Leader

Task 5.2Leader

Task 6.1 Leader

Task 6.2 Leader

Task 7.2Leader

Task 8.1Leader

Task 8.2Leader

is member of

is chair of is chair of

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

PartnerWorking

TeamLeader

EXAG

corresponds with

TASKCONTROLLERTASK

CONTROLLERTASKCONTROLLERTASK

CONTROLLER

AssociateWorking

TeamLeader

AssociateWorking

TeamLeader

AssociateWorking

TeamLeader

monitors

is member ofis member ofis member ofis member ofis member of is member ofis member ofis member ofis member ofis member ofis member of

Overview of I.P. HERCULES-(A) Workpackages

STRUCTURE OF THE WORK

54 Subprojects 18 Tasks 9 Workpackages

WP9

FRICTION

WP8 EXHAUST

AFTERTREATMENT

WP7 EMISSION

REDUCTION (2) WP6 EMISSION

REDUCTION (1)

WP4 ENERGY

RECOVERY

WP3 TURBOCHARGING

WP2 COMBUSTION

WP1 EXTREME ENGINE

WP11 CONTROL

From HERCULES- A,B,C to HERCULES-2

I.P. HERCULES (A) Targets and Achievements

CIMAC 2007 Congress: Best paper award !

Two-stage turbocharged 4-stroke engine

H - A: Variable turbocharging

Extreme Engine Extreme Engine

Combustion modelling Combustion

modelling and experimentationCombustion

visualization

Hot Engine

Multistage turbocharging

Emission Reduction: WIF, HAM, EGR, CGR

After-Treatment Systems, Sensors

Tribology

Engine Control systems

Combined Cycle

Intelligent Turbocharging

Extreme EGR, SCR, Scrubber

Tribology -Optimization

Advanced sensing and engine control

Advanced Injection, Spray and Combustionexperiments and

models

Integrated emission control

technologies

New materials and tribology

Adaptive engine control

and lifetime reliability

PTI / PTO

T/C with variable turbine nozzle vanes

T/C with variable compressor inlet guide vanes

H-B Advanced intelligent turbocharger

Optical cylinder covers for 2-stroke

H-B Combustion process visualization development

H-B Emission reduction - Exhaust Gas Recirculation and After-treatment

High Pressure Boiler installed on 4T50ME-X

Marine Diesel Engines for Tier III & beyond

OBJECTIVE Target VALUE Achieved

EFFICIENCY 3%

within project

1% • Low temperature Combustion

2% • Combustion optimization

1.5% • Intelligent engine / Advanced plant control • Health monitoring technologies

EMISSIONS

80%

within project

PM 50% THC 50% NOx 80%

• DF-engine

• EGR

• Combustion optimization / multi-fuel

• Aftertreatment (DPF, EGR)

• Charging (VGT)

RELIABILITY (lifetime)

++ • Sensors, Monitoring , Adaptive Control

+ • Tribology improvements

HERCULES-C Objectives and Achievements

WP 3: Injection, Spray Formation and Combustion

Optical cylinder head with optical access and viewing range

H-C :Substantial reduction in fuel consumption

H-C Models for flow and cavitation applicable to large engine injectors

Nozzle bore eccentricity investigation

CFD investigations of the nozzle internal flow

dense core

spray contour

Shadow-imaging PDA

droplet size and velocity

H-C Complete variability of turbocharging system combined with EGR equipment

H-C Retain high performance over plant lifetime

Cylinder lubrication concept for optimized emissions

Predicted Oil Film Thickness

Standard Design

Optimized Design

H-C Models for flow and cavitation applicable to large engine injectors

Instantaneous in-nozzle cavitation pattern for a two hole nozzle layout CFD tool for evaluation of flow coefficients and for describing in-nozzle flow and cavitation

H-C Combined SCR and Scrubber units

Sequential SCR concept

H-C Thermal Barrier Coatings

• Two- stage TC (+VG) (+VVT) • Increased Pmax, BMEP • Autotuning + Injection optimisation • Cylinder cut-out • PTI / PTO, Flexible T/C

• Waste Heat Recovery , Hot Engine

• SCR • Water-In-Fuel, Water injection • EGR • Scrubbers

• Tribology, Materials

24

HERCULES- A,B,C Marine Engine Technologies for the future

1. LOWER FUEL CONSUMPTION 2. EMISSIONS COMPLIANCE 3. OPERATIONAL RELIABILITY & FLEXIBILITY

TARGETS

HERCULES-2 Work

Near Zero Emissions

Flexible Fuel

Adaptive for Lifetime

Advanced Materials

Links from H-A , H-B and H-C to H-2

End of presentation. Thank you for your attention.