CIMAC CIRCLE 2012Turbocharging – an enabler for higher energy efficiency and emission compliance
Christian Roduner, ABB Turbo Systems Ltd
© ABB Group / ABB TurbochargingSeptember 13, 2012 | Slide 2 | filename
Technology driversEmissions – the reasoning …
Road TrafficMarine
NOx SOx PM
Tota
l ann
ual e
mis
sion
s
© ABB Group / ABB TurbochargingSeptember 13, 2012 | Slide 3 | filename
Fuel cost biggest portion of operational cost
Can be improved by various measures (engine core technology, propulsion system, waste heat recovery systems, ship design, power management …)
Driven by fuel prices and potential upcoming IMO measures (EEDI, EEOI, SEEMP and market-based mechanisms such as emission trading, GHG-fund …)
Technology driversFuel efficiency – the difference …
2.1%
4.2%
0.8%
2.0%
13.6%
70.8%
6.5%
Fuel consumptionLube oilCapexMaintenanceInsuranceFees&other costsMan power
12.6 MW Main Engine, 25y TCO 65 MEURWärtsilä, CIMAC/SMM 2010
© ABB Group / ABB TurbochargingSeptember 13, 2012 | Slide 4 | filename
Technology driversSummary – the task …
Significant reduction of NOx and SOx@
no visible smoke and highest fuel efficiency
Options for reducing emissions
Fuel:Gas, MDO/MGO, HFO or Multi Fuel, …
Exhaust gas aftertreatment:SCR, SOx-Scrubber, (PM Filter), …
Engine side measures/turbocharging, Injection/ignition/combustion process:Miller Cycle/2-stage turbocharging, homogenized combustion, EGR, Wet technologies …
Illustration: Rolls-Royce in-depth magazine, issue 17/2012
© ABB Group / ABB TurbochargingSeptember 13, 2012 | Slide 5 | filename
Secondary emission reductionmeasuresSCRDPFscrubberOxi-cat
© ABB Group / ABB TurbochargingSeptember 13, 2012 | Slide 6 | filename
Advanced technologiesOverview Primary emission
reduction measuresMillerEGRwet-
methods
Engine principle4-stroke diesel4-stroke gas4-stroke dual fuel2-stroke diesel2-stroke gas2-/4 -stroke gas/diesel
Injection systemspump-nozzlecommon
rail
Variable valve timingmechanicalmechanical-hydraulicfully hydraulic
Turbochargingsingle-stage2-stage
WHR systemspower turbinesteam turbinecombined systems
Options for fuel efficiency and emission reduction
ABB Turbocharging is developing key technologies to support fuel-efficient and emission-compliant engine concepts at the highest level of integration
Following examples will be introduced:
Gas as fuel for marine enginesEnhancing engine operating range and flexibility
SCR combined with Miller Cycle and 2-stage turbocharging The upcoming diesel IMO III solution
EGR for medium-speed enginesIMO III compliant “on-engine / non-urea” alternative
High pressure turbocharging and VCMEnhanced engine platform capabilities @ increase commonality
Concept: Extreme Miller w/o exhaust gas after-treatment or EGRThe future?
Integrated solutions
Month DD, Year | Slide 7© ABB Group
Gas as fuel for marine enginesEnhancing engine operating range and flexibility
Month DD, Year | Slide 8© ABB Group
Gas engines are known for:Low emissionsHigh efficiency
ABB contribution to limit combustion knock and further increase engine efficiencyLean burn combustion and increased Miller effect 2-stage turbochargingMinimizing cylinder-to-cylinder and cycle-to-cycle variations based on well distributed cylinder filling and high-energy ignition systems VCMControl concepts for fastest load acceptance without compromising on fuel efficiency VCM
Limitation by knocking:Variable speed operation (e.g. FPP)Power densityLoad acceptance
SCR and 2-stage turbochargingThe upcoming Diesel IMO III solution
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Opportunities• Improved engine efficiency
enabled by 2-stage turbocharging and Miller Cycle
• Engine tuning for lowest fuel consumption as NOx is reduced in the SCR
• Exhaust gas temperature fits for optimal SCR operation
• Compact SCR design due to higher gas density
Challenges• Urea injection and mixing• SCR operation with HFO• Thermal inertia of the SCR
100
200
300
400
500
0.0% 1.0% 2.0% 3.0% 4.0%
Increasing ammonia oxidation
Ammonium (bi)sulphateformation
Exha
ust g
as te
mpe
ratu
re [°
C]
Sulfur mass fraction [%]
TTI,HPMS 2St
TTO,LPMS 2St
TTI,LPMS 2St
© ABB Group September 13, 2012 | Slide 10
4-stroke diesel engineITSCR
Exhaust Gas Receiver
Air Receiver
Engine HPTurbocharger
LPTurbocharger
ITSCR
EGR and 2-stage turbocharging
EGR Blower/Turbocharger• turbocharger-like compressor• driven either by high speed motor or gas turbine
Opportunities• compact “on-engine” arrangement• enhanced engine efficiency with 2-stage turbocharging and Miller timing• enhanced efficiency and control capabilities with VCM
Challenges• contamination in EGR path• EGR rate at variable speed
operation• EGR blower vs. turbocharger
The IMO III compliant “on-engine/non-urea” alternative
© ABB GroupMonth DD, Year | Slide 11
HP turbine bypass
High-pressure turbocharging and VCMEnhanced platform capabilities to increase commonality
© ABB GroupMonth DD, Year | Slide 12
Increasing diversification of application leads to increasing complexity for multi-purpose engine platforms
• Different bore for diesel and gas• Increasing number of control elements (e.g. waste gate, bypass, throttle valve,
….) depending on engine application• Different valve timings and related cam shaft geometries
Above calls for compromise on engine commonality (production cost, logistics) and performance for individual fields of application
High-pressure turbocharging in combination with VCM enables enhanced engine performance for all applications while replacing conventional control elements• Potential for higher engine performance for all applications• Enhanced operation flexibility for all engine• High level of platform commonality (no other control element, one cam;
standardized cam shaft geometry)
Once technology modules such as Power2 and VCM are established, additional opportunities may be within reach
E.g, a simulation study*) indicates the potential for HS engines at full load to reach the IMO Tier 3 NOx limit at attractive fuel consumption
Outlook to future conceptsUsing only “diesel and air”
© ABB GroupMonth DD, Year | Slide 13
IMO
3
T4f n
on-r
oad
T4f s
tatio
nary
Gen
set
NOx
Ref. Engine1-stage
2-stage TC, strong Miller
bsfc
*) E. Codan, T. Huber; ABB Turbo Systems Ltd, Application of two stage turbocharging systems on large engines,10. International Conference on Turbochargers and Turbocharging, London, 2012