k. heinrich, abb turbo systems ltd., 2011-09-27, ship ... · © abb group / abb turbocharging...

© ABB Group / ABB Turbocharging December 22, 2011

Advanced Turbo Charging 2-Stage TC’s, Exhaust Gas Recirculation and Waste Heat Recovery

K. Heinrich, ABB Turbo Systems Ltd., 2011-09-27, Ship Efficiency 2011, 3rd International Conference

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

1975 1980 1985 1990 1995 2000 2005 2010 2015

Year

Fu

ll l

oad

pre

ssu

re r

ati

o

© ABB Group / ABB Turbocharging December 22, 2011 | Slide 2 | filename

Advanced Turbocharging Introduction

Full load pressure ratio with aluminum compressor wheel / base load application (50'000 rhrs)

maximum PIC

average 2-stroke

average 4-stroke



Emulsion

NOx -80% Many different methods for NOx

reduction, -80% only proven with SCR

and gas as fuel

Can other methods or a combination

thereof reach -80% better or at a lower

cost than SCR?

SCR

2-stage turbocharging

Humid air

EGR

Gas / dual fuel

VVT Common rail

Key technologies (mid term, IMO III)

Water injection



3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Year

Co

mp

res

so

r P

res

su

re R

ati

o [

-]

2-Stage Turbocharging

TPS-D/E, TPL-A/B

IMO I IMO II IMO III

TPS-F, TPL-C

For Reference only

A100-H/-M Series

A100-L Series

Remark: Pressure ratio without margins – ca. 0.2 bar for most applications


Advanced Turbocharging Outline

2-stage Turbocharging

Boundary conditions

Special Requirements for High Pressure TC’s

ABB Product Development

Exhaust Gas Recirculation

Challenges

Possible solutions

Waste Heat Recovery

Reasons for WHR

Potential

ABB Offerings




Boundary conditions




Challenges

Possible solutions

Waste Heat Recovery

Reasons for WHR

Potential

ABB Offerings


Advanced Turbocharging 2-stage Turbocharging

TPS-F / TPL-C

p C,overall

Value

2-stage p sC > 6.5

• Smaller frame sizes

• Higher hTC

• More flexibility for matching

• More flexibility for valve

timing necessary

1-stage

2-stage

1-stage p sC > 5.0

• Part load becomes

challanging

• TL-Frame size as known

• TL-Matching needs more

variants– Product portfolio

more complex

A100



For higher receiver pressure the step to

2-stage charging is necessary

Charging efficiency up to75%

Compressor pressure ratio up to 10 ÷ 12

expected

Higher DpCyl. over cylinder

Use of full potential of Miller cycle possible

Increased power density of the engine

Use of higher DpCyl. to reduce valve

overlap

Higher charge air pressure can be used

for either NOx or bsfc reduction



90

95

100

105

0 20 40 60 80 100 120 140 160NOx [%]

Sp

ec

ific

fu

el

Co

ns

um

pti

on

[%

]

Reference Miller - 2-stage turbocharging

red

uced

bs

fc

Reduced NOx



Requirements for a high pressure TC significant differ from standard TC,

new design is necessary

Higher pressure at TC flanges

higher forces new mounting concept

new casing and flange design

Higher air density at compressor inlet

Higher shaft torque appropriate design necessary

Higher axial thrust and thicker shaft new bearings needed

Higher pressure after compressor / before Turbine

Shaft sealing must be adjusted to have control over blow-by

Changed requirements for thermodynamically components

Compressor: Efficiency and swallowing capacity higher rated as total

pressure ratio, wide maps important

Turbine: High flow capacity needed

Turbine casing must be redesigned as kinetic energy at turbine outlet is

not a loss anymore – energy is available to LP turbine



HP TC HP TC

Test rig for 2-stage turbocharging HD-TL on test rig



ABB product strategy

Low pressure turbocharger

1st generation derived from existing

turbocharger types with partly newly

developed thermodynamic components

Product development for 2nd generation

LP TC’s ongoing

High pressure turbocharger

1st generation radial design finalized

First 2 radial frame sizes released for

sales

Product development for 2nd generation

axial and radial HP TC’s ongoing 1.0

2.0

3.0

4.0

5.0

.V298 in m3/s

ctot/tot

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A B BIB21-66e CTX100 SM05-2 TX54 TT18 TA1

1

Replaced by:

Replaces:

HZTL

2010.04.16

CAT/MaK 6M43 2-stageHP Stage, Case O WG

A B B

*sV

Dc = 257 mmCorVer = 1.0

EGR-off mode

EGR-on mode

Curve Nr. 7

Pre

ssure

ratio

Volume flow rate




Boundary conditions




Challenges

Possible solutions

Waste Heat Recovery

Reasons for WHR

Potential

ABB Offerings


Advanced Turbocharging Exhaust Gas Recirculation

Why EGR:

EGR is one method to reduce the NOx level

Technology known from automotive engines

All components needed for NOx reduction mounted to the engine – no

additional space needed

No additional media needed (e.g. urea)

HP EGR is thermodynamically more efficient compared to low pressure

EGR

With HP EGR the main compressors are protected from the exhaust gases

Possible solutions: EGR blower with electric motor or EGR turbocharger



Challenges:

Fuel Quality – EGR not feasible with HFO

Switch in between ECA and non-ECA (EGR on vs. EGR off mode)

Reliability of EGR compressor

Additional cooler capacity needed

Additional control elements needed



1.0

2.0

3.0

4.0

5.0

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ctot/tot

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bili

ty f

or

the c

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ness

and

com

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this

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ment.

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keit d

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rmation

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sique s

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copyright

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urb

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A B BSuMa CV12 CT75 DB09 CA17 CH01Stabi 6mm

1 Basis: VK0928303

Replaced by:

Replaces:

HZTL

2009.04.14

*sV

A B B CAT/MaK 6M43 2-stageLP Stage, Case O WG

EGR-on mode

EGR-off mode

EGR-off mode, HP-turbine BP

1.0

2.0

3.0

4.0

5.0

.V298 in m3/s

ctot/tot

We d

o n

ot

acc

ept

any lia

bili

ty f

or

the c

orr

ect

ness

and

com

ple

teness

of

this

docu

ment.

Fuer

die

Ric

htigkeit u

nd V

olls

taendig

keit d

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okum

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t l´

inté

gra

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ocu

ment.

We r

ese

rve a

ll rights

in t

his

docu

ment

and in t

he info

rmation

conta

ined t

here

in. Repro

duct

ion, use

or

dis

closu

re t

o t

hird

part

ies

without

expre

ss a

uth

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is

strict

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co

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ABB T

urb

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Fuer

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Dokum

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und d

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alle

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copyright

ABB T

urb

o S

yst

em

s 2010

Nous

nous

rése

rvons

tous

les

dro

its

sur

ce d

ocu

ment,

ain

sique s

ur

lóbje

ct y

fig

ura

nt.

La r

epro

duct

ion, l´

usa

ge o

u la

com

munic

ation à

des

tiers

sans

notr

e a

uto

risa

tion f

orm

elle

est

illi

cite

.

copyright

ABB T

urb

o S

yst

em

s 2010

A B BIB21-66e CTX100 SM05-2 TX54 TT18 TA1

1

Replaced by:

Replaces:

HZTL

2010.04.16

CAT/MaK 6M43 2-stageHP Stage, Case O WG

A B B

*sV

Dc = 257 mmCorVer = 1.0

EGR-off mode

EGR-on mode

Curve Nr. 7

HP Compressor

NP Compressor

EGR-off

1.0

2.0

3.0

4.0

5.0

.V298 in m3/s

ctot/tot

We d

o n

ot

acc

ept

any lia

bili

ty f

or

the c

orr

ect

ness

and

com

ple

teness

of

this

docu

ment.

Fuer

die

Ric

htigkeit u

nd V

olls

taendig

keit d

iese

s D

okum

ente

suebern

ehm

en w

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ein

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tung.

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ons

aucu

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bili

té c

once

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léxact

itude e

t l´

inté

gra

lité d

e c

e d

ocu

ment.

We r

ese

rve a

ll rights

in t

his

docu

ment

and in t

he info

rmation

conta

ined t

here

in. Repro

duct

ion, use

or

dis

closu

re t

o t

hird

part

ies

without

expre

ss a

uth

ority

is

strict

ly f

orb

idden

co

pyright

ABB T

urb

o S

yst

em

s 2010

Fuer

die

ses

Dokum

ent

und d

en d

arin d

arg

est

ellt

en G

egen-

stand b

ehalten w

ir u

ns

alle

Rech

te v

or.

Verv

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ung,

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abe a

n D

ritt

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Verw

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ung s

ein

es

Inhalts

sind

ohne u

nse

re a

usd

rueck

liche Z

ust

imm

ung v

erb

ote

n

copyright

ABB T

urb

o S

yst

em

s 2010

Nous

nous

rése

rvons

tous

les

dro

its

sur

ce d

ocu

ment,

ain

sique s

ur

lóbje

ct y

fig

ura

nt.

La r

epro

duct

ion, l´

usa

ge o

u la

com

munic

ation à

des

tiers

sans

notr

e a

uto

risa

tion f

orm

elle

est

illi

cite

.

copyright

ABB T

urb

o S

yst

em

s 2010

A B BSuMa CV12 CT75 DB09 CA17 CH01Stabi 6mm

1 Basis: VK0928303

Replaced by:

Replaces:

HZTL

2009.04.14

*sV

A B B CAT/MaK 6M43 2-stageLP Stage, Case O WG

EGR-on mode

EGR-off mode

EGR-off mode, HP-turbine BP

EGR-off

HP-turbine

bypass

HP-turbine

bypass

Pre

ssure

ratio

Pre

ssure

ratio

Volume flow rate Volume flow rate




Boundary conditions




Challenges

Possible solutions

Waste Heat Recovery

Reasons for WHR

Potential

ABB Offerings


Advanced Turbocharging Waste Heat Recovery

Reasons to apply Waste Heat Recovery WHR

Increasing fuel prices

Reduction in total fuel consumption

Reduction in exhaust emission

CO2

NOx

SOx

Particulars

“Green Vessel” Competitive advantage



• Gas

- Power turbine Generator

- Shaft motor or without shaft motor

• Steam & Gas

- Waste heat boiler

- Steam turbine

- Power turbine & steam turbine Generator

- Shaft motor



ηTCEngine = required min. turbocharger efficiency

PT = 4.0

PT = 3.5

PT = 3.0

η TC 100%

0

1

2

3

4

5

6

7

8

9

10

60 62 64 66 68 70 72 74 76 78

Turbocharger efficiency ηTC [%]

Me

ch

. o

utp

ut

[%]

+ 1% hTC

+ 8% output



6 0

6 2

6 4

6 6

6 8

7 0

7 2

7 4

7 6

7 8

1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Compressor pressure ratio [-]

Tu

rbo

ch

arg

er

eff

icie

nc

y[%

]

Dh= 2%A100-L

TPL..-B

6 0

6 2

6 4

6 6

6 8

7 0

7 2

7 4

7 6

7 8

1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0


Tu

rbo

ch

arg

er

eff

icie

nc

y[%

]

Dh= 2%

6 0

6 2

6 4

6 6

6 8

7 0

7 2

7 4

7 6

7 8

1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0


Tu

rbo

ch

arg

er

eff

icie

nc

y[%

]

Dh= 2%Dh= 2%A100-L

TPL..-B

Power increase by about 20% or

NOx reduction ("2-stroke Miller")

Reduction of fuel consumption

(with power turbine) A100-L

© ABB Group / ABB Turbocharging December 22, 2011 | Slide 22


PTL1700 800…1700kW

mech. output

PTL3200 1500….3200kW

mech. output

Power turbine in combination

with high efficiency A100-L

offers good potential for WHR


Advanced Turbocharging Conclusion

Driven by increasing engine power density, call for reduced specific fuel oil

consumption and tighter emission regulations a strong trend for higher

charge air pressure can be seen

Several technologies for emission reduction are under investigation. Many

of them call for adjusted charging systems

To meet the market requirements ABB develops it product portfolio

accordingly

First two stage turbocharging systems are introduced to the market already.

The product range will be expanded as needed.

ABB supports emission reduction technologies by adjusted charging

systems

Performance of actual A100-L turbo chargers has excellent potential to

apply waste heat recovery systems

k. heinrich, abb turbo systems ltd., 2011-09-27, ship ... · © abb group / abb turbocharging...

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