wärtsilä’s gas portfolio the road to a greener worldscavenging/ compression ... in prechamber...
TRANSCRIPT
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Content
• Gas Engine technologies
• 4-stroke Dual fuel
• 2-stroke Dual fuel
• LNGPAC
• Engine conversion
30 March 2015 2 © Wärtsilä
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Wartsila Ship Power
30 March 2015 3 © Wärtsilä
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Shipping until recently…
30 March 2015 Dual fuel - P.Bodman 4 © Wärtsilä
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Shipping from now on…
30 March 2015 5 © Wärtsilä
Established Emissions Controlled Areas
Emissions Controlled Areas under consideration
Shipping critical points
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30 March 2015 6 © Wärtsilä
Why Natural Gas – The emission advantage
CO2
NOx
SOx
Particulates
Dual-Fuel engine
in gas mode
Diesel
engine
0
10
20
30
40
50
60
70
80
90
100
Emission
values [%] -25%
-85%
-99%
-99%
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Content
30 March 2015 7 © Wärtsilä
• Introduction
• 4-stroke Dual fuel
• 2-stroke Dual fuel
• LNGPAC
• Engine conversion
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The gas engine history
30 March 2015 8 © Wärtsilä
DUAL-
FUEL (DF) GAS-DIESEL
(GD)
SPARK-IGNITION
GAS (SG)
1987 1992 1995
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Gas burning technologies
30 March 2015 9 © Wärtsilä
Gas-diesel (GD) engines:
• Runs on various gas / diesel
mixtures or alternatively on diesel.
• Combustion of gas, diesel and air
mixture in Diesel cycle.
• High-pressure gas injection.
Dual-fuel (DF) engines:
• Runs on gas with 1% diesel (gas
mode) or alternatively on diesel
(diesel mode).
• Combustion of gas and air mixture
in Otto cycle, triggered by pilot
diesel injection (gas mode), or
alternatively combustion of diesel
and air mixture in Diesel cycle
(diesel mode).
• Low-pressure gas admission.
Spark-ignition gas (SG) engines:
• Runs only on gas.
• Combustion of gas and air mixture in
Otto cycle, triggered by spark plug
ignition.
• Low-pressure gas admission.
34SG
32GD/46GD
20DF
Dual-fuel (DF) engines
Spark-ignition gas (SG) engines
Gas-diesel (GD) engines
32DF/34DF/50DF
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Doc.ID: Revision: Status: © Wärtsilä
Wärtsilä Dual-Fuel Application References
30 March 2015 DF reference
>1,300 engines >12,000,000 running hours
LNG Carrier
Multigas Carrier
Product tanker
Bulk tanker
CNG carrier
Offshore supply
FPSO
FSRU
Platform
FSO
Ferries
Tugs
ROPAX
Navy
Icebreaker
IWW
Guide ship
168 vessels
8 vessels
2 vessels
1 vessel
1 vessel
FPSO
RORO
Chemical tanker
Ferries
IWW
Chemical tanker
Container vessel
LNG Carrier
4 vessels
4 vessels
3 vessels
Plants 75
Output 4877 MW
Online since 1997
24 vessels
5 vessels
4 vessels
2 vessels
1 vessel
9 vessels
6 vessels
3 vessels
1 vessel
1 vessel
1 vessel
1 vessel
4 vessels
2 vessels
1 vessel
1 vessel
1 vessel
732 engines
123 engines
61 engines
28 engines
11 engines
352 engines
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© Wärtsilä
Wärtsilä 4-S DF engine portfolio
11
6L20DF 1.0 MW
8L20DF 1.4 MW
9L20DF 1.6 MW
6L34DF (SP) 3.0 MW
8L34DF (SP) 4.0 MW
9L34DF (SP/PP) 4.5 MW
12V34DF (SP) 6.0 MW
16V34DF (SP/PP) 8.0 MW
20V34DF (PP) 10.0 MW
6L50DF 5.9 MW
8L50DF 7.8 MW
9L50DF 8.8 MW
12V50DF 11.7 MW
16V50DF 15.6 MW
18V50DF 17.55 MW
20DF
5 10 15 MW
34DF
50DF
DBAD263346 Product Review Wärtsilä 34DFB
46DF 6L46DF 6.9 MW
8L46DF 9.2 MW
9L46DF 10.3 MW
12V46DF 13.7 MW
14V46DF 16.0 MW
16V46DF 18.3 MW
7L46DF 8.0 MW
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DF-engine
30 March 2015 12 © Wärtsilä
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Intake of
air and gas
Compression of
air and gas
Ignition by
pilot diesel fuel
Otto principle
Low-pressure gas admission
Pilot diesel injection
Gas mode: Ex. In. Ex. In. Ex. In.
Intake of
air
Compression of
air
Injection of
diesel fuel
Diesel principle
Diesel injection
Diesel mode: Ex. In. Ex. In. Ex. In.
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The marine favourite technology?
30 March 2015 13 © Wärtsilä
* * * * * * * * * * *
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GAS INJECTION
GAS INJECTION
GAS INJECTION
DUAL-FUEL (DF) Meets IMO Tier III on Gas
Back-up mode - MDF
Low pressure
SPARK-IGNITION GAS (SG) Meets IMO Tier III
No redundancy
No HFO flexibility
GAS-DIESEL (GD) Does NOT meet IMO Tier III
High gas pressure
Requires Exh Gas After-treatment
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Otto or Diesel cycles: effects on NOX
30 March 2015 Dual fuel - P.Bodman 14 © Wärtsilä
Big temperature
difference
NOx formation!
Diesel, max flame temp.
Otto, max flame temp.
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Wärtsilä‘s DF
30 March 2015 15 © Wärtsilä
* * * * * * * * * * *
GAS INJECTION
DUAL-FUEL (DF)
1 IMO Tier III compliant on Gas
2 Port to Port Operations on Gas
3 Low pressure gas ~4 Bar at the Engine
4 High Thermal Eff ~ 48% - 49% (46DF~50.1%)
5 Fuel flexibility; GAS, MDO and HFO
6 Back-up is MDF.
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Content
30 March 2015 Dual fuel - P.Bodman 16 © Wärtsilä
• Introduction
• Gas Engine Technologies
• 2-stroke Dual fuel
• LNGPAC
• Engine conversion
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4-stroke fuel inlet system 20DF
30 March 2015 17 © Wärtsilä
Pilot fuel common
rail 900bar
Main fuel
injection pipe
Main fuel
injection pump
Pilot fuel quill pipe
Main fuel quill pipe
Twin nozzle
injection valve
Inlet valve
Gas manifold
Gas bellow
Fine filter
Gas valve
Gas nozzle
Gas valve electrical connection
Injection valve electrical connection
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Fuel injection 50DF
30 March 2015 18 © Wärtsilä
Pilot solenoid valve
Pilot needle
Main needle
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Operating Modes
• Gas Mode – Gas & Pilot fuel.
– Pilot Fuel ~ 1%
• Diesel Mode – Jerk Pump & Pilot Fuel.
– Pilot Fuel maintains Injector nozzle is clean.
• Back-up Mode – Jerk Pump only.
– Enables Rapid Black-out Start.
30 March 2015 19 © Wärtsilä
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Start Sequence 50DF
30 March 2015 20 © Wärtsilä
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Transfer - MDO to GAS at 80% load
30 March 2015 21 © Wärtsilä
Speed
Load
Receiver pressure
Gas pressure
Pilot fuel pressure
Diesel actuator
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Transfer of Modes - GAS to MDO at 100% load
30 March 2015 22 © Wärtsilä
Speed
Load
Receiver pressure
Gas pressure
Pilot fuel pressure
Diesel actuator
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Operating window / Control System
30 March 2015 23 © Wärtsilä
Operating
window
Th
erm
al
eff
icie
nc
y [
% ]
NO
x e
mis
sio
ns [
g /
kW
h ]
BMEP [ bar ]
Air / Fuel ratio
Knocking
Mis
firing
Optimum performance
for all cylinders
Cylinder Control Unit – Controls GAV, Pilot Injection, duration/timing
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Stop/Shut Down & Emerg Stop
• Stop (Operator) :
– In Gas – Unload engine.
– GVU shut off/GAV de-activated.
– Pilot active during run-down initially.
– Pilot de-activated.
– Exhaust ventilated.
30 March 2015 24 © Wärtsilä
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• Shut Down (Automatic):
– Engine unloaded immediately.
– Stop signal initiated.
– If overspeed - Pilot Fuel stopped.
• Shut-Down – typically
– LO/HT Pres/Temp.
– Bearings or Cyl Liner Temp.
– Gas Leak
– Crankcase Pressure
– Speed sensor failure
– Oil Mist
• Emerg Stop (Operator):
– Stop initiated – engine & aux.
– Pilot fuel stopped immediately.
30 March 2015 25 © Wärtsilä
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Typical ER Arrangement
30 March 2015 26 © Wärtsilä
• ER is Gas Safe if Double Walled Pipes
used.
• Electrical Equipment not Ex proof.
• GVU can be in ER or external.
• Engines can suck from ER or outside –
IMO/IGC or IGF.
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Ventilation Layout
30 March 2015 27 © Wärtsilä
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Content
30 March 2015 Dual fuel - P.Bodman 28 © Wärtsilä
• Introduction
• Gas Engine Technologies
4-stroke dual fuel
• LNGPAC
• Engine conversion
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2-stroke GD-concept HIGH PRESSURE
30 March 2015 Dual fuel - P.Bodman 29 © Wärtsilä
Scavenging/
compression
Pilot fuel & HP
gas injection, ign Expansion
Principles:
• Engine operating accordingly to
Diesel process
• Injection of gas close to TDC.
Air is completely compressed
and, therefore, high pressure
gas injection (300 bar) is
required.
• No significant NOX reduction
• Requires SCR or EGR (not
proven) in order to meet IMO
Tier III levels
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2-stroke DF-concept LOW PRESSURE
30 March 2015 Dual fuel - P.Bodman 30 © Wärtsilä
Principles:
• Engine operating accordingly
to Otto process
• Injection of gas at mid-stroke.
Low pressure gas injection
(<16 bar)
• High impact on NOX reduction
• Meets IMO Tier III without
after treatment
Scavenging Compression/
gas admission
Ignition
expansion
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30 March 2015 Dual fuel - P.Bodman 31 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 32 © Wärtsilä
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The 2-stroke DF concept
The Principle:
• Engine operating
according to the Otto
process
• Pre-mixed ‘Lean
burn’ technology
• Low pressure gas
admission at ’mid
stroke’
• Ignition by pilot fuel
in prechamber
Low pressure Dual Fuel
12 November 2013 33 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 34 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 35 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 36 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 37 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 38 © Wärtsilä
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Engine Design
30 March 2015 39 © Wärtsilä
Wärtsilä two-stroke DF engines have the
same footprint as a conventional HFO engine
No SCR, Scrubber or EGR required in order
to meet upcoming emission regulations
No parasitic loads introduced thanks to low
pressure gas injection
Lower Opex compared to HP Gas engine
No HP cryo-pumps, HP evaporators,
“heavy” double wall piping
Minimization of hazards due to low pressure
gas injection
THINK ABOUT OVERALL SYSTEM
EFFICIENCY
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30 March 2015 Dual fuel - P.Bodman 40 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 41 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 42 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 43 © Wärtsilä
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RTX – 5 (RTFlex50DF)
30 March 2015 44 © Wärtsilä
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6X72DF 2-S Engine – 19350kw
30 March 2015 45 © Wärtsilä
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30 March 2015 Dual fuel - P.Bodman 46 © Wärtsilä
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Content
30 March 2015 Dual fuel - P.Bodman 48 © Wärtsilä
• Introduction
• Gas Engine Technologies
• 4-stroke dual fuel
• 2-stroke R&D dual fuel
• Engine conversion
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Dual Fuel installation
30 March 2015 Dual fuel - P.Bodman 49 © Wärtsilä
C. Dual-Fuel Main engine
A. Storage tanks
B. Evaporators
A complete and modularized
solution for LNG fuelled ships
C B
A
D. Dual-Fuel Aux engines
D
E. Bunkering station(s)
F. Integrated control system
E
F
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Complete solution – Viking Grace
30 March 2015 Dual fuel - P.Bodman 50 © Wärtsilä
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Gas solution components
30 March 2015 Dual fuel - P.Bodman 51 © Wärtsilä
GVU
Bunkering
Station Main Engine Gas
Valve
Bunkering line,
insulated pipes
Bottom tank
filling
Pressure build
up evaporator
LNG – gas evaporator
Water/Glycol
system
LNGpac
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Gas valve unit
30 March 2015 52 © Wärtsilä
• Regulating the gas pressure to the engine
• One unit per engine
• Enclosed type, no separate room needed
• Vertical and horizontal designs
• Ideally less than 10m away from the engine
• Compact
• Integrated ventilation with the engine
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Viking Grace – Stockholm - Turku
30 March 2015 53 © Wärtsilä
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Viking Grace
30 March 2015 54 © Wärtsilä
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Tank Spray Arrangements
30 March 2015 55 © Wärtsilä
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LNGpac Bit Viking - Retrofit
• Liquid LNG at -162 C
• 2 x 500 CBM Type C Tanks
• Various sizes designed &
Patented by Wärtsilä
30 March 2015 56 © Wärtsilä
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Viking Grace - Bunkering
30 March 2015 57 © Wärtsilä
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Emissions – The Reality
30 March 2015 58 © Wärtsilä
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Really!!
30 March 2015 59 © Wärtsilä
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“Other tank technologies are available”
30 March 2015 60 © Wärtsilä
“IMO Type C” “Membrane” “IMO Type A - B”
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LNG tank technologies
30 March 2015 61 © Wärtsilä
“IMO Type C” “Membrane” “IMO Type A - B”
Non-self-supporting
tanks which consist on a
thin layer (membrane)
supported through
insulation by the adjacent
hull structure.
Tanks which are
designed using model
tests, refined analytical
tools and analysis
methods to determine
stress levels, fatigue life
and crack propagation
characteristics.
Are also referred as
pressure vessels and are
tanks meeting IGC code
pressure vessels criteria
(accepting overpressure).
Optimum space
utilization (prismatic)
They need to be built
by the Shipyard
(quality/experience/cost)
They do not accept
pressure increases.
NBOG and FBOG
handling
Optimum space
utilization (prismatic)
They can be build in a
separate environment
They do not accept
pressure increases.
NBOG and FBOG
handling
NOT optimum space
utilization (cylindrical)
They can be build in a
separate environment
They accept pressure
increases so higher
flexibility in NBOG
handling. Available
“holding time”
* NBOG = Natural Boil-Off Gas ; FBOG = Forced Boil-Off Gas
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Content
30 March 2015 Dual fuel - P.Bodman 62 © Wärtsilä
• Introduction
• Gas Engine Technologies
• 4-stroke dual fuel
• 2-stroke R&D dual fuel
• Integrated products
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4-S Convertable products
30 March 2015 Dual fuel - P.Bodman 63 © Wärtsilä
Wärtsilä 20 Diesel Wärtsilä 20DF
Wärtsilä 32 Diesel Wärtsilä 34DF
Wärtsilä 46 Diesel Wärtsilä 50DF
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4-S DF conversion – Parts to be exchanged
© Wärtsilä
Turbochargers
modified for DF
operation
Camshaft
pieces for
DF Miller
valve timing
Cylinder
heads
Pistons &
piston
rings
Cylinder liner
& anti-
polishing ring
Connecting
rods
(upper part)
Dual-
needle
injection
valve
Control
system
UNIC
30 March 2015
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DF conversion – Components to be added
© Wärtsilä
Gas rail pipe
Gas admission
valves
Exhaust gas
waste gate
Pilot fuel system:
- Pilot fuel oil filter
- Common rail piping
- Pilot fuel oil pump
30 March 2015
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Retrofit - Diesel to dual-fuel
66 © Wärtsilä
RT-flex50DF and X- type DF RT-flex50
X-type
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2-S Retrofit - DF System Layout
Main fuel injector:
• L’Orange-type with built-in solenoid
Gas admission valves:
• Servo activated
• controlled by rail valve UNIC
cylinder module
Exhaust
valve
• 2/3x Pilot fuel injectors
• Adapted cylinder cover design
• 2x Gas Admission Valves (GAV)
• Adapted cylinder liner design or
remachined cylinder liner
• 2x Gas rail double walled
• MDO Supply Unit
• Support platform for MDO SU
• MDO Pipes to injectors
Pilot fuel injector:
• L’Orange-type with built-in solenoid
67 © Wärtsilä