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

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*) 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