WÄRTSILÄ CORPORATION MARINE SOLUTIONS … Italia R&D Laboratory ... SPARK-IGNITION GAS (SG) Low...

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WÄRTSILÄ CORPORATION MARINE SOLUTIONS ENGINES RESEARCH & DEVELOPMENT

USE OF LPG IN WÄRTSILÄ INTERNAL COMBUSTION ENGINES : ALTERNATIVE FUEL AND EXPERIMENTAL PURPOSES

Paolo ManganoWartsila Italia R&D Laboratory


Why WÄRTSILÄ at GTC and at WLPGA Forum

Because :

1. GAS is the FUTURE FUEL for Internal Combution Engines

2. WÄRTSILÄ has long and successful history in gas engines design

and production, and its R&D departments invested in LPG

storage, vaporization and internal distribution plants

3. LPG usage for experimental purposes is important for

technological reasons, gases mixtures combustion studies and

for designing environmental friendly solutions

4. Validation of W-products with LPG, Ethane and other gases

supports our portfolio development and future applications with

«associated gases» (available from oil fields and refining

processes), and opens market opportunities

CH4 C2H6 C3H8 C4H10


Fully owned sites

Sites with R&D

Joint Venture sites

Licensee sites

QMD (Qingdao, China)2-stroke engines

WQDC (Shanghai, China)4-stroke engines

Wärtsilä CME (Zhenjiang, China)Propulsion

WHEC (Mokpo, South Korea)4-stroke engines

Khopoli, IndiaGensets,

Auxiliary modules,Ecotech modules

Wuxi, ChinaPropulsion,

seals & bearings

Gothenburg, SwedenWater treatment, seals & bearings

Stord, NorwayElectrical & automation systems

Santander, SpainPropulsion

Hull, Reading Newcastle, UK Valves

Poole, UKWater systems

Aalborg, Denmark Deepwell pumps and seawater lift pumps

Singapore, Engine room pumps, pump room systems and Fi-Fi pumps

Suzhou, ChinaAssembly & sourcing

Geestacht, Germany Fresh water generation & condensation plants

Moss, NorwayInert gas and exhaust gas

scrubber systems

Trondheim, NorwayFrequency converters

Trieste, Italy4-stroke engines,propulsion, R&D

Vaasa, Finland4-stroke engines, R&D

Bermeo, SpainR&D

Winterthur, Switzerland2-stroke engines Services

WinGD, Winterthur, Switzerland

Helsinki & Espoo, FinlandR&D

Turku, FinlandR&D

Drunen, the NetherlandsR&D, Propulsion

Açu Superport, Brazil

4-stroke gensets,propulsion,

WÄRTSILÄ in the World

Toyama, JapanSeals & bearings

Havant, UK; Slough, UK

Seals & bearings

Vigo, SpainSeals & bearings


WÄRTSILÄ GROWTH AREAS

Environmental

solutions

Gas as a fuel

Environmental regulation and

increased focus on optimised lifecycle

efficiency create demand in the marine

industry.

Emission reduction and control are

key focus areas in Marine Solutions

Engines R&D

Economic and environmental reasons

increase the growth potential for gas

solutions in “Marine Solutions” and in

“Energy Solutions” end markets.

We continue to be the leading 4-

stroke engines provider for

• gas fuelled vessels in all

segments

• gas power plants

Smart Power

Generation

The transition to sustainable and

contemporary energy systems drives

the demand for smart power

generation.

Our engines are a core part of

«Energy Solutions» business,

supporting this transition with

• fuel flexibility

• efficiency

• operational flexibility


WÄRTSILÄ : focus and core competence areas

RELIABILITY

OPERATIONAL

FLEXIBILITY

=

Various fuels

ENERGY EFFICIENCY &

EMISSIONS

=

Various fuels

Core

technologies

and core

components

Power

systems

Air and Exhaust

systems

Fuel

systems

Automation

systems

Exhaust treatment

systems

Core

Competence

areas

Combustion &

chemistryProduct design Controls

Validation and integration

Effective

design

9.1.2015


WÄRTSILÄ : Medium Speed Engines Portfolio

Engine output (MW)

0 5 10 15 20 25

Wärtsilä 38

Wärtsilä 26

Wärtsilä 34DF

Wärtsilä 20

Wärtsilä 32

Wärtsilä 46/46F/46DF

Wärtsilä 50DF

Wärtsilä 34SG

Wärtsilä 50SG

Wärtsilä 20DF

Auxpac 16

Wärtsilä W31DF, W31SG

Wärtsilä 31 Diesel

Ethane (gas mode, «pilot» production)

LPG (gas mode, «pilot» production)

LPG (liquid mode,«pilot» production)

Gas

Diesel


WÄRTSILÄ Gas Technologies

******** ***

******** ***

*********

* *

GAS INJECTION

GAS INJECTION

GAS INJECTION

DUAL-FUEL (DF)

Low gas pressure

LFO pilot fuel

SPARK-IGNITION GAS (SG)

Low gas pressure

Pure gas engine

GAS-DIESEL (GD)High gas pressure

LFO pilot fuel

9.1.2015

1987 1992 1995

DUAL-FUEL (DF)GAS-DIESEL (GD) SPARK-IGNITION GAS (SG)


Otto or Diesel ideal cycles: effects on NOX

Big temperature

difference

NOx formation!

Diesel, max flame temp.

Otto, max flame temp.

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 [%]

Environmental benefits moving from liquid to gas fuels!


WÄRTSILÄ Engines Research & Development locations

Trieste, Italy• Technology

Development Programs

• Design, Analysis and

Expertise

• Performance, Testing &

Validation

Bermeo, Spain

• Performance, Testing

& Validation

Finland• Technology Development Programs

• Product Development Programs

• Research & Innovation Management

• Design, Analysis and Expertise

• Performance, Testing & Validation

• Environmental Products &

Technologies

• Automation & Controls

Espoo, Finland

Vaasa, Finland

Turku, Finland

• Marine Solutions Engines R&D ~480

• Strong emphasis on technology

leadership and innovation

• Long-term co-operation with research

institutes and partners

~ 200 employees

4 sites and laboratories

22 test engines

~ 20 test rigs

2 Single Cylinder Engines

2 Gas Mixing Stations

WÄRTSILÄ R&D laboratories


W6L20DFCRW10V31SG W6L34 DF W9L20DF

W6L32EW10V31DF

W6L50SG W8L46DF

W6L50DFW16V34SG W6L20DF W20V32SG

WÄRTSILÄ R&D LABS : ”gas technology” engines

RTX-5

Ethane

LPG in gas mode (Exp)

LPG + NG (Exp)

LPG in liq.mode (Exp)

NG or Dual Fuel (*)

(*) NG + LFO

(**) = in «pilot» production

Exp = Experimental

(**)


Gas Mixing Station : why

• It needs to study how gas composition affects anti-knocking properties

• Knocking is sharp sound caused by premature combustion of part of the

compressed air-fuel mixture in the cylinder

• Several mixtures of gases in various compositions can be prepared and tested, to

simulate customers conditions and study knocking characteristics

• Generally CH4 and inert gases have high anti-knock properties

• Long hydrocarbon chains e.g. n-C6H14 cause knocking, even if their amount is low

in gas fuel mixture


Motor Octane Number (MON)

• Octane system is used mainly for liquid fuels (i.e. petrol, gasoline); it has been suggested

also for gaseous fuels, but it is not really suitable for them

• MON method was applied to small bore test engines with a stoichiometric mixture : the

conditions in large bore engines cylinder are totally different ones

• CH4 MON is out of range, about 130…140

KNOCKING SENSITIVITY 1

N-Butane Number (NBN)

• NBN system uses n-butane as a pro-knock component instead of Hydrogen, based on

engine tests done in 1980’s on large bore lean burn engines (bore 228 and 450 mm).

• Other non-methane hydrocarbons are “reduced” to n-butane with correction factors; if a

gas mixture has NBN 5, it means that the mixture knocks as easily as mixture of 95% CH4

and 5% n-C4H10

There is no universally accepted standard for determining knock sensitivity of gaseous

fuels.


• MN conventionally represents gas knocking properties; GMS aims at preparing and

studying gas mixtures knocking effects

• Methane (CH4) as anti-knocking element MN = 100

• Hydrogen (H2) as knocking element MN = 0

• Propane (C3H8) MN = approx. 35

In early 1970’s a “MN model” was developed based on tests on small engines and

stoichiometric mixture with Hydrogen as a reference fuel and no heavier hydrocarbons

than butane

• Heavier hydrocarbons decrease MN

• Inert gases increase MN

Correction factors are introduced by engine manufacturers to adjust the model

Examples of natural gases MN (just indicative data) : Russian 92, North Sea 73,

Algeria 71, Japan 63, Canada 91, The Netherland 90

KNOCKING SENSITIVITY 2

Methane Number (MN)

Tests results show that gaseous fuel sensitivity to knocking saturates when

the share of pro-knocking component gets very high


Methane Number (MN) systems

BLEND 1 BLEND 2 BLEND 3

Methane 68 80 90

Ethane 13 8 5

Propane 14 5 3

Iso-Butane 0 2 1

N-Butane 3 2 1

lso-Pentane 0 1 0

N-Pentane 0 1 0

Hexane 2 0 0

Heptane 0 1 0

C/H ratio 0.29 0.27 0.26

H/C ratio 3.61 3.74 3.88

Waukesha 51 56.1 77.3

MN (AVL-meth) 47.4 50.1 67.2

MN Wärts Corr 45 43.8 67.2

MN CAT 25.7 26.3 67.6

Binary CH4 mixtures

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

vol-% in CH4

MN

H2

C2H6

C3H8

C4H10

1:1


Gas combustion, knocking & Methane Number

Knock

margin

Change in knock margin due to various parametersGas engine output derating due to MN

(indicative graph)

Gas Engine Combustion map; BMEP = Brake Mean Effective Pressure (proportional to engine power)


LPG and Gas Mixing Station in WÄRTSILÄ Italy, TriesteLPG liquid to

vaporizer

LPG liquid to «GD» type engine;

technology & plant not yet released

LPG gaseous or LPG + NG mixture

13 bar stream

NG stream to GMS

LPG gaseous or LPG + NG mixture

8 bar stream


Conclusion : LPG and Gas Mixing Station in WÄRTSILÄ

1. LPG & GMS plant for experimental purposes in WÄRTSILÄ Italy:

capacity up to 2000 kg/h

2. GMS plant ready for upgrades to inert gases (N2, CO2) and other fuels

3. Experimental gas engines power with LPG fuel : 2100 - 6000 kW

LPG gas engines portfolio : 3000 - 7500 kW, with LPG composition : C3H8 min.

97%, C4 + heavier alkanes max. 3%, alkenes max 2%

GAS is the future fuel for Internal Combustion Engines, but natural gas / LNG

are not the only winning gaseous fuels :

1. Combustion processes are to be simulated and variables influence studied

by altering NGs composition, to fine-tune gas engines setup &

performances;

2. As «associated gases» from oil fields or crude oil refining, other mixtures

of gases and LPG are important energy sources for future energy

solutions!


Thank you All and to ....

Wartsila Italia team :

and the partners :

Studio Ingegneria e Dintorni

Piero Michele Sergio Roberto

Marine & Energy Solutions

Radovani Servizi di Ingegneria

Date post:	07-May-2018
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