Air Emissions Management with two-stage turbocharging

Air Emission ManagementPower2 & VCM

§ BIMCO panel at Nor Shipping / Oslo, 2015-06-02

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 2 | filename

Advanced TurbochargingPower2 – two-stage turbocharging

Basic potential

§ Pressure ratios of up to 12

§ Turbocharging efficienciesabove 75%

Dp C

ylÞ

Dh T

CÞ tintercooling 25°C

tintercooling 60°C

Pressure ratio [-] Þ

75%

hTC = 65%

68%

77%

Power21-stage

Texh const

§ With higher pressure ratio …

Þ … increase in hTC

Þ … increase in DpCyl

Þ … more compact 2-stagesystem

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 3 | filename

Advanced Valve Train TechnologyVCM – valve control management

Conventional (fixed) valve timing

§ Reduced valve lift withenhanced MillerÞ increasing throttling lossesÞ limited Miller timing

Crank angle [°CA] Þ

Inle

tval

velif

tÞIn

letv

alve

liftÞ

reduced lift

increasedlift

cycle-to-cycle

VCMFixed VT

VCM

§ Steep closing flanksÞ increased valve liftÞ advanced Miller timing

§ Variation from cycle-to-cycleÞ replacing conventional

control elements

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 4 | filename

Marine PropulsionFrom conventional to Power2 & VCM

Principles

§ Accommodate high pressure ratiosto benefit from high turbochargingefficiencies

§ strong Miller timing enabled byVCMÞ low NOx for DieselÞ increased knock margin

for gas

§ high engine power density

§ Use VCM as the air managementcontrol replacing conventionalelements (e.g. waste gate, bypass,throttle valves)

Dp C

ylÞ

75%

hTC = 65%

68%

77%

Bmep

Þ

Schematic view

IMO IImod. Miller

TC pressure ratio [-] Þ

strongMiller

Sta

te-o

f-the

-art

1-st

age

Power21-stage

Texh const

Remarks: based on simulations, NOx rather indicative

1 g/kWh

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 5 | filename

Marine PropulsionExample: Medium Speed Diesel – FPP

Reference:

• 25 bar bmep @ 750 rpm

• 3-pulse, mod. Miller, 1-stage

Power2 & VCM:

• Engine power up 15%

• Const. pZmax and lv at full load

• Change from pulse to MPC

• Miller optimization for optimumefficiency (Fuel opt.) and minimumNOx (NOx opt.)

• Later IVC towards lower loadswith VCM (reduction of Miller effect)

D to ref. Bsfc E3 / 50% NOx E3 Ref. / IMO II

Fuel opt. -3.1% / -4.2% -30% / -38%

NOx opt. -0.5% / -1.9% -45% / -51%

5 g/kWh

ReferencePower2 & VCM

Fuel opt.NOx opt.

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 6 | filename

Marine PropulsionExample: Medium Speed Gas – n = const

Reference:

• 22 bar bmep @ 750 rpm

• e = 12, mod. Miller, 1-stage

• lv control with WG

Power2 & VCM:

• Engine power up 20% @ const.pZmax / bmep and lv at full load

• Strong Miller, repl. WG by VCM

• Increase compression ratio tosame end of compressiontemperature

Þ hE +3.2%pts ® 6.5% / 12.5g/kWh lower bsfc at full load

Reference

IVC

-20°CA

epsilon+2.5

IVC

-35°CA

Bm

ep+20%

IVC

-45°CA

epsilon+3.5

IVC

-50°CA

100% load

VCM

Power2

Remarks: based on simulations

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 7 | filename

Marine PropulsionPower2 and VCM – summary

Power2 and VCM enable significant …

• … lower NOx for Diesel engines of 30 to 60% vs, IMO II concepts

• … lower fuel consumption in Gas and Diesel engines of ±5%pts

• … higher engine power densities w/o increased of thermal loading

Further potentials:

• Increased robustness in regard to gas qualities (lower MN w/o de-rating)

• Fuel and NOx optimized operating modes incl. switching capabilities(operation in ECA vs. non-ECA)

• Enhanced engine operating range (e.g. torque rise)

• Improved Diesel mode in Dual Fuel engine

• Improved transient capabilities

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 8 | filename

Marine PropulsionScared of 2-stage …?

Removal of compressorcasing

Removal of air inlet Removal of insulation Removal of air outlet flangeconnection

Removal of oil connections Removal of cartridge group

Removal of air inlet casing together withthe insert wall

Removal of cartridge group

Service steps …

1-Stage Power2

© ABB Group / ABB TurbochargingJune 8, 2015 | Slide 9 | filename

The Power of Power2 …

© ABB GroupJune 8, 2015 | Slide 10