Paolo Mangano Wartsila Italia R&D Laboratory. Draft

Transcription

1 WÄRTSILÄ CORPORATION MARINE SOLUTIONS ENGINES RESEARCH & DEVELOPMENT USE OF LPG IN WÄRTSILÄ INTERNAL COMBUSTION ENGINES : ALTERNATIVE FUEL AND EXPERIMENTAL PURPOSES Paolo Mangano Wartsila Italia R&D Laboratory

2 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

3 WÄRTSILÄ in the World Moss, Norway Inert gas and exhaust gas scrubber systems Havant, UK; Slough, UK Seals & bearings Gothenburg, Sweden Water treatment, seals & bearings Trondheim, Norway Frequency converters Stord, Norway Electrical & automation systems Hull, Reading Newcastle, UK Valves Poole, UK Water systems Aalborg, Denmark Deepwell pumps and seawater lift pumps Vaasa, Finland 4-stroke engines, R&D Turku, Finland R&D Helsinki & Espoo, Finland R&D QMD (Qingdao, China) 2-stroke engines Suzhou, China Assembly & sourcing WHEC (Mokpo, South Korea) 4-stroke engines Drunen, the Netherlands R&D, Propulsion Vigo, Spain Seals & bearings Santander, Spain Propulsion Geestacht, Germany Fresh water generation & condensation plants Wärtsilä CME (Zhenjiang, China) Propulsion Toyama, Japan Seals & bearings Açu Superport, Brazil 4-stroke gensets, propulsion, Bermeo, Spain R&D Winterthur, Switzerland 2-stroke engines Services WinGD, Winterthur, Switzerland Trieste, Italy 4-stroke engines, propulsion, R&D Khopoli, India Gensets, Auxiliary modules, Ecotech modules Wuxi, China Propulsion, seals & bearings WQDC (Shanghai, China) 4-stroke engines Singapore, Engine room pumps, pump room systems and Fi-Fi pumps Fully owned sites Sites with R&D Licensee sites Joint Venture sites

4 WÄRTSILÄ GROWTH AREAS Gas as a fuel Environmental solutions Smart Power Generation 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 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 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

5 WÄRTSILÄ : focus and core competence areas RELIABILITY Core technologies and core components Power systems Air and Exhaust systems Fuel systems Automation systems Exhaust treatment systems Effective design Core Competence areas Combustion & chemistry Product design Validation and integration Controls OPERATIONAL FLEXIBILITY = Various fuels ENERGY EFFICIENCY & EMISSIONS = Various fuels

6 WÄRTSILÄ : Medium Speed Engines Portfolio LPG (gas mode, «pilot» production) LPG (liquid mode,«pilot» production) Ethane (gas mode, «pilot» production) Wärtsilä 46/46F/46DF Wärtsilä 50SG Wärtsilä 50DF Wärtsilä 38 Wärtsilä 34SG Wärtsilä 34DF Wärtsilä 32 Wärtsilä 31 Diesel Wärtsilä W31DF, W31SG Wärtsilä 20 Wärtsilä 20DF Wärtsilä 26 Diesel Auxpac Engine output (MW) Gas

7 WÄRTSILÄ Gas Technologies ** ** ** ** * * DUAL-FUEL (DF) Low gas pressure LFO pilot fuel GAS INJECTION *** ** ** ** * ** ** * * SPARK-IGNITION GAS (SG) Low gas pressure Pure gas engine GAS INJECTION * * GAS-DIESEL (GD) High gas pressure LFO pilot fuel GAS INJECTION GAS-DIESEL (GD) SPARK-IGNITION GAS (SG) DUAL-FUEL (DF)

8 Otto or Diesel ideal cycles: effects on NO X Big temperature difference NOx formation! CO 2 NO x SO x Particulates Diesel 0 Dual-Fuel engine engine in gas mode Emission values [%] Diesel, max flame temp. Otto, max flame temp. Environmental benefits moving from liquid to gas fuels!

9 WÄRTSILÄ Engines Research & Development locations Finland Technology Development Programs Product Development Programs Research & Innovation Management Design, Analysis and Expertise Performance, Testing & Validation Environmental Products & Technologies Automation & Controls Vaasa, Finland Turku, Finland Espoo, Finland Bermeo, Spain Performance, Testing & Validation Marine Solutions Engines R&D ~480 Strong emphasis on technology leadership and innovation Long-term co-operation with research institutes and partners Trieste, Italy Technology Development Programs Design, Analysis and Expertise Performance, Testing & Validation WÄRTSILÄ R&D laboratories ~ 200 employees 4 sites and laboratories 22 test engines ~ 20 test rigs 2 Single Cylinder Engines 2 Gas Mixing Stations

10 WÄRTSILÄ R&D LABS : gas technology engines NG or Dual Fuel (*) LPG in gas mode (Exp) LPG + NG (Exp) W10V31DF W6L32E (**) LPG in liq.mode (Exp) Ethane W10V31SG W6L20DFCR W6L34 DF W9L20DF (*) NG + LFO (**) = in «pilot» production Exp = Experimental W16V34SG W6L50DF W6L20DF W20V32SG W6L50SG W8L46DF RTX-5

11 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

12 KNOCKING SENSITIVITY 1 There is no universally accepted standard for determining knock sensitivity of gaseous fuels. 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 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

13 KNOCKING SENSITIVITY 2 Methane Number (MN) 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 Tests results show that gaseous fuel sensitivity to knocking saturates when the share of pro-knocking component gets very high

14 Methane Number (MN) systems BLEND 1 BLEND 2 BLEND 3 Methane Ethane Propane Iso-Butane N-Butane lso-pentane N-Pentane Hexane Heptane C/H ratio H/C ratio Waukesha MN (AVL-meth) MN Wärts Corr MN CAT Binary CH4 mixtures H2 C2H6 C3H8 C4H :1 60 MN Doc.ID: vol-% Revision: in CH Status:

15 Gas combustion, knocking & Methane Number Gas Engine Combustion map; BMEP = Brake Mean Effective Pressure (proportional to engine power) Knock margin Change in knock margin due to various parameters Gas engine output derating due to MN (indicative graph)

16 LPG and Gas Mixing Station in WÄRTSILÄ Italy, Trieste LPG liquid to vaporizer LPG gaseous or LPG + NG mixture 13 bar stream LPG gaseous or LPG + NG mixture 8 bar stream NG stream to GMS LPG liquid to «GD» type engine; technology & plant not yet released

17 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 : kw LPG gas engines portfolio : 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!

18 Thank you All and to... Wartsila Italia team : and the partners : Piero Michele Sergio Roberto Studio Ingegneria e Dintorni Radovani Servizi di Ingegneria Marine & Energy Solutions