Research on combustion in Switzerland. Liebherr Machines Bulle SA

Transcription

1 Research on combustion in Switzerland Liebherr Machines Bulle SA

2 Applications with Liebherr Diesel / Gas Engines Research on combustion in Switzerland - ETHZ / Suchet

3 Content Market need Customer need kw Price Legislation Low LCC Endurance, Flexibility, Availability, etc. Globalization Emission Fuel Research on combustion in Switzerland - ETHZ / Suchet

4 Chronology of exhaust legislation: on- vs. off-highway EATS introduction Stage V 0.40/0.01 PN: 1x10 12 #/kwh NOx / PM [g/kwh] Research on combustion in Switzerland - ETHZ / Suchet

5 Requirements on heavy-duty diesel (end customer) Total Costs of Ownership TCO Durability Reliability Availability Performance Easy Servicing Legislation Research on combustion in Switzerland - ETHZ / Suchet

6 Same emission target as on-highway, different conditions Water Dust Inclined position Heat Research on combustion in Switzerland - ETHZ / Suchet

7 Diversity of variants: machine-specific application Base engine Application AGN-Integration Duty cycle D936 A min Research on combustion in Switzerland - ETHZ / Suchet

8 Flexible solution for global market Emission limits Fuel quality (sulfur) Market share /// 1 Base engine for : Tier 0, 2, 3 and T4f as well as Stage V Research on combustion in Switzerland - ETHZ / Suchet

9 Mega trends Boundary conditions energy sources raw materials What does the legislature want? less emissions (emissions) sustainability ( CO2) What does the customer want? TCO Simple technical solution (customer buys fonctions, not "technology ) What does the manufacturer want? global solutions enough advance to fulfill the decision to the legislator profitably produce and market Research on combustion in Switzerland - ETHZ / Suchet

10 Behavior of O-Ring Material Research on combustion in Switzerland - ETHZ / Suchet

11 TCO Spart plug: maintenance cost Expected life time Cost Maintenance time Research on combustion in Switzerland - ETHZ / Suchet

12 Specific consumption 350 MAN Krupp 2 Takt MAN D0226 spez. Kratstoffverbrauch [g/kwh] R. Diesel 1897 Stationärmotor =0,261 Carnot-Prozeß =0,732 (b_e=115 g/kwh) MAN 1937 G-Verfahren Schiffsdiesel 2 Takt =0,55 Euro 0 (1990) Euro 1 (1993) Euro 2 (1996) Euro 3 (2000) Euro 4 (2005) MAN D20 =0,455 Euro 5 (2009) y = 0,007x 2-28,464x Baujahr Research on combustion in Switzerland - ETHZ / Suchet

13 Limitations of internal engine consumption improvement Best-Point ref. level: 187 g/kwh at NOx=11 g/kwh Rated-Speed ref. level: 202 g/kwh at NOx=11 g/kwh High Pressure Cycle -0.3% Optimized air to fuel mixture -0.5% TC match (actual benefit on Rated Speed) Gas Exchange Friction Reduction -0.3% Valve lift optimization -0.3% Dethrottling, exhauts manifold, intake port capacity) -0.2% Friction reduction for Best-Point -0.4% Friction reduction for Rated-Speed -1.0% Var.Volumetric Oil Pump BSFC reduction in Best-Point: BSFC reduction at Rated-Speed: - 2.1% > 187 g/kwh = 183 g/kwh - 2.3% > 202 g/kwh = 197,5 g/kwh /// There is certainly even more potential for improvement! Research on combustion in Switzerland - ETHZ / Suchet

14 Device-side optimization, hybridization Pactronic : hydraulic hybrid impulse for harbor mobile cranes Energy storage during load reduction into a hydraulic storage Use of the stored energy in the working stroke The system is maintenance free (10 years inspection interval) Compared to Liebherr harbor cranes with conventional drive and the same handling capacity (tonnes / hour), Pactronic hybrid version consumes 30% less fuel Research on combustion in Switzerland - ETHZ / Suchet

15 Device-side optimization, hybridization Pactronic :(Harbour Mobile Crane) Research on combustion in Switzerland - ETHZ / Suchet

16 Pactronic : XXXXX Research on combustion in Switzerland - ETHZ / Suchet

17 Total efficiency: Example: Excavator Total Energy Efficiency of Excavator (Quelle Yanmar) Research on combustion in Switzerland - ETHZ / Suchet

18 Energy Recovery Cylinder (ERC) Research on combustion in Switzerland - ETHZ / Suchet

19 Technic Diesel engine Specific power 35 y = 0,0013x 2-4,8352x , Krupp 2 Takt spez. Leistung [kw/l] MAN Turbo Volvo Titan Turbo MAN R. Diesel 1897 Stationärmotor Euro 0 (1990) Euro 1 (1993) Euro 2 (1996) Specific power (kw/l) Iveco; Crusor 8 Euro 2 Double stage Single stage MAN D20 Euro 3 (2000) Euro 4 (2005) Euro 5 (2009) Year Baujahr of construction Research on combustion in Switzerland - ETHZ / Suchet

20 Unit development for a typical 50 tons Crawler Exclavator R95X Emissions Level Engine Type Bore / Stroke [mm] Displacement [liters] Rated Power [kw] Stage I D926 TI-E A P3000 2V 1-S - 122/ Stage II D926 TI-E A P7100 2V 1-S - Stage IIIA D936 A6 pme [bar] Spec. Power [kw/l] be [%] FIE Cyl. Head TC& CAC Emissions Control PLD 4V 1-S Internal EGR Stage IIIB D936 A CR 4V 2-S eegr + DPF Stage IV D936 A7 122/ Stage V D936 A Adblue 98+ AdBlue CR 4V 1-S SCR CR 4V 1-S SCRF D926 TI-E A3 D936 A6 D936 A Research on combustion in Switzerland - ETHZ / Suchet

21 Evolution of the emission regulations over time Specific fuel consumption by operating rpm and full-load over time Research on combustion in Switzerland - ETHZ / Suchet

22 2002:D 926 TI-E A3 Stage II/T2 2011: D 936 A7 Stage IIIB/T4i (EGR) 10 l 220 kw 1800 rpm 10.5 l 320 kw 1800 rpm Research on combustion in Switzerland - ETHZ / Suchet

23 Optimization of the engine Future technologies - industrial engine Reduction of fuel consumption Right-sizing (power used in normal use of the target device) Phlegmatization (peak power is covered by hybrid) Operating point shift to optimum consumption Stop start (idle ratio wheel loader up to 30%, mobile crane up to 80%) Reduction losses (auxiliary drives, auxiliary units on the engine) Intelligent thermal management (engine, exhaust gas aftertreatment) Waste heat recovery Increasing the integration depth (from the installation engine to the power pack) Shift of the system limits for optimal system design and standardization Integration of Powerpack functions (fan control, exhaust gas aftertreatment) into the engine control unit Interchangeability of powerpacks for different markets (emission requirements, fuel quality, cold vs. hot countries) Research on combustion in Switzerland - ETHZ / Suchet

24 Consumption at idling speed (D944) field test current Challenges: Speed auxiliary units Load changes Wear Thermo management Vibrations Research on combustion in Switzerland - ETHZ / Suchet

25 HP pump Expander Evaporator Introduction Waste heat recovery Expander Vane Scroll Rankine Cycle (5 to 6%) Turbogenerator (4 to 5%) Turbo compound (2 to 4%) accumulator cooler Piston Turbine Axial impulse turbine Dynamic turbine Research on combustion in Switzerland - ETHZ / Suchet

26 The Off-Road World in 2030* (summary) Research on combustion in Switzerland - ETHZ / Suchet

27 New fuels - PTL (power to liquid) PTG (power to gaz) Electro mobility vs combustion engines Results and conclusions from the FVV scenario study «Renewables in Transport 2050 Europe and Germany» Patrick R. Schmidt / Werner Zittel / Werner Weindorf / Tetyana Raksha LBST, Ludwig-Bölkow-Systemtechnik GmbH March 2016, Munich, Germany Research on combustion in Switzerland - ETHZ / Suchet

28 Source : Schmidt et al. (2016) Fuel mix / interest renewable fuels Fuel mix (per MJ fuel) Share of renewable fuels New fuels PtG: Power-to-Gases PtL: Power-to-Liquids /// Target scenario: All fuels 100% renewable by Research on combustion in Switzerland - ETHZ / Suchet

29 Source : Schmidt et al. (2016) Conclusions from the FVV Future Fuel study (EU) in a nutshell Transportation demand development (pkm, tkm) is strongest driver for fuel/electricity demand. All scenarios but PTL + HIGH could technically be satisfied with demestic renewable electricity in the EU. Depending on the scenario, total electricity demand in 2050 is a factor 3 to 4.5 of the electricity demand today. PtX fuel costs could half between 2015 and 2050; PtL imports ~ 20% lower in cost. Further cost reductions are subject to project-specific business cases. PtX costs are dominated by electricity costs, which strongly depends on the fuel choice (H 2, CH 4, PTL) and associated olant efficiencies. Fuel distribution infrastructure costs are negligible compared to the upstream investments required for any of the scenarios analysed. Cumulated investments for Energiewende (energy transition) in the transportation sector seem manageable for any of the scenarios analysed. Transport must get more electric, with regard to the fuel and the propulsion system Research on combustion in Switzerland - ETHZ / Suchet

30 Source : Technische Universität Darmstadt OME (Polyoxymethylene dimethyl ethers) Research on combustion in Switzerland - ETHZ / Suchet

31 Source : Technische Universität Darmstadt OME (rust free combustion) Research on combustion in Switzerland - ETHZ / Suchet

32 Thank you! Research on combustion in Switzerland - ETHZ / Suchet