Energy, the Environment and Transportation Natural Gas Reciprocating Engine Technolgy July 24, 2012

Transcription

1 Energy, the Environment and Transportation Natural Gas Reciprocating Engine Technolgy July 24, 2012

2 Introduction 2 Dave Petruska Engineering Manager at Woodward Licensed Professional Engineer (PE) BS and MS in Electrical Engineering

3 Overview 3 Energy Market and the Future of Natural Gas Natural Gas Reciprocating Engines Ignition and Combustion in Lean Burn Natural Gas Engines System Engineering

4 4

5 Woodward Business Segments 5 Aerospace Energy Gas Turbine Control Steam Turbine Control Engine Control (Air, Fuel, Combustion, Safety) Renewable and Power Conversion Systems Compressor Control Power Generation and Control Engine Control Diesel Natural Gas

6 Energy Market and Natural Gas 6

7 Global Energy Outlook - Demand 7 Population and income growth are driving production & consumption of energy * 37% overall increase in energy demand Driving energy infrastructure investment of over $34 Trillion! Source: BP Energy Outlook *Source: International Energy Agency Special Report

8 Global Energy Outlook - Emissions 8 Expanding emissions regulations will impact both Energy mix, and Energy efficiency Renewable energy Conservation More efficient use of waste fuels

9 Global Energy Outlook - Gas 9 Gas displaces coal and nuclear, motivated by environmental policy and safety concerns Source: International Energy Agency Special Report

10 10

11 Global Energy Outlook - Gas 11 Gas production & consumption grow significantly through 2035 $8 Trillion in gas infrastructure investment >50% increase in total gas consumed Gas share of total energy consumption 21% 25% Unconventional sources of gas rise Source: International Energy Agency Special Report

12 Energy Transportation - LNG 12 Compression Natural Gas Engines Process Safety & Control

13 G G G G G G G G C C C C C C C C C C C C E E E E E E E E E E P P P P P P P P P P S S S S S S S S 13 Oil and Gas Landscape

14 Energy Value Stream 14

15 Natural Gas Engines 15

16 Why Natural Gas Engines 16 Burns cleaner than conventional diesel or gas Lower carbon content Can reduce greenhouse gas life cycle emissions Lower carbon content Low petroleum usage in the production phase With combined cycle reduction up to 70% reduction relative to coal Abundant Domestic Supply Reduced transportation Job growth

17 17 Combined Heat & Power Application

18 4-Stroke Engine 18

19 What is Lean Burn Engine 19 Stoichiometric => just enough O 2 to burn all the fuel Rich => not enough O 2 to burn all the fuel Lean => excess O2

20 Lean Burn Combustion Strategy 20 Reduced combustion temperatures result in lower NOx emissions Reduced combustion temperatures can be achieved with leaner mixtures => excess air is mixed with the fuel Leaner mixtures burn slower => reduces efficiency Induce turbulence to speed up burn rate of air / fuel mix Turbulence negatively impacts the initial sparking or lighting of the air / fuel mixture

21 4-Stroke Engine 21

22 Ignition Sub System 22

23 Ignition System Approach 23 All system components must work together Chain is only as strong as its weakest link (23) PROPRIETARY

24 Ignition Sub System Requirements 24 ISS consists of Driver, Coil, Extender, Plug ISS must spark plug at exactly the correct time ISS must be capable of providing high voltage to jump the gap at very high in cylinder pressures ISS must be capable of delivering adequate energy to spark kernel to get the fire started ISS needs to consistently initiate combustion in cylinder ISS needs to provide long life without shutdown or maintenence

25 High Energy Ignition for Lean Burn 25 Engine Requirements for Lean Burn Capable of extremely high pressures associated with turbo boost Valve porting and cylinder design need to induce appropriate turbulence for rapid combustion Air and fuel need to be homogeneously mixed prior to entering cylinder Turbocharger matched / tuned to overall system performance

26 What is a spark plug? 26 Electrical device that fits into the cylinder head of some internal combustion engines and ignites a compressed air-fuel mixture by means of a spark Examples of J-gap plugs 1 Ground Electrode 1 High Voltage Electrode RB77CC Nickel electrodes 4 Ground Electrodes RB77WPCC Iridium electrodes 1 High Voltage Electrode

27 Woodward Spark Plugs 27 Pre-Chamber Spark Plugs Pre chamber creates flame jets to light off main chamber Precious metal electrodes for long life Reduce combustion variation and increased fuel efficiency relative to J gap plugs

28 Driver and Coil Provide high voltage to spark plug to jump or breakdown gap Provide high energy to spark after initial breakdown The IC-1100 system is a break-through, patent pending spark ignition system with programmable spark current amplitude and durations Capable of delivering 10x spark energy relative to typical CD Capable of extremely long spark current duration Spark current profile can be customized for each engine operating point 28 c

29 Driver and Coil 29 Engine Application Concern Misfire at light load, cold start, low BTU fuel conditions High combustion variation at low emissions Drive towards higher fuel efficiency Spark plug life IC-1100 Solution Ultra long spark duration reduce misfire propensity significantly High energy spark has demonstrated reduced combustion variation High energy spark has demonstrated leaner operating limits Program optimum spark profile for each engine operating point Change spark profile as plug gap grows High energy allows for smaller initial gap High kv capability regardless of spark amplitude and duration Clean Engine Technologies

30 Extenders Provide high voltage connection to spark plug Large engines have long travel through engine block to reach spark plug => results in very high dielectric stress Woodward is pursuing extender materials and designs capable of withstanding greater voltages (E fields) than existing technology Teflon extenders Injection molded extenders Reduced price Looking at new materials that increase reliability compared to Teflon

31 Natural Gas Opportunites 31

32 Natural Gas Engine Opportunities 32 Dual fuel engines Combined cycle power plants Pre-chamber spark plugs Laser ignition Natural gas vehicular applications (CNG, LNG) Improvements on traditional technologies

33 System Engineering 33

34 System Engineering 34 Complex problems Multidisciplinary teams Big picture vs. small picture optimizations Need to be deep and wide Ability to communicate effectively

35 Wide Range of Skill Sets Needed Job Title Skills / Responsibilities Project Manager Logistics, Budget System Engineer Interfaces, Optimization, Teamwork Electrical Engineer Digital, Analog, Power Mechanical Engineer Air, Fuel, Combustion, Durability Manufacturing Engineer Processes, Ergonomics Software Engineer Embedded, HMI Compliance Engineer CE, CSA, UL, Marine Approvals, SAE Technicians Electrical, Mechanical Draftsman / CAD Operaters Electrical, Software Analysts FEA, CFD Marketing What products are needed 35

36 Product Life Cycle 36 Research Doing something brand new Focus is primarily on new concept Limited range of scope Development Converting research to product Complete demonstration of product Meeting cost goals Production Designing processed to recreate product consistently

37 Team Dynamics 37 Need to learn how to disagree respectfully Assume positive intent Avoid artificial harmony

38 Solutions for Engines 38 E