Improving engine Performance through innovation and design

Transcription

1 Gino Rizzetto Engine Performance Manager, Testing & Performance WÄRTSILÄ Italia S.p.a. Improving engine Performance through innovation and design 1 Wärtsilä G. Rizzetto

2 List of content WÄRTSILÄ in brief New emissions requirements impact on fuel consumption and smoke Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine High pressure TC (single stage new generation and two stage TC) to lower NOx emission keeping high engine efficiency Combustion process optimization to improve NOx emission 2 Wärtsilä G. Rizzetto

3 List of content WÄRTSILÄ in brief New emissions requirements impact on fuel consumption and smoke Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine High pressure TC (single stage new generation and two stage TC) to lower NOx emission keeping high engine efficiency Combustion process optimization to improve NOx emission 3 Wärtsilä G. Rizzetto

4 WÄRTSILÄ in brief: our offering WE ARE A LEADING SUPPLIER OF FLEXIBLE POWER PLANTS FOR THE DECENTRALIZED POWER GENERATION MARKET Engines Propulsors Power Plants Ship Power systems OEM services Merchant O&M Ship services OUR OFFERING COVERS ALL KEY SHIPPING SEGMENTS Offshore Competitors Cruise engines and Ferry Navy Special Vessels 4 Wärtsilä G. Rizzetto

5 WÄRTSILÄ in brief: network services Product Company Network Workshop 5 Wärtsilä G. Rizzetto

6 WÄRTSILÄ in brief: Global R&D and T&P locations Rubbestadneset, Norway CPP, Gears Stord, Norway Electrical & Automation systems Trondheim, Norway Frequency converters Vaasa, Finland W20; W32/32DF/34SG, Ecotech Turku, Finland Ecotech Espoo, Finland Fuel cells, Ecotech Havant, UK; Slough, UK Face Seals, Synthetic Bearings Drunen, The Netherlands CPP, FPP, Thrusters Winterthur, Switzerland 2-stroke: RT-flex, RTA Trieste, Italy W26, W38, W46, W46F, W50DF, W64 Toyama, Japan Rubber Seals & Bearings Bermeo, Spain W34SG, W50DF 6 Wärtsilä G. Rizzetto - Define and validate new concepts - Provide tech. information on products - Develop expertise

7 List of content WÄRTSILÄ in brief New emissions requirements impact on fuel consumption and smoke Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine High pressure TC (single stage new generation and two stage TC) to lower NOx emission keeping high engine efficiency Combustion process optimization to improve NOx emission 7 Wärtsilä G. Rizzetto

8 New emissions requirements impact on fuel consumption and smoke Wärtsilä engine portfolio 4 - stroke 2 - stroke (MW) Wärtsilä 20 Wärtsilä 26 Wärtsilä Vasa32 Wärtsilä 32 Wärtsilä 38 Wärtsilä 46 Wärtsilä 46F Wärtsilä 64 Wärtsilä 34SG SG Wärtsilä 34SG-B Wärtsilä 50SG Wärtsilä 32LNGD GD Wärtsilä 46GD Wärtsilä 32DF DF Wärtsilä 50DF Diesel engines Gas and Gas and Dual Dual fuel engines fuel engines Dual fuel engines. solutions for marine and land based power generation. from 0.8 MW to 80 MW. from 61 rpm to 1200 rpm. (Turbocharged) Gas, Diesel and Dual Fuel operation 8 Wärtsilä G. Rizzetto

9 New emissions requirements impact on fuel consumption and smoke Revised Marpol Annex VI ( ) NOx (g/kwh) Cycle NOx 4 2 4s Wärtsilä Wärtsilä engines -80% engines 2000 Tier1 limit g/kwh ISO NOx 2011 Tier2 limit g/kwh ISO NOx -20% NOx emission control drives engine performance development 2016 Tier3 limit g/kwh ISO NOx Only designated area (ECA) (Baltic Seat, North Sea, Costal Water) 0 9 Wärtsilä G. Rizzetto Rated engine speed (rpm) Tier I kw - New ships 2000 NOx weight Tier II factor kw - New ships 2011 Cycle\Load Tier III kw - New 100ships in designated 50 areas E2/E3 29% 55% 11% 5% 0% D2 11% 40% 32% 16% 2% Tier 3 load point limit < 1.5 NOx cycle average g/kwh ISO NOx

10 New emissions requirements impact on fuel consumption and smoke 10 Wärtsilä G. Rizzetto

11 New emissions requirements impact on fuel consumption and smoke Severe NOx emission limits will strongly penalize SFOC and smoke. New technologies development to find a compromise between these contesting objectives/constraints. Players to reach specific emission levels: Fuel quality to avoid scrubber or particulates filter High Exhaust Gas temp. according to the fuel sulphur content for SCR use To limit the SCR UREA consumption NOx must be reduced at the engine stage 11 Wärtsilä G. Rizzetto

12 New emissions requirements impact on fuel consumption and smoke Tier2 is the NOx level we are currently facing by means of: a. Low NOx combustion tuning High compression ratio & retarded inj. timing TDC) Triangular injection rate shape Optimized injection pressure in the 50% - 75% load range (CR engines) Combustion space optimization (piston top and injector geometry) b. Turbo Charging Remarkable Miller timing Valve timing flexibility Lower receiver temperature Early inlet valve closure: Shorter compression stroke Lower charge temperature inside cylinder 12 Wärtsilä G. Rizzetto

13 New emissions requirements impact on fuel consumption and smoke Increased compression ratio and retarded injection timing + Improved SFOC/NOx trade off Worse Pmax/SFOC trade off NOx, ISO corr [g/kwh] g/kwh % timing swing 568 rpm NOx-SFOC 15 FIRING PRESSURE av. cock g/kwh eps Wärtsilä G. Rizzetto BSFC, ISO corr 42.7MJ/kg SOI eps 16.8 Retarded timing for NOx emission deteriorates the Smoke Emission (AVL FSN) smoke [FSN] NOx reduction limited penalty in SFOC at constant firing pressure Wärtsilä 8L46F-TP PROTO3, 1200kW/cyl, Smoke vs NOx Emission SOI swing - 10% load SOI swing - 25% load SOI swing - 35% load NOx [g/kw]

14 New emissions requirements impact on fuel consumption and smoke Combination needed to meet Tier3 target High pressure TC sys. (2-stage) Low NOx combustion tuning EGR system HOW TO GET Charge air humidification CLOSER Water Fuel TO Emulsion TIER3? Direct Water Injection NOR system Gas and Dual Fuel tech. NOR (Nitrogen Oxide Reducer) IMO2 IMO NOx reduction potential [%] Example of possible combinations (4-stroke) 2-stage charging system + Wetpac 2-stage charging system + EGR Dual Fuel engine / Fuel conversion + DF engine EGR (internal/external) + Wetpac 2-stage NOx opt. / Fuel optimized + SCR (NOR) 14 Wärtsilä G. Rizzetto Exhaust scrubber + above combinations (HFO operation)

15 New emissions requirements impact on fuel consumption and smoke 2-stage charging system + EGR Exhaust gas recirculation provides big step on NOx reduction, but SFOC and smoke deteriorations have to be paid The driving goal for Tier3 is the best compromise between: CAPEX vs OPEX Reliability Complexity of the solution 2stage + EGR 2stage 2stage + EGR 2stage NOx emission [g/kwh] Smoke emission [FSN] SFOC [g/kwh] 2stage + EGR 2stage engine load [%] IMO engine load [%] 15 Wärtsilä G. Rizzetto engine load [%]

16 New emissions requirements impact on fuel consumption and smoke Dual Fuel engine / Fuel conversion + DF engine The facility to reach Tier3 has to pay: On board gas system Reformer technology Liquid mode efficiency Emission values [%] Development drivers: 50 Output and efficiency 40 Liquid mode performance CO 2 NO x Low methane number operation Methane slip SO x Particulates Dual-Fuel engine in gas mode Diesel engine Wärtsilä G. Rizzetto

17 New emissions requirements impact on fuel consumption and smoke IMO Tier 2 Product development IMO TIER 2 (2009) Efficiency change to TIER 1: -1to +1% Output change to TIER 1: 0 to -4% IMO TIER 2 (2009) -30% NOx Efficiency change to TIER1 +3% Output change to TIER 1: 0 % IMO TIER 2 (2012) Efficiency change to TIER1; +1,5 to +3,5 % Output change to TIER 1: 0 % to +10% IMO Tier II in force Max SFOC penalty 1% Max output penalty 4% High pressure charging system Improved Tier II concept, higher output / efficiency IMO Tier III in force IMO Tier 3 Product development Wärtsilä G. Rizzetto IMO TIER 3, after treatment Efficiency change; +0 to 3% Output change: +0 to 15 % Focus on engine and aftertreatment integration IMO TIER 3, based on 2-stage technology Efficiency change from TIER 2: 0 to -5% Output change from TIER 2: 0 to -5 % IMO TIER 3, gas and gas conversion Efficiency change from TIER 2: 0 to +2 % Output change from TIER 2: 0 to -10 % Focus on technical feasibility and OPEX Focus on: - Liquid mode eff. - Gas mode output

18 List of content WÄRTSILÄ in brief New emissions requirements impact on fuel consumption and smoke Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine High pressure TC (single stage new generation and two stage TC) to lower NOx emission keeping high engine efficiency Combustion process optimization to improve NOx emission 18 Wärtsilä G. Rizzetto

19 Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine VICVariable Inlet Closure has been introduced VIC allows to control timing for inlet valve closure Why: To lower NOx emission, early IVC is used at high loads VIC to enhance low load Smoke and thermal load and Load acceptance P IC TDC Pressure ratio - NOx trade off <<<<< Earlier IVC Inlet valve lift TDC BDC 0 BDC N O x % VIC OFF VIC ON VIC detail 300,0 320,0 340,0 360,0 380,0 400,0 420,0 440,0 460,0 480,0 500,0 520,0 540, CA VIC effect CA deg Reference

20 Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine VIC to allow late inlet valve closure at part load: Smoke benefit during steady state operation Wärtsilä 8L46F-TP PROTO3, 1200kW/cyl, 600rpm TPL76-C33 CV33CT60CD06CA13 TV11TT40TF15TN05TA14 VIC on off eps DPPpiston -12x0.72x symm scav - Jan CS - VIC Smoke emission (FSN) Engine Load (%) 7L32C without VIC. Load ramp from 0% up to 100% in 10s Smoke benefit during transient operation Improved load pick-up with reduced speed drop speed [rpm] Improved speed 7L32C with VIC. Load ramp from 0% up to 100% in 10s recovery with VIC 20 Wärtsilä G. Rizzetto Time [s]

21 List of content WÄRTSILÄ in brief New emissions requirements impact on fuel consumption and smoke Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine High pressure TC (single stage new generation and two stage TC) to lower NOx emission keeping high engine efficiency Combustion process optimization to improve NOx emission 21 Wärtsilä G. Rizzetto

22 High pressure TC to lower NOx emission keeping high engine efficiency: Diesel Compared to the current supercharging status, higher boost pressure availability at higher TC efficiency level would provide: New TC system (KBB ST27, ABB A100M, Napier 8) Higher TC efficiency +3% Pressure ratio up to 5.8 Further increased Miller timing VIC rolled out on all portfolio Up to 2% lower SFOC OR 10%...15% higher output 2-stage system SFOC optimized TC system efficiency 75% Pressure ratio > 8.0 Optimized extreme Miller timing Multi steps VIC Up to 5% lower SFOC AND 10%..15% higher output The extreme Miller drawbacks will be faced by means of the variable valve timing: Difficult engine start-up and low load running Increased smoke emissions 22 Wärtsilä G. Rizzetto Worse load pick-up

23 High pressure TC to lower NOx emission keeping high engine efficiency: Diesel 2stage TC IMO2: Expected performance on variable SOI engine: Power output kW/cyl (+10%) SFOC reduction on E2 cycle ~ -10g/kWh 2stage TC towards IMO3: 50% NOx reduction at constant SFOC: p6 LP t6 LP t5 LP p5 LP p5 HP t5 HP t4 delta BSFC [g/kwh] t0 IMO2 with LP 2 stage turbine W46F 2stage 600rpm - expectation at IMO tier2 Reference 2-stage p0 t1 LP p1 LP ntc LP LP compressor t2 LP p2 LP Wärtsilä G. Rizzetto power output [kw/cyl] IC t1 HP ntc HP NOx [g/kwh] p1 HP HP turbine HP compr. 6L20CR 2stage - eps bar 1000 rpm 1 g/kwh Miller 33 IMO Tier2 Miller 96 Miller 83 t2 HP p2 HP Towards IMO3 with 2 stage 5 g/kwh Charge air receiver AC SFOC [g/kwh] -50% p3 1- stage reference t3

24 High pressure TC to lower NOx emission keeping high engine efficiency: Gas High Pressure TC on DF engine Development drivers: Output and efficiency Limiting factors Knock margin Firing pressure Available boost level High boost pressure system is a key factor as well in the Gas engine development Liquid mode performance Low comp. ratio High NOx emission CO 2 Solutions Emission values [%] Strong Miller timing 100 New hardware platform 90 New TC generation Strong Miller timing & 60 higher compression ratio New TC generation Low MN operation NO x Knock margin SO x Particulates Dual-Fuel engine in gas mode New TC generation 10 Diesel engine 20 Strong Miller timing 0 24 Wärtsilä G. Rizzetto

25 List of content WÄRTSILÄ in brief New emissions requirements impact on fuel consumption and smoke Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine High pressure TC (single stage new generation and two stage TC) to lower NOx emission keeping high engine efficiency Combustion process optimization to improve NOx emission 25 Wärtsilä G. Rizzetto

26 Combustion process optimization to improve NOx emission CFD+engine verification for optimized comb. chamber ISO NOx g/kwh Piston top shape & fuel spray pattern Eps, SFOC NOx, SFOC p_max, exhaust temp., piston heat flux, soot are considered Injector geometry optimization (CFD and experimental) is a part of the process 1g/kWh 26 Wärtsilä G. Rizzetto Spray angle swing: influence on SFOC/NOx at constant firing pressure Wärtsilä 8L46F-TP proto3, 1200kW/cyl, 600rpm NOx BSFC, ISO corrected eps DPPpiston -12x0.72x165-85% eps DPPpiston -12x0.72x163-85% eps DPPpiston -12x0.72x161-85% eps DPPpiston -12x0.72x159-85% SFOC > target ISO SFOC 42.7 MJ/kg [g/kwh] ISO NOx g/kwh SFOC g/kwh 9 Wärtsilä 8L46F-TP proto3, 1200kW/cyl, 600rpm NOx ISO corrected - p_max normalised -3/-4 g/kwh eps DPPpiston -12x0.72x165-85% eps DPPpiston -12x0.72x163-85% eps DPPpiston -12x0.72x161-85% eps DPPpiston -12x0.72x159-85% At constant firing pressure 165 angle allows the best SFOC or Tier II area Baseline piston SOI ±2 CA Non allowed area NOx 210 g/kwh p_max [bar] At constant NOx emission 165 angle allows the lowest SFOC and p_max

27 People in Wärtsilä and R&D Research Technology development Product development People are important in Wärtsilä: we need people University can be a partner Wärtsilä offer: Summer Job 3 months (fee and accommodation) Master Thesis 6 months (fee and accommodation) Post Laurea internship 6 months (fee and accommodation) Phd/cooperation with University case by case agreement 27 Wärtsilä Overview

28 Thank you for your attention! Every third ship you see is powered by us Every second ship you see is serviced by us One per cent of Global energy is produced by Wärtsilä We are the doers We make things happen We are the Engine of Industry 28 Wärtsilä G. Rizzetto