2-Stage TC s, Exhaust Gas Recirculation and Waste Heat Recovery

Transcription

1 K. Heinrich, ABB Turbo Systems Ltd., , Ship Efficiency 2011, 3 rd International Conference Advanced Turbo Charging 2-Stage TC s, Exhaust Gas Recirculation and Waste Heat Recovery December 22, 2011

2 Introduction Full load pressure ratio maximum PIC average 2-stroke average 4-stroke Year Full load pressure ratio with aluminum compressor wheel / base load application (50'000 rhrs) December 22, 2011 Slide 2 filename

3 Introduction Humid air Key technologies (mid term, IMO III) Gas / dual fuel SCR NOx -80% Many different methods for NOx reduction, -80% only proven with SCR and gas as fuel Can other methods or a combination thereof reach -80% better or at a lower cost than SCR? Emulsion Water injection 2-stage turbocharging VVT Common rail EGR December 22, 2011 Slide 3 filename

4 Introduction Compressor Pressure Ratio [-] 7.0 For Reference only 2-Stage Turbocharging TPS-F, TPL-C TPS-D/E, TPL-A/B A100-H/-M Series A100-L Series IMO I IMO II IMO III Year December 22, 2011 Slide 4 filename Remark: Pressure ratio without margins ca. 0.2 bar for most applications

5 Outline 2-stage Turbocharging Boundary conditions Special Requirements for High Pressure TC s ABB Product Development Exhaust Gas Recirculation Challenges Possible solutions Waste Heat Recovery Reasons for WHR Potential ABB Offerings December 22, 2011 Slide 5 filename

6 Outline 2-stage Turbocharging Boundary conditions Special Requirements for High Pressure TC s ABB Product Development Exhaust Gas Recirculation Challenges Possible solutions Waste Heat Recovery Reasons for WHR Potential ABB Offerings December 22, 2011 Slide 6 filename

7 2-stage Turbocharging Value 1-stage 2-stage 1-stage p sc > 5.0 Part load becomes challanging TL-Frame size as known TL-Matching needs more variants Product portfolio more complex 2-stage p sc > 6.5 Smaller frame sizes TPS-F / TPL-C A100 p C,overall Higher h TC More flexibility for matching More flexibility for valve timing necessary December 22, 2011 Slide 7 filename

8 2-stage Turbocharging For higher receiver pressure the step to 2-stage charging is necessary Charging efficiency up to75% Compressor pressure ratio up to expected Higher Dp Cyl. over cylinder Use of full potential of Miller cycle possible Increased power density of the engine Use of higher Dp Cyl. to reduce valve overlap Higher charge air pressure can be used for either NOx or bsfc reduction December 22, 2011 Slide 8 filename

9 2-stage Turbocharging Specific fuel Consumption [%] reduced bsfc 105 Reference Miller - 2-stage turbocharging 100 Reduced NOx NOx 140[%] 160 December 22, 2011 Slide 9 filename

10 2-stage Turbocharging Requirements for a high pressure TC significant differ from standard TC, new design is necessary Higher pressure at TC flanges higher forces new mounting concept new casing and flange design Higher air density at compressor inlet Higher shaft torque appropriate design necessary Higher axial thrust and thicker shaft new bearings needed Higher pressure after compressor / before Turbine Shaft sealing must be adjusted to have control over blow-by Changed requirements for thermodynamically components Compressor: Efficiency and swallowing capacity higher rated as total pressure ratio, wide maps important Turbine: High flow capacity needed Turbine casing must be redesigned as kinetic energy at turbine outlet is not a loss anymore energy is available to LP turbine December 22, 2011 Slide 10 filename

11 2-stage Turbocharging HD-TL on test rig Test rig for 2-stage turbocharging HP TC HP TC December 22, 2011 Slide 11 filename

12 We do not accept any liability for the correctness and completeness of this document. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden copyright ABB Turbo Systems 2010 Pressure ratio Fuer die Richtigkeit und Vollstaendigkeit dieses Dokumentes uebernehmen wir keine Gewaehrleistung. Fuer dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfaeltigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrueckliche Zustimmung verboten copyright ABB Turbo Systems 2010 Nous n assumons aucune responsabilité concernant l exactitude et l intégralité de ce document. Nous nous réservons tous les droits sur ce document, ainsi que sur l object y figurant. La reproduction, l usage ou la communication à des tiers sans notre autorisation formelle est illicite. copyright ABB Turbo Systems 2010 Advanced Turbocharging 2-stage Turbocharging ABB product strategy 5.0 Low pressure turbocharger 1 st generation derived from existing turbocharger types with partly newly developed thermodynamic components 4.0 EGR-off mode EGR-on mode Curve Nr. 7 Product development for 2 nd generation LP TC s ongoing 3.0 High pressure turbocharger 1 st generation radial design finalized c tot/tot First 2 radial frame sizes released for sales 2.0 Product development for 2 nd generation axial and radial HP TC s ongoing 1.0 * sv. V 298 in m 3 /s Volume flow rate December 22, 2011 Slide 12 filename A B B IB21-66e CTX100 SM05-2 TX54 TT18 TA Replaced by: Replaces: HZTL

13 Outline 2-stage Turbocharging Boundary conditions Special Requirements for High Pressure TC s ABB Product Development Exhaust Gas Recirculation Challenges Possible solutions Waste Heat Recovery Reasons for WHR Potential ABB Offerings December 22, 2011 Slide 13 filename

14 Exhaust Gas Recirculation Why EGR: EGR is one method to reduce the NOx level Technology known from automotive engines All components needed for NOx reduction mounted to the engine no additional space needed No additional media needed (e.g. urea) HP EGR is thermodynamically more efficient compared to low pressure EGR With HP EGR the main compressors are protected from the exhaust gases Possible solutions: EGR blower with electric motor or EGR turbocharger December 22, 2011 Slide 14 filename

15 Exhaust Gas Recirculation Challenges: Fuel Quality EGR not feasible with HFO Switch in between ECA and non-eca (EGR on vs. EGR off mode) Reliability of EGR compressor Additional cooler capacity needed Additional control elements needed December 22, 2011 Slide 15 filename

16 e do not accept any liability for the correctness and mpleteness of this document. e reserve all rights in this document and in the information ontained therein. Reproduction, use or disclosure to third arties without express authority is strictly forbidden copyright ABB Turbo Systems 2010 We do not accept any liability for the correctness and completeness of this document. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden We do not accept any liability for the correctness and completeness of this document. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden Fuer die Richtigkeit und Vollstaendigkeit dieses Dokumentes uebernehmen wir keine Gewaehrleistung. copyright ABB Turbo Systems 2010 Fuer dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfaeltigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrueckliche Zustimmung verboten copyright ABB Turbo Systems 2010 Pressure ratio copyright ABB Turbo Systems 2010 Fuer die Richtigkeit und Vollstaendigkeit dieses Dokumentes uebernehmen wir keine Gewaehrleistung. Fuer dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfaeltigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrueckliche Zustimmung verboten copyright ABB Turbo Systems 2010 Fuer die Richtigkeit und Vollstaendigkeit dieses Dokumentes uebernehmen wir keine Gewaehrleistung. Fuer dieses Dokument und den darin dargestellten Gegenstand behalten wir uns alle Rechte vor. Vervielfaeltigung, Bekanntgabe an Dritte oder Verwertung seines Inhalts sind ohne unsere ausdrueckliche Zustimmung verboten copyright ABB Turbo Systems 2010 Nous n assumons aucune responsabilité concernant l exactitude et l intégralité de ce document. Nous nous réservons tous les droits sur ce document, ainsi que sur l object y figurant. La reproduction, l usage ou la communication à des tiers sans notre autorisation formelle est illicite. copyright ABB Turbo Systems 2010 Pressure ratio Nous n assumons aucune responsabilité concernant l exactitude et l intégralité de ce document. Nous nous réservons tous les droits sur ce document, ainsi que sur l object y figurant. La reproduction, l usage ou la communication à des tiers sans notre autorisation formelle est illicite. copyright ABB Turbo Systems 2010 Nous n assumons aucune responsabilité concernant l exactitude et l intégralité de ce document. Nous nous réservons tous les droits sur ce document, ain que sur l object y figurant. La reproduction, l usage ou la communication à des tiers sans notre autorisation formell est illicite. copyright ABB Turbo Systems 201 Advanced A B B Turbocharging Exhaust Gas LP Stage, Recirculation Case O WG CAT/MaK 6M43 2-stage NP Compressor c tot/tot EGR-on mode EGR-off mode EGR-off mode EGR-on mode Curve Nr. 7 HP Compressor c tot/tot 4.0 EGR-off mode, HP-turbine BP HP-turbine bypass EGR-on mode EGR-off mode EGR-off mode, HP-turbine BP 3.0 EGR-off * sv c tot/tot EGR-off HP-turbine bypass 2.0 * sv 1.0 December 22, 2011 Slide 16 filename A B B 2.0. V 298 in m 3 /s IB21-66e CTX100 SM05-2 TX54 TT18 TA 1 1 * sv Volume flow rate Replaced by: Replaces: 1.0 A B B HZTL SuMa CV12 CT75 DB09 CA17 CH01 Stabi 6mm 1 Basis: VK Replaced by: Replaces: HZTL. V 298 in m 3 /s Volume flow rate

17 Outline 2-stage Turbocharging Boundary conditions Special Requirements for High Pressure TC s ABB Product Development Exhaust Gas Recirculation Challenges Possible solutions Waste Heat Recovery Reasons for WHR Potential ABB Offerings December 22, 2011 Slide 17 filename

18 Waste Heat Recovery Reasons to apply Waste Heat Recovery WHR Increasing fuel prices Reduction in total fuel consumption Reduction in exhaust emission CO 2 NOx SOx Particulars Green Vessel Competitive advantage December 22, 2011 Slide 18 filename

19 Waste Heat Recovery Gas - Power turbine Generator - Shaft motor or without shaft motor Steam & Gas - Waste heat boiler - Steam turbine - Power turbine & steam turbine Generator - Shaft motor December 22, 2011 Slide 19 filename

20 Mech. output [%] Advanced Turbocharging Waste Heat Recovery η TCEngine = required min. turbocharger efficiency Turbocharger efficiency η TC [%] + 1% h TC + 8% output P T = 4.0 P T = 3.5 P T = 3.0 η TC 100% December 22, 2011 Slide 20 filename

21 Turbocharger efficiency [%] Advanced Turbocharging Waste Heat Recovery Dh = 2% A100-L TPL..-B Compressor pressure ratio [-] Power increase by about 20% or NO x reduction ("2-stroke Miller") Reduction of fuel consumption (with power turbine) A100-L December 22, 2011 Slide 21 filename

22 Waste Heat Recovery PTL kW mech. output PTL kW mech. output Power turbine in combination with high efficiency A100-L offers good potential for WHR December 22, 2011 Slide 22

23 Conclusion Driven by increasing engine power density, call for reduced specific fuel oil consumption and tighter emission regulations a strong trend for higher charge air pressure can be seen Several technologies for emission reduction are under investigation. Many of them call for adjusted charging systems To meet the market requirements ABB develops it product portfolio accordingly First two stage turbocharging systems are introduced to the market already. The product range will be expanded as needed. ABB supports emission reduction technologies by adjusted charging systems Performance of actual A100-L turbo chargers has excellent potential to apply waste heat recovery systems December 22, 2011 Slide 23 filename

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