German Weisser WÄRTSILÄ SWITZERLAND LTD. 3rd Technical Meeting 2013/14 of The Greek Section of The Society of Naval Architects and Marine Engineers

Transcription

1 German Weisser WÄRTSILÄ SWITZERLAND LTD Current Trends in the Development of Large Two-Stroke Marine Diesel Engines in the Light of Significantly Changing Market Requirements and Environmental Regulations 3rd Technical Meeting 2013/14 of The Greek Section of The Society of Naval Architects and Marine Engineers 1 Wärtsilä

2 Presentation outline General trends Regulatory framework Market requirements Product development activities Retrofit solutions for existing installations New generation of large two-stroke diesel engines Introduction of large two-stroke dual-fuel engines Technology development and research activities Emissions reduction technologies Efficiency enhancement solutions Fundamental combustion research 2 Wärtsilä

3 Regulatory framework Annex VI of MARPOL 73/78, Regulation 13 (Nitrogen oxides) NO X emissions, g/kwh IMO Tier II IMO Tier III Tier II: since , global after 2016, outside emission control areas * Introduction date still under discussion, adoption of shift to 2021 pending Tier III: after 2016, inside emission control areas nominal engine speed, rpm * * 3 Wärtsilä

4 Regulatory framework Annex VI of MARPOL 73/78, Regulation 14 (Sulphur oxides, PM) fuel sulphur content, % California EU ports global ECA year 4 Wärtsilä

5 Regulatory framework Annex VI of MARPOL 73/78, Emission Control Areas (ECAs) ECA for fuel sulphur content, extension to NOx control under consideration ECA for fuel sulphur content and NOx control (including Hawaii and part of the Carribean Sea under US authority) 5 Wärtsilä

6 Regulatory framework Annex VI of MARPOL 73/78, new Chapter 4: Energy Efficiency Design Index (EEDI) Ship design 6 Wärtsilä

7 Market requirements Market developments vessel speed and fleet utilisation* average ship speed, knots /08 11/08 anchored 05/09 11/09 ship speed idle 05/10 11/10 05/11 11/11 05/12 11/12 05/13 27% 21% 15% 9% 3% inactive percentage of fleet -21.7% * source: Bloomberg time, months 7 Wärtsilä

8 Retrofit solutions for existing installations Intelligent combustion control (ICC), closed-loop cylinder pressure adjustment Cylinder Press. Sensor Cylinder Pressure Measurement Comparison Injection Begin offset Suction air temperature Scavenge air temperature Setpoint correction Barometric Pressure Engine Load Calculated setpoint 8 Wärtsilä

9 Retrofit solutions for existing installations Slow-steaming upgrade kit (SSUK), single turbocharger deactivation 9 Wärtsilä

10 Single turbocharger deactivation Change of operating line in compressor map with turbocharger cut-out compressor pressure ratio, all T/Cs in operation 1 out of 4 cut out 1 out of 3 cut out 1 out of 2 cut out volume flow rate, m3/s 10 Wärtsilä

11 Single turbocharger deactivation Turbocharging system contribution to engine output / efficiency indicator (p scav - p amb ) / bmep ratio, all T/Cs in operation 1 out of 4 cut out 1 out of 3 cut out 1 out of 2 cut out load, % 11 Wärtsilä

12 Single turbocharger deactivation Fuel consumption improvement with turbocharger cut-out bsfc reduction from all T/Cs in operation levels relative to maximum saving, out of 4 cut out 1 out of 3 cut out 1 out of 2 cut out load, % 12 Wärtsilä

13 Single turbocharger deactivation NO X emissions impact of turbocharger cut-out NO X emissions relative to certified levels, all 3 T/Cs in operation 1 out of 3 cut out all 2 T/Cs in operation 1 out of 2 cut out load, % 13 Wärtsilä

14 Single turbocharger deactivation Cylinder pressure and temperature impact of turbocharger cut-out (25%) average gas property relative to peak value with all T/Cs in operation, all T/Cs in operation 1 out of 3 cut out temperature pressure crank angle, deg 14 Wärtsilä

15 Single turbocharger deactivation Residual content impact of turbocharger cut-out (25%) residual content relative to level with all T/Cs in operation, % 20% 40% 60% 80% 100% percentage of T/C capacity with cut-out, - 15 Wärtsilä

16 Multiple turbocharger deactivation Residual content impact of extended turbocharger cut-out (25%) residual content relative to level with all T/Cs in operation, % 20% 40% 60% 80% 100% percentage of T/C capacity with cut-out, - 16 Wärtsilä

17 Multiple turbocharger deactivation Fuel consumption impact of extended turbocharger cut-out (25%) bsfc reduction from all T/Cs in operation levels relative to maximum saving, % 20% 40% 60% 80% 100% percentage of T/C capacity with cut-out, - 17 Wärtsilä

18 Wärtsilä product portfolio Wärtsilä 2-stroke Diesel engine portfolio new Generation X Engine series Power, kw Wärtsilä Generation X Engines Wärtsilä X35 Wärtsilä X40 Wärtsilä X62 Wärtsilä X72 Wärtsilä X82 Wärtsilä X92 Wärtsilä RT-flex / RTA Engines Wärtsilä RT-flex48T-D / RTA48T-D Wärtsilä RT-flex50-B / -D Wärtsilä RT-flex58T-D ER-3 Wärtsilä RT-flex58T-D / RTA58T-D Wärtsilä RT-flex58T-E Wärtsilä RT-flex60C Wärtsilä RT-flex68-D / RTA68-D Wärtsilä RT-flex84T-D / RTA84T-D Wärtsilä RT-flex82T / RTA82T Wärtsilä RT-flex82C / RTA82C Wärtsilä RT-flex96C / RTA96C 18 Wärtsilä

19 Wärtsilä product portfolio 19 Wärtsilä

20 Generation X Engine characteristic features Optimised stroke-to-bore ratio Lower specific fuel consumption Optimum engine weight per power output Compact and service-friendly design Light but robust construction Minimum constraints in engine room layout due to favourable piston dismantling height Slim engine design for enabling minimum shaft length in modern hull designs for high propulsion efficiency Broad application range (towards low rated speeds) and extended derating capability for significant gains in total efficiency without compromises in terms of reliability 20 Wärtsilä

21 Generation X Engine target applications Handysize Bulk Carrier New W-X35 engine Product Tanker New W-X40 engine dwt 35,000 dwt 21 Wärtsilä

22 Generation X Engine target applications Panamax Bulk carrier New W-X62 engine Feeder / Panamax Container New W-X62/72 engine 60, ,000 dwt 1,600 4,500 TEU Capesize Bulk carrier New W-X72 engine Aframax / Suezmax Tanker New W-X62/72 engine 100, ,000 dwt 80, ,000 dwt 22 Wärtsilä

23 Generation X Engine target applications Very Large Crude Carrier New W-X82 engine Panamax Container New W-X82 engine 320,000 dwt 5,000 TEU Very Large Ore Carrier New W-X82 engine Large / ultra-large Container New W-X92 engine 400,000 dwt >8000 TEU 23 Wärtsilä

24 Low pressure Dual Fuel engines Wärtsilä RT-flex50DF the first commercially available of a planned complete series of low pressure Dual Fuel engines Pre-mixed lean-burn combustion Working principle: Engine operating according to the Otto process Pre-mixed Lean burn technology Low pressure gas admission at mid stroke Ignition by pilot fuel in prechamber Scavenging Compression/ gas admission Ignition à expansion 24 Wärtsilä

25 Low pressure Dual Fuel engines A few key technologies make the difference Micro-pilot + Common Rail Pre-chamber technology Gas admission system Engine Control & Automation system 25 Wärtsilä

26 Low pressure Dual Fuel engines Key technologies: Micro pilot and Pre-chamber technology Electronically controlled injectors + Common Rail fuel supply Pilot fuel (for ignition) only 1% - minimizing fuel costs Pre-chamber technology for best combustion stability and reduced emissions Option for HFO as pilot will be available Pre-chamber 26 Wärtsilä

27 Low pressure Dual Fuel engines Key technologies: Gas admission system 2 x GAV (Gas Admission Valve) per cylinder GAV actuated hydraulically Hydraulic power supply from exhaust valve servo oil system Precise gas admission control from full load to idling The key to optimized fuel/air mixture formation engine performance Double walled piping for enhanced safety 27 Wärtsilä

28 Low pressure Dual Fuel engines Key technologies: Engine control and automation system Wärtsilä UNIC based control system All essential controls in one system Individual control of combustion related parameters optimized engine performance Inbuilt Redundancy for single main engine application Safety functions related to gas operation including knock- and misfire detection Exhaust valve Control system Pilot fuel injectors 2x Gas admission valves Pilot fuel injector Gas pressure Gas admission valves Exhaust valve drive Pilot fuel pressure Engine speed/ CA-signal Engine stop signal Gas duration 28 Wärtsilä

29 Low pressure Dual Fuel engines Product specification options Optimum performance for all cylinders Limited range of operating parameter selection for reliable operation without knocking / pre-ignition and misfiring Lower maximum rating than corresponding diesel engine model BMEP Knocking Operating window Misfiring Thermal efficiency NOx emissions Air / Fuel ratio 29 Wärtsilä

30 Low pressure Dual Fuel engines Total emissions performance CO2 and SOx reduced in gas operation due to fuel composition NOx reduced to levels below Tier III PM further reduced by DF technology with Lean-burn Otto-combustion with pre-chamber ignition -25% -25% -25% -85% Tier3! -96% -99% -98% -37% 30 Wärtsilä

31 Tier III technology development NO X emission, g/kwh Tier II (global) -76.4% Tier III (ECAS only) engine speed, rpm Engineinternal measures Not-to-exceed limit for NO X under Tier III Lowsulphur fuel Scrubber fuel sulphur content, % global ECA year SCR Equivalence clause (specifically applicable for SO X control) 31 Wärtsilä

32 Tier III technology development Selective catalytic reduction (SCR) schematics 32 Wärtsilä

33 Tier III technology development Selective catalytic reduction (SCR) the inlet temperature challenge temperature before turbine, C SCR requirement all T/Cs in operation 1 out of 4 cut out 1 out of 3 cut out 1 out of 2 cut out load, % 33 Wärtsilä

34 Tier III technology development Exhaust gas recirculation (EGR) schematics 34 Wärtsilä

35 Tier III technology development Exhaust gas recirculation (EGR) the recirculation rate target 0 NO X reduction, % EGR rate, % 35 Wärtsilä

36 Energy efficiency technology development Waste heat recovery Exhaust gas economiser Ship service steam Power turbine Steam turbine G Ship service power G Aux. Engine Turbochargers Shaft motor / generator G Aux. Engine M/G Main Engine G Aux. Engine G Aux. Engine Frequency control system 36 Wärtsilä

37 Energy efficiency technology development Waste heat recovery Increase of total efficiency in the 10% range 37 Wärtsilä

38 Injection system development The RT-flex concept - basic concept kept unchanged throughout the past 10 years WECS 9520 Control system Crank angle sensor 50µ 6µ VCU Valve Control Unit (VCU) Injection Control Unit (ICU) Rail Unit: Pressurized fuel and system oil ICU up to ~1000 bar fuel HFO / MDO 200 bar servo oil and control oil 30 bar starting air 38 Wärtsilä

39 Injection system development Next generation injection system Volume controlled injection Injection Control Unit (ICU) + conventional injectors Time controlled injection New injectors with integrated solenoid control FAST injectors 39 Wärtsilä

40 Advanced development tools utilisation Computational fluid dynamics simulations of low pressure gas admission and mixing Pre-selection of concepts Evaluation of the impact of key parameters such as GAV number GAV location GAV design Gas admission pressure Gas admission timing Better understanding of relevant phenomena Preparation for the simulation of Dual Fuel combustion Gas velocity distribution during the initial phase of gas injection Lambda 40 Wärtsilä

41 Fundamental experimental investigations Combustion systems characteristics Combustion chamber components with different cooling concepts Injection from the periphery into a strongly swirling flow Non-symmetric injector design ~> strong impact of injector-internal geometry features Wide range of length and time scales Large variety of fuels fuel sulphur content, % 5 4 global ECA year recovery, % boiling point, C 41 Wärtsilä

42 Fundamental experimental investigations Spray combustion chamber test facility: Operating principle illustration and impressions of installation 42 Wärtsilä

43 Spray characterisation Parameter investigations Fuel type impact at evaporating conditions 43 Wärtsilä

44 Spray characterisation spray tip penetration, mm Parameter investigations Fuel type impact at evaporating conditions on spray tip penetration and spray angle relative to reference and orifice axis HFO MDO time after SOI, ms spray angle relative to MDO case and orifice axis, - 125% 100% 75% 50% 25% 0% HFO MDO -25% time after SOI, ms 44 Wärtsilä

45 Research collaboration The HERCULES series of projects funded by the EC Extreme Engine Combustion modelling Combustion visualization Hot Engine Multistage turbocharging Extreme Engine Combustion modelling and experimentation Combined Cycle Intelligent Turbocharging Advanced Injection, Spray and Combustion experiments and models Integrated emission control technologies Emission Reduction: WIF, HAM, EGR, CGR After-Treatment Systems, Sensors Tribology Engine Control systems Extreme EGR, SCR, Scrubber Tribology - Optimization Advanced sensing and engine control New materials and tribology Adaptive engine control and lifetime reliability 45 Wärtsilä

46 Summary The further evolution of environmental standards for marine applications in combination with changing market requirements is triggering substantial development efforts Retrofitting solutions such as the SSUK allow increasing the efficiency of marine transport without impairing environmental impact The new Generation X Engine series is responding to the market need for highly efficient engines suitable for modern ship designs based on slim hulls and low rated speeds without impairing reliability The new low pressure Dual Fuel engine design allows using gas as a fuel on large two-stroke engines without having to revert to expensive high pressure gas equipment and is inherently Tier III compliant Various technologies are applied for achieving improved overall engine and propulsion systems performance and lower emissions This involves extensive utilisation of advanced tools, which are in parallel further developed on the basis of fundamental research 46 Wärtsilä

47 Acknowledgments The PowerTech R&D as well as the Ship Power 2-stroke Product Development and Engineering departments at Wärtsilä Our partners in various research programs, in particular the HERCULES series of projects coordinated by Prof. Nikolaos Kyrtatos Public funding received for our research activities from the European Commission and various Swiss funding agencies 47 Wärtsilä

48 Thank you for your interest German Weisser Dr. sc. techn. Senior Manager Performance, Testing & Validation PowerTech Research & Development Wärtsilä Switzerland Ltd PO Box 414, Zürcherstrasse 12 CH-8401 Winterthur, Switzerland Tel