Air Emissions Management with two-stage turbocharging
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A presentation at BIMCO's Maritime Environmental Efficiency Management Seminar on Air Emission Management for marine engines. The presentation looks at how the two-stage turbocharging technology enhances an engine's efficiency to allow lower fuel consumption and lower thermal load.
![© ABB Group / ABB Turbocharging
June 8, 2015 | Slide 2 | filename
Advanced Turbocharging
Power2 – two-stage turbocharging
Basic potential
§ Pressure ratios of up to 12
§ Turbocharging efficiencies
above 75%
DpCylÞDhTCÞ
tintercooling 25°C
tintercooling 60°C
Pressure ratio [-] Þ
75%
hTC = 65%
68%
77%
Power2
1-stage
Texh const
§ With higher pressure ratio …
Þ … increase in hTC
Þ … increase in DpCyl
Þ … more compact 2-stage
system](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
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- 1. Air Emission Management Power2 & VCM § BIMCO panel at Nor Shipping / Oslo, 2015-06-02
- 2. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 2 | filename Advanced Turbocharging Power2 – two-stage turbocharging Basic potential § Pressure ratios of up to 12 § Turbocharging efficiencies above 75% DpCylÞDhTCÞ tintercooling 25°C tintercooling 60°C Pressure ratio [-] Þ 75% hTC = 65% 68% 77% Power2 1-stage Texh const § With higher pressure ratio … Þ … increase in hTC Þ … increase in DpCyl Þ … more compact 2-stage system
- 3. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 3 | filename Advanced Valve Train Technology VCM – valve control management Conventional (fixed) valve timing § Reduced valve lift with enhanced Miller Þ increasing throttling losses Þ limited Miller timing Crank angle [°CA] Þ InletvalveliftÞInletvalveliftÞ reduced lift increased lift cycle-to- cycle VCM Fixed VT VCM § Steep closing flanks Þ increased valve lift Þ advanced Miller timing § Variation from cycle-to-cycle Þ replacing conventional control elements
- 4. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 4 | filename Marine Propulsion From conventional to Power2 & VCM Principles § Accommodate high pressure ratios to benefit from high turbocharging efficiencies § strong Miller timing enabled by VCM Þ low NOx for Diesel Þ increased knock margin for gas § high engine power density § Use VCM as the air management control replacing conventional elements (e.g. waste gate, bypass, throttle valves) DpCylÞ 75% hTC = 65% 68% 77% BmepÞ Schematic view IMO II mod. Miller TC pressure ratio [-] Þ strong Miller State-of-the-art1-stage Power2 1-stage Texh const
- 5. Remarks: based on simulations, NOx rather indicative 1 g/kWh © ABB Group / ABB Turbocharging June 8, 2015 | Slide 5 | filename Marine Propulsion Example: Medium Speed Diesel – FPP Reference: • 25 bar bmep @ 750 rpm • 3-pulse, mod. Miller, 1-stage Power2 & VCM: • Engine power up 15% • Const. pZmax and lv at full load • Change from pulse to MPC • Miller optimization for optimum efficiency (Fuel opt.) and minimum NOx (NOx opt.) • Later IVC towards lower loads with VCM (reduction of Miller effect) D to ref. Bsfc E3 / 50% NOx E3 Ref. / IMO II Fuel opt. -3.1% / -4.2% -30% / -38% NOx opt. -0.5% / -1.9% -45% / -51% 5 g/kWh Reference Power2 & VCM Fuel opt. NOx opt.
- 6. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 6 | filename Marine Propulsion Example: Medium Speed Gas – n = const Reference: • 22 bar bmep @ 750 rpm • e = 12, mod. Miller, 1-stage • lv control with WG Power2 & VCM: • Engine power up 20% @ const. pZmax / bmep and lv at full load • Strong Miller, repl. WG by VCM • Increase compression ratio to same end of compression temperature Þ hE +3.2%pts ® 6.5% / 12.5 g/kWh lower bsfc at full load Reference IVC-20°CA epsilon+2.5 IVC-35°CA Bmep+20% IVC-45°CA epsilon+3.5 IVC-50°CA 100% load VCM Power2 Remarks: based on simulations
- 7. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 7 | filename Marine Propulsion Power2 and VCM – summary Power2 and VCM enable significant … • … lower NOx for Diesel engines of 30 to 60% vs, IMO II concepts • … lower fuel consumption in Gas and Diesel engines of ±5%pts • … higher engine power densities w/o increased of thermal loading Further potentials: • Increased robustness in regard to gas qualities (lower MN w/o de-rating) • Fuel and NOx optimized operating modes incl. switching capabilities (operation in ECA vs. non-ECA) • Enhanced engine operating range (e.g. torque rise) • Improved Diesel mode in Dual Fuel engine • Improved transient capabilities
- 8. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 8 | filename Marine Propulsion Scared of 2-stage …? Removal of compressor casing Removal of air inlet Removal of insulation Removal of air outlet flange connection Removal of oil connections Removal of cartridge group Removal of air inlet casing together with the insert wall Removal of cartridge group Service steps … 1-Stage Power2
- 9. © ABB Group / ABB Turbocharging June 8, 2015 | Slide 9 | filename The Power of Power2 …
- 10. © ABB Group June 8, 2015 | Slide 10