improving engine gino rizzetto performance through ...unina.stidue.net/universita' di...
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1 © Wärtsilä G. Rizzetto
Improving engine Performance through innovation and design
WÄRTSILÄ Italia S.p.a.
Gino RizzettoEngine Performance Manager, Testing & Performance
2 © Wärtsilä G. Rizzetto
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
List of content
3 © Wärtsilä G. Rizzetto
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
List of content
4 © Wärtsilä G. Rizzetto
WÄRTSILÄ in brief: our offering
EnginesPropulsors
Ship Powersystems
O&M
PowerPlants
Competitors’engines
OEMservices
Shipservices
WE ARE A LEADING SUPPLIER OF FLEXIBLE POWER PLANTS FOR THE
DECENTRALIZED POWER GENERATION MARKET
Merchant Offshore Cruiseand Ferry Navy Special
Vessels
OUR OFFERING COVERS ALL KEY SHIPPING SEGMENTS
5 © Wärtsilä G. Rizzetto
WÄRTSILÄ in brief: network services
Workshop
Product Company
Network
Trieste, ItalyW26, W38, W46,
W46F, W50DF, W64
Bermeo, SpainW34SG, W50DF
Winterthur, Switzerland2-stroke: RT-flex, RTA
Vaasa, FinlandW20; W32/32DF/34SG,
Ecotech
Havant, UK; Slough, UK
Face Seals,Synthetic Bearings Toyama, Japan
Rubber Seals &Bearings
Stord, NorwayElectrical &
Automation systems
Trondheim, NorwayFrequency converters
Rubbestadneset, Norway
CPP, Gears Espoo, FinlandFuel cells, Ecotech
Drunen, The NetherlandsCPP, FPP, Thrusters
Turku, FinlandEcotech
6 © Wärtsilä G. Rizzetto
WÄRTSILÄ in brief: Global R&D and T&P locations
- Define and validate new concepts- Provide tech. information on products- Develop expertise
7 © Wärtsilä G. Rizzetto
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
List of content
8 © Wärtsilä G. Rizzetto
New emissions requirements impact on fuel consumption and smoke
Wärtsilä engine portfolio
…. 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
4 - stroke 2 - stroke0 5 10 15 20 25
Wärtsilä 64
Wärtsilä 46F
Wärtsilä 38Wärtsilä 32
Wärtsilä Vasa32Wärtsilä 26Wärtsilä 20
Wärtsilä 34SG-BWärtsilä 34SG
Gas and Dual fuel engines
Diesel engines
(MW)
SG
Wärtsilä 46
0 5 10 15 20 25
Wärtsilä 64
Wärtsilä 46F
Wärtsilä 38Wärtsilä 32
Wärtsilä Vasa32Wärtsilä 26Wärtsilä 20
Wärtsilä 34SG-BWärtsilä 34SG
Gas and Dual fuel engines
Diesel engines
(MW)
SG
Wärtsilä 46
Wärtsilä 46GDWärtsilä 32LNGD Dual fuel engines
Wärtsilä 50DFWärtsilä 32DF
GD
DF
Wärtsilä 46GDWärtsilä 32LNGD Dual fuel engines
Wärtsilä 50DFWärtsilä 32DF
GD
DF
Wärtsilä 50SG
Gas and Dual fuel engines
4s Wärtsiläengines
0
2
4
6
8
10
12
14
16
18
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100
Rated engine speed (rpm)
NO
x (g
/kW
h)
9 © Wärtsilä G. Rizzetto
New emissions requirements impact on fuel consumption and smoke
Wärtsilä engines
Tier I - 130 kW - New ships 2000 Tier II - 130 kW - New ships 2011
Revised Marpol Annex VI (9.10.2008)
Tier III - 130 kW - New ships 2016 in designated areas
2011 Tier2 limit14.4 – 9.0 g/kWh ISO NOx
2000 Tier1 limit17.0 – 11.3 g/kWh ISO NOx
2016 Tier3 limit3.4 – 2.3 g/kWh ISO NOxOnly designated area (ECA)(Baltic Seat, North Sea, Costal Water)
-20%
-80%
Cycle\Load 100 75 50 25 10E2/E3 29% 55% 11% 5% 0%D2 11% 40% 32% 16% 2%
NOx weight factor
Cycle NOx
Tier 3 load point limit < 1.5 NOx cycle average5.1 – 3.4 g/kWh ISO NOx
NOx emission control drives engine performance
development
10 © Wärtsilä G. Rizzetto
New emissions requirements impact on fuel consumption and smoke
11 © Wärtsilä G. Rizzetto
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:
High Exhaust Gas temp. according to the fuel sulphur content for SCR use
To limit the SCR UREA consumption NOxmust be reduced at the engine stage
Fuel quality to avoid scrubber or particulates filter
12 © Wärtsilä G. Rizzetto
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 (SOC @ 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
89
1011121314151617181920
175 180 185 190 195
BSFC, ISO corr 42.7MJ/kg
NO
x, IS
O c
orr [
g/kW
h]
15
13.5
12
235 230 220 210
FIRING PRESSURE av. cock
SOI
85% timing swing 568 rpm – NOx-SFOC
16.5
3g/
kWh
4 g/kWh
eps 16.2
eps 16.8
+ 5 - 5 - 15+ 10
13 © Wärtsilä G. Rizzetto
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 reduction
• limited penalty in SFOC
• at constant firing pressure
– Retarded timing for NOx emission deteriorates the Smoke Emission (AVL FSN)
smok
e [F
SN
]
NOx [g/kW]
Smoke vs NOx Emission
SOI swing - 10% load
SOI swing - 25% load
SOI swing - 35% load
Wärtsilä 8L46F-TP PROTO3, 1200kW/cyl,
0 20 40 60 80 100
NOx reduction potential [%]
IMO3IMO2
High pressure TC sys. (2-stage) Low NOx combustion tuning EGR system Charge air humidification Water Fuel Emulsion Direct Water Injection NOR system Gas and Dual Fuel tech.
Com
bina
tion
need
ed
to m
eet T
ier3
targ
et
14 © Wärtsilä G. Rizzetto
New emissions requirements impact on fuel consumption and smoke
NOR (Nitrogen Oxide Reducer)
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)
Exhaust scrubber + above combinations (HFO operation)
Example of possible combinations (4-stroke)
HOW TO GET CLOSER TO TIER3 ?
15 © Wärtsilä G. Rizzetto
New emissions requirements impact on fuel consumption and smoke
2-stage charging system + EGR
Smok
e em
issi
on [F
SN]
engine load [%]
2stage + EGR
2stage
NO
x em
issi
on [g
/kW
h]
engine load [%]
2stage + EGR
2stage
IMO3
SFO
C [g
/kW
h]
engine load [%]
2stage + EGR
2stage
Exhaust gas recirculation provides big step on NOx reduction, but SFOC and smoke deteriorations have to be paidThe driving goal for Tier3 is the best compromise between:
CAPEX vs OPEXReliabilityComplexity of the solution
20 40 60 80 1000 20 40 60 80 1000
20 40 60 80 1000
16 © Wärtsilä G. Rizzetto
CO2
NOx
SOx
Particulates
Dual-Fuel enginein gas mode
Dieselengine
0
10
20
30
40
50
60
70
80
90
100
Emissionvalues [%]
New emissions requirements impact on fuel consumption and smoke
The facility to reach Tier3 has to pay:• On board gas system • Reformer technology• Liquid mode
efficiency
Dual Fuel engine / Fuel conversion + DF engine
Development drivers:• Output and efficiency • Liquid mode
performance• Low methane number
operation• Methane slip
17 © Wärtsilä G. Rizzetto
IMO TIER 2 (2009)Efficiency change to TIER 1: -1to +1%Output change to TIER 1: 0 to -4%
IMO TIER 2 (2012)Efficiency change to TIER1; +1,5 to +3,5 %Output change to TIER 1: 0 % to +10%
IMO TIER 2 (2009) -30% NOxEfficiency change to TIER1 +3%Output change to TIER 1: 0 %
IMO TIER 3, based on 2-stage technologyEfficiency change from TIER 2: 0 to -5%Output change from TIER 2: 0 to -5 %
IMO TIER 3, after treatmentEfficiency change; +0 to 3%Output change: +0 to 15 %
IMO TIER 3, gas and gas conversionEfficiency change from TIER 2: 0 to +2 % Output change from TIER 2: 0 to -10 %
2010 2012 2014 2016
IMO
Tie
r 2Pr
oduc
t de
velo
pmen
t IM
O T
ier 3
Prod
uct
deve
lopm
ent
2008
IMO Tier II in force IMO Tier III in force
New emissions requirements impact on fuel consumption and smoke
Max SFOC penalty 1%Max output penalty 4%
Improved Tier II concept, higher output / efficiency
High pressure charging system
Focus on engine and aftertreatment integration
Focus on technical feasibility and OPEX
Focus on: - Liquid mode eff. - Gas mode output
18 © Wärtsilä G. Rizzetto
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
List of content
Pressure ratio - NOx trade off
456789
10
<<<<< Earlier IVC
PIC
020406080100120
NOx
%
Flexible valve timing: how to combine low NOx, low smoke with high efficiency engine
VIC Variable 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
300,0 320,0 340,0 360,0 380,0 400,0 420,0 440,0 460,0 480,0 500,0 520,0 540,0°CA
Reference
TDC BDC
300,0 320,0 340,0 360,0 380,0 400,0 420,0 440,0 460,0 480,0 500,0 520,0 540,0
TDC BDC
VIC OFF
VIC ON
CA deg
Inlet valve lift
VIC detail VIC effect
0 10 20 30 40 50 60 70 80 90 100 110
Sm
oke
emis
sion
(FS
N)
Engine Load (%)
Wärtsilä 8L46F-TP PROTO3, 1200kW/cyl, 600rpm TPL76-C33 CV33CT60CD06CA13 TV11TT40TF15TN05TA14
eps 16.8 - DPPpiston -12x0.72x165°- 286 - symm scav - Jan. 10 - CS - VICVIC off
20 © Wärtsilä G. Rizzetto
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
Smoke benefit during transient operation
Improved load pick-up with reduced
speed drop
7L32C without VIC. Load ramp from 0% up to 100% in 10s
7L32C with VIC. Load ramp from 0% up to 100% in 10s
Time [s]
spee
d [rp
m]
Improved speed recovery with VIC
VIC on
21 © Wärtsilä G. Rizzetto
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
List of content
22 © Wärtsilä G. Rizzetto
High pressure TC to lower NOx emission keeping high engine efficiency: Diesel
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
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
Up to 2% lower SFOC OR10%...15% higher output
Compared to the current supercharging status, higher boost pressure availability at
higher TC efficiency level would provide:
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
• Worse load pick-up
Charge air receiver
AC
HP turbine
HP compr.
LP turbine
LP compressor IC
nTC LPt0 p0t1 LP
p1 LP p2 LP
t2 LP
p1 HP
t1 HP
p2 HP
t2 HP
p3
nTC HP
t3
p5 HP p5 LP
t5 HP
t5 LP
p6 LP
t6 LP t4
NO
x [g
/kW
h]
SFOC [g/kWh]
6L20CR 2stage - eps 16 - 27.3 bar bmep @ 1000 rpm
Miller 33 IMO Tier2
Miller 96
Miller 83
1 g/
kWh
5 g/kWh-15
-10
-5
0
5
0 200 400 600 800 1000 1200 1400
delta
BSF
C [
g/kW
h]
power output [kW/cyl]
W46F 2stage 600rpm - expectation at IMO tier2
Reference
2-stage
23 © Wärtsilä G. Rizzetto
High pressure TC to lower NOx emission keeping high engine efficiency: Diesel
2stage TC IMO2:Expected performance on variable SOI engine:
Power output 1200 1320kW/cyl (+10%)
SFOC reduction on E2 cycle ~ -10g/kWh
2stage TC towards IMO3:50% NOx reduction at constant SFOC:
1- stage reference
-50%
IMO2 with 2 stage Towards IMO3 with 2 stage
24 © Wärtsilä G. Rizzetto
CO2
NOx
SOx
Particulates
Dual-Fuel enginein gas mode
Dieselengine
0
10
20
30
40
50
60
70
80
90
100
Emissionvalues [%]
High pressure TC to lower NOx emission keeping high engine efficiency: Gas
Development drivers:
Limiting factors Solutions
Output and efficiency
• Knock margin• Firing pressure• Available boost level
• Strong Miller timing• New hardware platform• New TC generation
Liquid mode performance
• Low comp. ratio• High NOx emission
• Strong Miller timing & higher compression ratio• New TC generation
Low MN operation
• Knock margin • Strong Miller timing• New TC generation
High boost pressure system is a key factor as well in the Gas engine development
High Pressure TC on DF engine
25 © Wärtsilä G. Rizzetto
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
List of content
26 © Wärtsilä G. Rizzetto
Combustion process optimization to improve NOx emission
Baseline pistonSOI ±2°CA
NOx g/kWhSF
OC
g/k
Wh
-3/-4 g/kWh
Tier II area
NOx BSFC, ISO corrected
89
1011121314151617181920
175 180 185 190ISO SFOC 42.7 MJ/kg [g/kWh]
ISO
NO
x g/
kWh
eps 16.8 - DPPpiston -12x0.72x165° - 85%
eps 16.8 - DPPpiston -12x0.72x163° - 85%
eps 16.8 - DPPpiston -12x0.72x161° - 85%
eps 16.8 - DPPpiston -12x0.72x159° - 85%
Wärtsilä 8L46F-TP proto3, 1200kW/cyl, 600rpm
NOx ISO corrected - p_max normalised
89
1011121314151617181920
180 190 200 210 220 230 240 250p_max [bar]
ISO
NO
x g/
kWh
eps 16.8 - DPPpiston -12x0.72x165° - 85%
eps 16.8 - DPPpiston -12x0.72x163° - 85%
eps 16.8 - DPPpiston -12x0.72x161° - 85%
eps 16.8 - DPPpiston -12x0.72x159° - 85%
Wärtsilä 8L46F-TP proto3, 1200kW/cyl, 600rpm
SFOC > target
Non allowed area
Spray angle swing: influence on SFOC/NOx at constant firing pressure
• At constant firing pressure 165° angle allows the best SFOC or…• At constant NOx emission 165° angle allows the lowest SFOC and p_max
165° 163°
161°
159°
• CFD+engine verification for optimized comb. chamber
• Piston top shape & fuel spray pattern
• Eps, SFOC – NOx, SFOC – p_max, exhaust temp.,
piston heat flux, soot are considered
1g/kWh
• Injector geometry optimization (CFD and experimental) is a part of the process
27 © Wärtsilä Overview
People in Wärtsilä and R&D
• 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
Research
Technology development
Productdevelopment
28 © Wärtsilä G. Rizzetto
”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”
Thank you for your attention !