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ABB Turbo Systems’ interest incombustion research
Warum interessiert sich ein Turbolader-Hersteller für die Verbrennungsforschung?
German Weisser / Tagung Verbrennungsforschung in der Schweiz, 9. September 2015
Main purpose:§ Provide pressurized air for the
combustion process by utilizingresidual energy of the exhaust gas
§ Increase the specific power output ofthe engine
Key performance figures:§ Achievable compressor pressure ratio§ Turbocharger efficiency§ Specific airflow§ Load response capabilities
Customer benefits:§ 300% more power§ Up to 10% lower fuel consumption§ Up to 60% lower NOx emissions
TurbochargingTechnology
© ABB Group / Turbocharging10/16/2015 | Slide 2
ABB TurbochargingIndustries and applications we serve
MarineMarine
container ships,tankers, bulkers,
LNG carriers,dredgers, yachts,cruise & ferries,tugs, coastal &river shipping
We offer turbochargers and technologies for engines >500 kW (up to 28’000 kW per turbocharger)We offer turbochargers and technologies for engines >500 kW (up to 28’000 kW per turbocharger)
Oil & gasOil & gas
onshore drilling,production and
pipelines,offshore drilling,
FPSO,transportation andsupply & support
vessels
PowerPower
peak and baseload electrical
power generation(EPG), back uppower plants,nuclear powerplants (NPP)
MiningMining
off-highway trucks,excavators
10/16/2015© ABB Group / Turbocharging
| Slide 3
RailRail
locomotives
About 200’000 turbochargers in operation: 60% marine, 30% power, 10% remaining industriesAbout 200’000 turbochargers in operation: 60% marine, 30% power, 10% remaining industries
ABB TurbochargingOur vision: To be our customers’ very first choice
Our product and service customers are:
§ Engine builders for large diesel and gas engines
§ End users of large diesel and gas engines in all industries
10/16/2015© ABB Group / Turbocharging
| Slide 4
ABB Turbocharging
§ Engine power density has been constantly on the rise in recentyears
§ Requirements for turbochargers have therefore also increased
§ Higher air density in the cylinderà Higher compressor pressure ratio
§ Lower thermal load and improved engine scavengingà Higher turbocharging efficiency
Historical evolution of engine power density
© ABB GroupOctober 16, 2015 | Slide 5
2013
?bmep
years
VTR..0VTR..4
TPLA200-LπComp
ABB Turbocharging
Single-stage turbocharginglimited by
§ High turbocharger efficiencyin combination with
§ High-pressure ratios and
§ High specific flow capacity
Turbocharging system development - what’s next?
© ABB GroupOctober 16, 2015 | Slide 6
Two-stage turbochargingoffers
§ Virtually no limit in overallpressure ratio
§ High turbocharger efficiencywith intercooling
ABB TurbochargingHistorical evolution of key performance parameters
© ABB GroupOctober 16, 2015
55.00
60.00
65.00
70.00
75.00
80.00
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
peak efficiency ηTC [%]
2.00
4.00
6.00
8.00
10.00
12.00
14.00
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
available pressure ratio πc
| Slide 7
single stage
single stage
55.00
60.00
65.00
70.00
75.00
80.00
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
peak efficiency ηTC [%]
2.00
4.00
6.00
8.00
10.00
12.00
14.00
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
available pressure ratio πc
two stage
two stage
ABB TurbochargingR&D – Striving for quantum leaps
© ABB Group / Turbocharging10/16/2015 | Slide 8
§ More than 5% of Turbocharging's revenue invested annually in R&D§ Approximately 200 scientists and engineers§ Close collaboration with industry partners, universities and research
institutes§ R&D activities enhance functional performance and cost efficiency while
increasing reliability of our products and solutions§ Pushing the boundaries of enabling technologies, through further
investment into testing, or simulation technology (e.g. aero-,thermodynamics, structure mechanics, acoustics)
§ First in developing technologies in the industry – two-stage turbocharging,TPR with VTG, highest pressure ratio in single-stage turbocharging
§ R&D brings together market specific products for different applicationsacross varying operational environments while ensuring product durability
ABB Turbocharging
§ Limited fossil fuel resources and need to curb greenhouse gasemissions
§ Efficiency of power generation units to be further improved§ Quality of liquid fuels declining§ Increasing shift towards gaseous fuels§ Utilisation of ICE-based power plants changing
§ Further tightening of emissions regulations
§ More advanced emissions control technologies required§ More flexible control of engines and associated systems needed
§ Turbochargers are a (vital) component of an engine, which in turn is apart of a complete power generation / propulsion unit
§ Optimisation of matching engine / turbocharging system required§ Optimisation of performance of the entire system essential
General trends and market drivers
© ABB GroupOctober 16, 2015 | Slide 9
ABB Turbocharging
§ Proprietary engine and systems simulation suite ACTUS
Simulation capabilities
© ABB GroupOctober 16, 2015 | Slide 10
Turbocharging systems developmentDiesel engine NOx/BSCF trade-off, 1- and 2-stage TC
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 11 |filename
λ l =0.90 λ l =0.79 λ l =0.70
λ l =0.59
λ l =0.90
λ l =0.79 λ l =0.69 λ l =0.59
λ l =0.53
90
95
100
105
110
115
120
20 40 60 80 100 120
NOx [%]
BSF
C[%
]
pzmax=240 bar
pzmax=240 bar
1-stage, eta TL=67%, pme=25 bar2-stage, eta TL=73%, pme=28 barlambda V mean=2.1TTI=530 oC
phi VA max~720 oCA
admissible domain PiV<5.2 (TPL-C)additional admissibledomain PiV<5.6 (A100)
reference
Turbocharging systems developmentDiesel engine limitations
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 12 |filename
Turbocharging systems developmentDiesel engine limitations
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 13 |filename
Turbocharging systems developmentGas engine limitations
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 14 |filename
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0.200 0.700
Air/Fuel Ratio
Mea
nEf
fect
ive
Pres
sure
THC
rich
NOx
NOx Limit
Mechanical Limit
ApplicableOperatingWindow
lean
Knocking
Misfiring
Turbocharging systems developmentGas engine limitations
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 15 |filename
Naturally aspirated Otto engine Turbocharged Otto engine
Turbocharging systems developmentGas engine control alternatives
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 16 |filename
Exhaust Gas Receiver
Air Gas Mixture Receiver
Fuel Gas
Exhaust
Engine
Exhaust Waste Gate EWG
Intake
VTG
Throttle ValveTHR
CompressorRecirculation BYP
VVTTurbocharger TC
1-stage turbocharging
Throttle valve THRVariable valve timing VVTCompressor recirculation BYPVariable turbine geometry VTGExhaust gas waste gate EWG
Turbocharging systems developmentGas engine control alternatives
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 17 |filename
Line bTHRVVT
Line aEWGVTG
Line cBYP
Note: With VVT, both engine and turbocharger work on lineb in steady-state conditions.
Turbocharging systems developmentGas engine control alternatives
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 18 |filename
- transient behaviour
Turbocharging systems development
§ Much better load acceptance thanks to lower inertia of 2-stage system(Island operation example with 4 bar load steps)
Gas engine transient behaviour, 1- and 2-stage TC
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 19 |filename
Turbocharging systems developmentExhaust gas recirculation strategies for diesel engines
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 20 |filename
§ Classic donor cylinder (1)§ EGR blower (2)§ EGR turbocharger (3)§ Semi-short route (4)§ Semi-short route with
donor cylinders (5)
1
2
3
4
5
Turbocharging systems developmentExhaust gas recirculation strategies for diesel engines
© ABB Group / ABB TurbochargingOctober 16, 2015 | Slide 21 |filename
§ Optimisation potentialValidation options
5.3% 4.9%
3.4%3.9% 3.6%
3.1%2.7% 2.7% 2.6%
semi-short route semi-short donor egr tc
splitoptimised
split & Milleroptimised
EGRbaseline
4.4%3.6% 3.5%
0.1% 0.1%0.7%
EGR on EGR off
SSRDonor
SSR EGR TC
ABB Turbocharging
§ Better understanding of phenomena when approaching the limits ofengine combustion systems§ Combustion and emissions formation characteristics of Diesel
engines at extreme Miller conditions§ Ignition and combustion of premixed gas engines when
approaching the knock and misfiring limits§ Particularities of combustion and emissions formation in transient
operationand how to control them
§ Models for the description of those phenomena§ Sufficiently accurate§ Computationally efficient
to allow fast and reliable predictions when integrating them into ourproprietary simulation platform ACTUS
§ Options for the experimental evaluation of new concepts
Requirements towards combustion research
© ABB GroupOctober 16, 2015 | Slide 22
ABB Turbocharging
§ Ability to cooperate with leading engine developers / systemintegrators in designing most advanced solutions
§ Ability to consult and support engine manufacturers with lessprofound knowledge in developing products fit for the market
§ Effectiveness of product planning on the basis of well-foundedprojections of the potential of such products
§ Turbochargers§ Advanced turbocharging systems§ New products
§ Ability to devise solutions for existing installations that offer a realbenefit to the customers owning / operating those installations
§ Securing of challenging and inspiring jobs and work environmentfor our present and future employees
Expected benefits of successful combustion research
© ABB GroupOctober 16, 2015 | Slide 23