PORTFOLIO MARINE - Baumot Group · 2018-05-23 · PORTFOLIO TWINTECBAUMOT GROUP ... (TBG), a...
Transcript of PORTFOLIO MARINE - Baumot Group · 2018-05-23 · PORTFOLIO TWINTECBAUMOT GROUP ... (TBG), a...
MARINE
PORTFOLIO MARINE
DEVELOPMENT, APPLICATION AND PRODUCTION ALL FROM A SINGLE SOURCE
EGINE. EGA. SYSTEM SOLUTIONS.
PORTFOLIO
TWINTECBAUMOT GROUP
THE 360° EMISSION CONTROL COMPANY
2
COMPANY PORTRAIT
Twintec AG is the parent company of TwintecBaumot Group (TBG), a leading supplier in the
area of exhaust gas aftertreatment and engine development. In that context, TBG offers its
customers high-quality solutions in Design & Engineering and Products & Solutions as well as
Testing & Validation Services. TBG applies those products and services across a wide range
of industries in the business fields OEM (original equipment), retrofitting, aftermarket (repair,
spare parts) and catalytic coating. In so doing, it covers the entire value creation chain for
the exhaust gas aftertreatment sector. The market segments include, in particular, on-road
(e.g. cars, trucks and other commercial vehicles), off-road (e.g. construction machinery,
agricultural machinery or stationary plant) and miscellaneous applications such as maritime
or medical technology.
Within its four subsidiaries, TwintecBaumot Group has more than 380 employees and deca-
des of experience in the field of exhaust gas aftertreatment. Acquired in 2015, Kontec
GmbH, together with its subsidiary DIF (Die Ideenfabrik GmbH), represents the OEM develop-
ment arm of the company, offering low-emission engines and exhaust gas aftertreatment
systems to well-known original equipment manufacturers. Baumot AG, which was acquired
in 2014, is one of the leading providers of selective catalytic reduction (SCR) systems as
well as active and passive particulate filters in the OEM and retrofitting business sectors.
In addition, as a specialist in the development of emissions technology, Twintec Technologie
GmbH offers its customers innovative solutions for reducing exhaust gas emissions especial-
ly in the retrofitting and aftermarket segments. Through Interkat GmbH, TBG has expertise
in catalytic coating services, which are offered across a wide range of industries.
FROM POWERTRAIN TO EGAALL FROM A SINGLE SOURCE
FMEA
Production
CFD
Exhaust System
Development
Development of
Functionalities
Software Development
Project Management
Product Design with CAD/CAE
Samples and prototypes
ElectronicControl
Unit
RapidPrototyping
Strength and durability tests e.g. Hot shake
Catalyst testing (light-off, aging and poisoning)
Validation on engine bench
3D- measurements
Emission testing
Simulation of system
functionality
Set up demonstrator
vehicles
Set up engine
test benches
After treatment calibration
Measurement and Data
Acquisition
Benchmarking
System Integration Exhaust
Aftertreatment
Homologation/ Certification
FEMValidation �On road / field test
DEVELOPMENT
APPLICATIONS
DESIGN & SIMULATION
TESTING
PROTOTYPING
KEY
STRUCTURETWINTEC AG
HoldingTWINTEC AG
Holding
INTERKAT Katalysatoren GmbH
Air Cleaning Catalytic solutions,Coating
KONTEC Automotive Engineering GmbH
Sustainable Mobility, Engineering, Automotive Services
BAUMOT AG Emission Control Products,
Retrofit/Aftermarket
KONTEC Testing Validation & LAB GmbH
Design, Testing & Validation Services
KONTEC Testing Validation & LAB GmbH
Lab
KONTEC Motoren- entwicklungsgesellschaft mbH
Test Benches
DIF GmbH Emission control solutions
OEM
KONTEC Maschinenbau Engineering GmbH
Ultra Clean Air industrial applications, Industrial Services
DESIGN & ENGINEERING PRODUCTS & SOLUTIONS TESTING & VALIDATION
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TWINTECBAUMOT GROUP
MOTIVATION
In the future, it will be necessary to develop strategies and concepts to comply with future
emissions limits (SCR; DPF; CRT for the reduction of nitrogen oxide and particulates with
improvement of fuel consumption = CO2 reduction).
We are in a position to develop such concepts, and to generate and evaluate the cost/
benefit assessments and risk analyses corresponding to the customer-specific applications.
After comparing all possible scenarios, our engineers develop and apply the most effective
Exhaust Gas Aftertreatment (EGA) solution.
Marine, offroad, rail and special-purpose vehicle drive systems are subject to very strict
– and in future even more strict – exhaust emission limits relative to nitrogen oxide (NOx)
and particulates (PM). For special environmental protection zones (e.g. for marine, national
coastal waters, ports, lakes and rivers), legislation imposing significantly stricter regulations
is also currently being passed.
Systems with emission reductions of 80% and more are available for diesel main engines
and auxiliary engines. They consist of robust, maintenance-free metal SCR (selective cata-
lytic reduction) catalytic converters and metal diesel particulate filters (DPFs).
NON-ROAD EMISSIONS REGULATIONS AT A GLANCE
Stage IITier 2
2000
Stage II Stage III BStage III A
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2019
Stage V
Stage III ATier 3
STAGE III B TIER 4i
→ Stage V Emission Regulation is coming in 2019
0.4 2.0 6.0 NOx [g/kWh]
PM [g/kWh]
4.0
0.02
0.2
0.1
TIER 4
Stag
e V:
NOx
0,4
; PM
0,0
15
PN: 1
x10e
xp12
NON-ROAD EMISSION REGULATIONS
CONCEPT DEVELOPMENT
IN THE FUTURE, IT WILL BE IMPOSSIBLE TO COMPLY WITH NEW EXHAUST EMISSIONS LEGISLATION WITHOUT AN EXTERNAL EGA SYSTEM SUCH AS THE BAUMOT BNOx.
Stage IITier 2
Stage III ATier 3
STAGE III B TIER 4i
0.4 2.0 6.0 NOx [g/kWh]
PM [g/kWh]
4.0
0.02
0.2
0.1
TIER 4
EGA MEASURES
In-Engine EGR
DPF+SCR
SCR - EGA
DPF
In-E
ngin
e
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TWINTECBAUMOT GROUP
MOTIVATION
NOx emission limits are set for diesel engines depending on the engine maximum operating
speed (n, rpm), as shown in the following Table and Figure. Tier I and Tier II limits are global,
while the Tier III standards apply only in NOx Emission Control Areas.
In order to comply with the new European Stage V regulations for Non-road vehicles, vehicles
of certain power classes which currently do not require a DPF will also have to be equipped
with one in the future.
CONSEQUENCES OF STAGE V ORDINANCE FOR DPF AND SCR TECHNOLOGIES
MARPOL ANNEX VI NOX EMISSION LIMITS
CATEGORY NET POWER
(kW)
DATE CO
(g/kWh)
HCA
(g/kWh)
NOx
(g/kWh)
PM
(g/kWh)
PN
(1/kWh)
PROPULSION ENGINES — CATEGORY IWP
IWP-v/c-1 37 - 75 2019 5.00 4.70B 4.70B 0.30B -
IWP-v/c-2 75 - 130 2019 5.00 5.40B 5.40B 0.14 -
IWP-v/c-3 130 - 300 2019 3.50 1.00 2.10 0.11 -
IWP-v/c-4 300 - 1000 2020 3.50 0.19 1.20 0.02 1×1012
IWP-v/c-5 ≥ 1000 2021 3.50 0.19 0.40 0.01 1×1012
AUXILIARY ENGINES — CATEGORY IWA
IWA-v/c-1 560 - 1000 2020 3.50 0.19 1.20 0.02 1×1012
IWA-v/c-2 ≥ 1000 2021 3.50 0.19 0.40 0.01 1×1012
CATEGORY IGN. NET POWER
(kW)
DATE CO
(g/kWh)
HC
(g/kWh)
NOx
(g/kWh)
PM
(g/kWh)
PN
(1/kWh)
NRE-v/c-1 CI < 8 2019 8.00 7.50A,C 7.50A,C 0.40B -
NRE-v/c-2 CI 8 - 19 2019 6.60 7.50A,C 7.50A,C 0.40 -
NRE-v/c-3 CI 19 - 37 2019 5.00 4.70A,C 4.70A,C 0.015 1×1012
NRE-v/c-4 CI 37 - 56 2019 5.00 4.70A,C 4.70A,C 0.015 1×1012
NRE-v/c-5 All 56 - 130 2020 5.00 0.19C 0.40 0.015 1×1012
NRE-v/c-6 All 130 - 560 2019 3.50 0.19C 0.40 0.015 1×1012
NRE-v/c-7 All ≥ 560 2019 3.50 0.19D 3.50 0.045 -
TIER DATE NOx Limit
(g/kWh)
n < 130 130 ≤ n < 2000 n ≥ 2000
Tier I 2000 17.0 45 · n-0.2 9.8
Tier II 2011 14.4 44 · n-0.23 7.7
Tier III 2016 † 3.4 9 · n-0.2 1.96
PROPOSED STAGE V EMISSION STANDARDS FOR NONROAD ENGINES
PROPOSED STAGE V EMISSION STANDARDS FOR INLAND WATERWAY VESSELS
2000 400 600 800 1000 1200 1400 1600 1800 2000 22000
2
4
6
8
10
12
14
16
18
Rated Engine Speed (rpm)
Tier I Tier II (Global) Tier III (NOx Emission Control Areas)
NO
x Li
mit
(g/
kWh)
A: HC+NOx, B: 0.60 for hand-startable, air-cooled direct injection engines, C: A = 1.10 for gas engines, D: A = 6.00 for gas engines
A: A = 6.00 for gas engines, B: HC+NOx
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Unlike in oxygen oxidation, with the DPF-BAB system the oxidation of the soot begins already
at 250°C. Regeneration occurs automatically while the vehicle is in operation.
THE BENEFITS AT A GLANCE
• Reduction of particle emissions by more than 99%
• Elimination of hydrocarbons (HC) by 87%
• Reduction of carbon monoxide (CO) by more than 97%
• Low-maintenance, fully passive system with autonomous regeneration
• No additives or electric heating required
• Housing made of corrosion-free, high-temperature resistant, extra-strength stainless
steel
• Long service life due to extremely durable filter construction
• Permanent recording and monitoring of the filter function with data logger
BAUMOT DPF-BAB SYSTEM
Diesel engines ≥ 56 kW will require a DPF
as a result of the PN limitation and also an
SCR due to the NOx limits.
SCR required: BNOx-System
Diesel engines ≥ 19 kW will require a DPF as
a result of the PN limitation.
DPF required: DPF-BA / DPF-BAB
• Reduction of harmful nitrogen oxides through standard SCR systems
• Use of BAUMOT-patented NH3 generators for operation at low exhaust
gas temperatures
• Combined BNOx system for reducing nitrogen oxide and soot particles
The BNOx SCR system comprises the BAUMOT BNOx ammonia generator, which meters
the NH3 gas directly into the exhaust gas line. Unlike with conventional SCR systems, this
principle of operation eliminates the need for functionally critical hydrolysis in the exhaust
gas stream.
BAUMOT HAS THE ANSWERS TO WORLDWIDE CUSTOMER DEMANDS
BAUMOT BNOx SYSTEM
With the high-efficiency BNOx SCR system, you will raise your vehicle emissions to the li-
mits of a EURO VI and beyond! In collaboration with global OE customers, the system was
developed for series production and expanded under the same, very strict quality standards
into a dependable, package space-optimized SCR system.
THE BENEFITS AT A GLANCE
• The system works at exhaust gas temperatures as low as150°C
• NOx reduction rates of 99% are possible (test cycles)
• “Real Live Operation” NOx emissions are reduced by 94%
• Less package space is required, compact design
• No crystallization occurs in the exhaust
gas stream at low temperatures
TWINTECBAUMOT GROUP
TECHNICAL SOLUTIONS
BAUMOT’S TECHNOLOGICAL SOLUTIONS FOR LOWER EMISSIONS
DPF-BAB BNOx
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As a competent partner, we offer you the full spectrum of services ranging from minor tasks
for “extra credit” to the management and implementation of complete development projects.
We provide you with solutions which result from the innovative force, dynamism, flexibility
and reliability of our employees. Collaborative relationships with our customers are the key
to our shared success. We promise only what we can also deliver.
• Design of drive train and transmission as well as their development
• Development and adaptation of combustion, supercharging and injection systems
• Mechanical development tasks for drives and internal combustion engines
• Development and optimization of emissions aftertreatment and exhaust gas aftertreat-
ment (EGA) systems
• EGA prototypes, retrofit/optional products for niche markets (e.g. marine)
• Concepts, studies, and simulation, calculation and construction services
• Field engineering, service support, and application support as well as approval
• Consulting, training courses
• Test stand / manufacturing facilities and special tools
DESIGN CONSTURCTIONCFD, FEM,
SIMULATIONPROTOTYPING
APPLICATION, TESTING
TWINTECBAUMOT GROUP
DEVELOPMENT & DESIGN
ALWAYS THE RIGHT SOLUTION
• Engineers from mechanical engineering and vehicle construction,
vaerospace, mechatronics and many other disciplines
• Test engineers and technicians
• Graduate physicists and mathematicians
• Quality and FMEA specialists
• Industrial engineers
• Technical purchasing personnel
OUR QUALIFICATIONS
FROM INSPIRATION TO THE IDEA TO THE FINISHED PRODUCT
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THE TwintecBaumot SERVICE PACKAGE
With its highly trained staff, TwintecBaumot Group offers a complete service package.
It includes, among other things:
Installation:You can install the system yourself, but of course you can also
rely on our well-trained employees. In that case, our workshops on
four-wheels install the system at your premises. On request, your
employees can also be trained.
Cleaning:Our service package provides a complete cleaning of filters by our
partners. This service includes, among other things, the removal,
professional cleaning and check of the filter system. That ensures a
long live time and a trouble free operation of you EGA System. For
highest availability a filter exchange service can be offered which
literally eliminates the down time of your machine.
Temperature profile:If you have problems determining the temperature profile of the
engine you are retrofitting, don’t hesitate to contact us. We will be
glad to conduct these measurements and evaluate the data for you.
Technical consultation:From the handling of your query by our specialists, to the profes-
sional integration of the EGA systems, to a customer-based main-
tenance and cleaning concept, we leave nothing to chance. Whate-
ver your question, we’re always glad to provide you with advice and
assistance.
PURCHASING ADVICESO THAT PRICE AND PERFORMANCE ARE BOTH JUST RIGHT
TECHNICAL ADVICESO THAT EVERYTHING IS CLEAR
INSTALLATION TEAMSO THAT EVERYTHING WORKS
MAINTENANCE TEAMSO THAT IT ALL STAYS THAT WAY
TWINTECBAUMOT GROUP
SERVICE PACKAGE
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International regulations governing exhaust gas standards, limits and environmental protec-
tion zones for shipping are becoming increasingly complex and strict – and thereby pose an
ever greater challenge for shipbuilders and boat manufacturers.
The British luxury yacht builder Sunseeker was looking for an emissions reduction solution
for its Manhattan 52 motor yacht, so it would comply with the BSO II standard (Bodensee
Schifffahrtsordnung) and thereby obtain a permit to operate on Lake Constance.
FREE SAILING ON LAKE CONSTANCE
Using feasibility and package space studies, our engineers worked in close cooperation with
Sunseeker and Volvo Penta to integrate our BAUMOT Marine SCR system in the Manhattan
52 motor yacht. Simulations of exhaust gas back pressure, catalytic converter flows and
urea water metering kept costs and risks at a low level.
With the BAUMOT Marine SCR system, we were able to reduce NOx emissions by 92% in
the cycle, comply with the required exhaust gas standards, and deliver the first Sunseeker
OEM-integrated system.
SCR catalyst
NOx downstream
Urea Injector
Temp downstream
NOx upstream
Temp upstream
EMISSIONS REDUCTION FOR MOTOR YACHTS
BAUMOT MARINE EXHAUST GAS AFTERTREATMENT TWIN UNIT
Exhaust gas aftertreatment system for the Sunseeker Manhattan 52 motor yacht to comply with the BSO II standard
TWINTECBAUMOT GROUP
REFERENCES
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Since January 2016, the IMO MARPOL Tier III standards require an exhaust gas purification
system in the Emission Control Areas (ECA). To comply with the NOx limits, special exhaust
gas aftertreatment systems based on SCR full extrudates have already been established in
advance. These can also be used with the sulfur-containing marine fuels.
Based on the engine power ratings of several megawatts, corresponding requirements
related to material and stability must be met. For that reason, the systems are designed,
manufactured and installed according to the requirements of the classification societies
such as ABS or DNV-GL.
Optional combination with practice-proven DPF systems also enables the removal of the par-
ticles and therefore permits the use of the engines as a genset for the EPA Tier 4 legislation.
EMISSIONS REDUCTION FOR LARGE MARINE ENGINES
SCR 1SCR 2Spark arres-
tor
Wallflow DPF
Full-flow burner
(MDO-compa-tible)
T, pressure
T, NOx
T, NOx
Urea metering
SCR part with integrated silencerDPF part with active burner regeneration
EXHAUST GAS AFTERTREATMENT EGA FOR LARGE MARINE ENGINES
SCR and DPF systems for use in the seagoing ship segment with sulfur-containing fuels with integrated silencer
TWINTECBAUMOT GROUP
REFERENCES
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Together with Stadler Rail AG, we developed a diesel electric train drive unit for EURO IIIB
with hybrid function. For this project, Stadler provided us with specifications that our team
had to achieve. Based on package space and installation variant studies, including FMEA
tests, on-roof installation was identified as the optimal solution: a so-called “Hi-Pack”.
In a subsequent concept study, the performance of the cooling system and the engine/ge-
nerator were simulated relative to driving requirements, vibration and strength simulations
were prepared, and a preliminary design of the exhaust gas aftertreatment system with SCR
technology (EURO IIIB) was developed. Our previous industry-specific expertise enabled us to
refine the proposed concept further in certain respects.
FURTHER DEVELOPMENT
• Intake-, exhaust gas system; intake-, exhaust stream
independent of direction of travel (patented)
• Development of modular cooling packages with flow through
• independent of direction of travel
• Safer maintenance access
• Cover concept (protection against dirt, snow, ice)
Generator
Exhaust gas outlet
Diesel engine
Package space for catalytic converters
Exhaust gases outlet diesel engine Exhaust gases inlet exhaust gas unit
Air intake filter
POWERUNIT FOR RAILCAR POWERHEAD
DRIVE SYSTEMSDIESEL ELECTRIC TRAIN POWER UNIT FOR EURO IIIB WITH HYBRID FUNCTION
Concept and design development of the diesel electric power unit for a rail car according to the latest emission legislation EURO IIIB
TWINTECBAUMOT GROUP
HIGH QUALITY SOLUTIONS NOT ONLY FOR MARINE APPLICATION
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One of the known problems in the off-road segment is the extremely wide range of engine
and exhaust variants. In order to deal with all these different application, each EGA system
has to be specifically tailored and designed for the relevant machines, which implicates tre-
mendous development costs.
The objective, therefore, was to develop a system which can be used in over 50 different
types of vehicle with four different diesel engines (power range: 120 - 505 kW), including
certification, actual application and vehicle-specific documentation.
MODULAR SCR SYSTEM
Through the use of standardized and proven components, we were able to develop within 14
months a certified modular off-road EGA system, based on one low-power and one high-po-
wer catalytic converter, for an extremely wide range of package space configurations and
application areas (US EPA Tier4i, EURO IV and Euro Stage IIIB). Within the framework of the
development program, we were responsible not only for the delivery of all prototypes and
pre-series production models, but also for the organization and management of the individual
components and suppliers.
SCR catalyst
Slip catalyst
Variable final chamber
Pre-combustion chamber
Urea Water metering
Hydro cat.
ADDRESSING THE WIDE RANGE OF VARIANTS
EXHAUST GAS AFTERTREATMENT MODULAR SCR SYSTEM FOR THE WIDE RANGE OF OFF-ROAD VEHICLE VARIANTS
Exhaust gas aftertreatment system for over 50 different vehicle types with four different diesel engines
TWINTECBAUMOT GROUP
HIGH QUALITY SOLUTIONS NOT ONLY FOR MARINE APPLICATION
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The engines of ZETOR TRACTORS a.s. had previously complied only with the emission stan-
dard Stage III A. The objective of the development order was to have their engines meet
the latest emissions standard III B, which has been in force since 2012. Timing restrictions
imposed by imminent pending legislation necessitated a precisely coordinated development
plan, in order to ensure that the supplied product, despite limited time, would comply with
both our quality standards and those of our customer. Under those constraints, we were
able to develop and approve a passive DPF system and to make it ready for series production
within a period of just 12 months.
MILESTONES
01/12 Calculation and design of a prototype of the EGA system based on OEM data
03/12 Installation of the prototype in a test vehicle for test runs on the dynamometer and analysis of the package space situation with FARO laser
04/12 Field tests with an extremely wide range of load scenarios and subsequent evaluation and analysis
09/12 Final review of all measurement data and drawing and manufacturing of a pre-series production model
12/12 Type approval, on certified test stand
01/13 Serial delivery
STAGE IIIB-COMPLIANT EGA SYSTEM
EXHAUST GAS AFTERTREATMENT EGA SYSTEM FOR TRACTOR SERIES PRODUCTION
Development and design of an EGA system for a Stage III A engine for compliance with the Stage III B standard in the shortest possible time frame
TWINTECBAUMOT GROUP
HIGH QUALITY SOLUTIONS NOT ONLY FOR MARINE APPLICATION
Version: 16
.09
.16
TWINTEC AG
DIF DIE IDEENFABRIK GMBH KONTEC GMBH
TWINTEC TECHNOLOGIE GMBH
BAUMOT AGINTERKAT KATALYSATOREN GMBH
A COMPANY OF
TwintecBaumot GROUPPOWERTRAIN. EAT. SYSTEM SOLUTIONS.
EXHAUST AFTERTREATMENT SYSTEMS I
CATALYTIC COATING I
ON ROAD OEM ENGINEERING I
OFF ROAD OEM ENGINEERING I
MEASUREMENT AND TESTING TECHNOLOGY I
GERMANYTWINTEC TECHNOLOGIE GmbHEduard-Rhein-Strasse 21-23 | 53639 KönigswinterP. +49 (0)2244/91 80 40F. +49 (0)2244/91 83 70www.twintecbaumot.de | [email protected]
SWITZERLANDBAUMOT AGThurgauerstrasse 105 | 8152 GlattparkP. +41(0)44 . 954 80 70F. +41(0)44 . 954 34 36www.twintecbaumot.ch | [email protected]