Efficient engines with ultra-low emissions for ships:

The HERCULES project

Nikolaos P. Kyrtatos

Professor of Marine Engineering NTU Athens Hercules Coordinator

Presentation at Ship Efficiency: The Event – London 8-9th September 2015

HERCULES is developing new technologies for marine diesel engines:

• Increase engine reliability

• Reduce emissions gaseous particulate

• Increase engine efficiency Reduce fuel consumption Reduce CO2 emissions Reduce lifecycle cost

HERCULES timeline

I.P. HERCULES – Consortium

WARTSILA Finland Oy. WARTSILA Schweiz AG

MAN DIESEL SAS WARTSILA NEDERLANDS BV

32 Partners. Industrial 60% - Universities/Research Inst. 40%

External Associates Group

MAN Diesel & Turbo SE (DE, DK)

HERCULES - B Consortium

HERCULES Management

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Overview of I.P. HERCULES-(A) Workpackages

STRUCTURE OF THE WORK

54 Subprojects 18 Tasks 9 Workpackages

WP9

FRICTION

WP8 EXHAUST

AFTERTREATMENT

WP7 EMISSION

REDUCTION (2) WP6 EMISSION

REDUCTION (1)

WP4 ENERGY

RECOVERY

WP3 TURBOCHARGING

WP2 COMBUSTION

WP1 EXTREME ENGINE

WP11 CONTROL

From HERCULES- A,B,C to HERCULES-2

I.P. HERCULES (A) Targets and Achievements

CIMAC 2007 Congress: Best paper award !

Two-stage turbocharged 4-stroke engine

H - A: Variable turbocharging

Extreme Engine Extreme Engine

Combustion modelling Combustion

modelling and experimentationCombustion

visualization

Hot Engine

Multistage turbocharging

Emission Reduction: WIF, HAM, EGR, CGR

After-Treatment Systems, Sensors

Tribology

Engine Control systems

Combined Cycle

Intelligent Turbocharging

Extreme EGR, SCR, Scrubber

Tribology -Optimization

Advanced sensing and engine control

Advanced Injection, Spray and Combustionexperiments and

models

Integrated emission control

technologies

New materials and tribology

Adaptive engine control

and lifetime reliability

PTI / PTO

T/C with variable turbine nozzle vanes

T/C with variable compressor inlet guide vanes

H-B Advanced intelligent turbocharger

Optical cylinder covers for 2-stroke

H-B Combustion process visualization development

H-B Emission reduction - Exhaust Gas Recirculation and After-treatment

High Pressure Boiler installed on 4T50ME-X

Marine Diesel Engines for Tier III & beyond

OBJECTIVE Target VALUE Achieved

EFFICIENCY 3%

within project

1% • Low temperature Combustion

2% • Combustion optimization

1.5% • Intelligent engine / Advanced plant control • Health monitoring technologies

EMISSIONS

80%

within project

PM 50% THC 50% NOx 80%

• DF-engine

• EGR

• Combustion optimization / multi-fuel

• Aftertreatment (DPF, EGR)

• Charging (VGT)

RELIABILITY (lifetime)

++ • Sensors, Monitoring , Adaptive Control

+ • Tribology improvements

HERCULES-C Objectives and Achievements

WP 3: Injection, Spray Formation and Combustion

Optical cylinder head with optical access and viewing range

H-C :Substantial reduction in fuel consumption

H-C Models for flow and cavitation applicable to large engine injectors

Nozzle bore eccentricity investigation

CFD investigations of the nozzle internal flow

dense core

spray contour

Shadow-imaging PDA

droplet size and velocity

H-C Complete variability of turbocharging system combined with EGR equipment

H-C Retain high performance over plant lifetime

Cylinder lubrication concept for optimized emissions

Predicted Oil Film Thickness

Standard Design

Optimized Design

H-C Models for flow and cavitation applicable to large engine injectors

Instantaneous in-nozzle cavitation pattern for a two hole nozzle layout CFD tool for evaluation of flow coefficients and for describing in-nozzle flow and cavitation

H-C Combined SCR and Scrubber units

Sequential SCR concept

H-C Thermal Barrier Coatings

• Two- stage TC (+VG) (+VVT) • Increased Pmax, BMEP • Autotuning + Injection optimisation • Cylinder cut-out • PTI / PTO, Flexible T/C

• Waste Heat Recovery , Hot Engine

• SCR • Water-In-Fuel, Water injection • EGR • Scrubbers

• Tribology, Materials

24

HERCULES- A,B,C Marine Engine Technologies for the future

1. LOWER FUEL CONSUMPTION 2. EMISSIONS COMPLIANCE 3. OPERATIONAL RELIABILITY & FLEXIBILITY

TARGETS

HERCULES-2 Work

Near Zero Emissions

Flexible Fuel

Adaptive for Lifetime

Advanced Materials

Links from H-A , H-B and H-C to H-2

End of presentation. Thank you for your attention.