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