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DEVELOPMENT IN ENGINE

TECHNOLOGY

FOR THE FUTURE MARINE


ELIAS BOLETIS
Director, Programs & Technologies MARKET
Propulsion

WÄRTSILÄ CORPORATION

1 © Wärtsilä 19 November 2010


- Strategy - How we see the future

- Engine development and trends

- Concluding remarks

2 © Wärtsilä 19 November 2010


- Strategy - How we see the future

- Engine development and trends

- Concluding remarks

19 November 2010
Changes in customer demands:
 Total cost of ownership
 Environmental footprint
and global awareness
 System integration approach
 Reliability

14 © Wärtsilä 19 November 2010


Wärtsilä Diesel Engine Portfolio (1)
20 4L20 0.8 MW
6L20 1.2 MW
8L20 1.6 MW
9L20 1.8 MW

26 6L26 2.0 MW
8L26 2.7 MW
9L26 3.1 MW
12V26 4.1 MW
16V26 5.4 MW
18V26 6.1 MW
32 6L32 3 MW
7L32 3.5 MW
8L32 4 MW
9L32 4.5 MW
12V32 6 MW
16V32 8 MW
18V32 9 MW
20V32 9.2 MW Only for Power Plant use
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0 5 10 15
Wärtsilä Diesel Engine Portfolio (2)
38 6L38 4.35 MW 10 15 20
8L38 5.8 MW
9L38 6.5 MW
12V38 8.7 MW
16V38 11.6 MW
46 12V46 12.6 MW
16V46 16.8 MW
18V46 Only for Power Plant use 17.55 MW

46F 6L46F 7.2 MW


7L46F 8.4 MW
8L46F 9.6 MW
9L46F 10.8 MW
12V46F 14.4 MW
14V46F 16.8 MW
16V46F 19.2 MW
20V46F Only for Power Plant use 23 MW
64 6L64 12.9 MW
7L64 15.1 MW
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08L64 5 10 15 17.2 MW
Wärtsilä 46F

W46F references
• 18 engines / 126 cylinders successfully in operation
on 10 vessels
• 8 engines / 160 cylinders successfully in operation
in powerplants
• More than 180’000 cumulative running hours
• More than 16’000 running hours on one engine
Order book
• 82 engines on order for marine and powerplant
installations
Performance development progress of the W46F:
Engine W46F engine W46 engine
NOx level IMO Tier2 IMO Tier2
Power per cyl kW/cyl 1200 1050
Engine speed rpm 600 514
SFOC with pumps 85% load g/kWh 182 185
SFOC with pumps 75% load g/kWh 191 193

17 © Wärtsilä 19 November 2010


Wärtsilä 12V32E

• Increased power output:


– 580 kW / cylinder @ 750 rpm, i.e.
16% higher output compared to current W32
• Main design actions:
– pmax increased to 230 bar
– New reinforced engine block, crankshaft
and cylinder head
– Turbocharging system with increased
pressure ratio
• Additional features:
– arctic option, i.e. -50 °C suction air
– engine inclination of 25 degrees in all directions

18 © Wärtsilä 19 November 2010


Wärtsilä Auxpac 26

• The Auxpac 26 extends the


standard range of low voltage
generating sets for commercial
vessels
• Key feature is the compact design
with common base frame and fully
integrated auxiliary components
(pumps, valves, filters, coolers)
• All connections available at free
end for easy installation and
maintenance

19 © Wärtsilä 19 November 2010


Wärtsilä 6L20L locomotive genset

• Engine characteristics
– Nominal output 1025kW
– Speed range 350-1000rpm
– Fast load response
– For wide range of altitudes
and ambient conditions

• Engine features
– Designed as flange-mounted
genset
– Common rail fuel injection
system
– Variable valve timing
– Low inertia, high pressure ratio turbocharger
– Closed crankcase ventilation system with oil mist separation
– Fully integrated advanced UNIC C3 engine control system

20 © Wärtsilä 19 November 2010


Wärtsilä dual-fuel (DF) engines – Wärtsilä 50DF

LNG vessels equipped with W50DF engines


2250
Provalys and Gaselys
DF-electric LNG Carrier 56 vessels with an
2000
Gaz de France installed power of
Alstom Chantiers de l’Atlantique
2x Wärtsilä 12V50DF + 2x6L50DF 2000 MW 1750
Total 72’000 running hours for 2 ships

Installed power [ MW ]
1500
Gaz de France Energy
DF-electric LNG Carrier
1250
Gaz de France
Alstom Chantiers de l’Atlantique
4x Wärtsilä 6L50DF 1000
Total 42’000 running hours

750
British Emerald
DF-electric LNG Carrier 500
BP Shipping
Hyundai Heavy Industries 250
2x Wärtsilä 12V50DF + 2x9L50DF
Total 38’000 running hours
0
2006 2007 2008 2009 2010 2011
Estimated ship delivery date

21 © Wärtsilä 19 November 2010


Wärtsilä 34DF for offshore applications

• The Wärtsilä 34DF applies the latest dual fuel engine


concept on the Wärtsilä 32 platform, replacing the
32DF engine
• Applicable as generating set as well as direct
mechanical drive (CPP)
• Fuel flexibility and redundancy with dual fuel
technology
– IMO Tier II-compliant in diesel mode
– IMO Tier III-compliant in gas mode
• Closed-loop cylinder pressure control

Wärtsilä 34DF
Cylinder bore / stroke [mm] 340 / 400
Engine speed [rpm] 720 / 750
Output per cylinder [kW] 435 / 450
Available cylinder configurations 6L, 9L, 12V, 16V & 20V

22 © Wärtsilä 19 November 2010


Latest dual fuel engine development: Wärtsilä 20DF

• Latest member of the Wartsila DF family


• W20DF design is based on proven W20
engine platform to ensure reliability and
maximum communality for easy conversion
• Applicable as marine genset and main
engine
• Otto principle with a common rail pilot fuel
system for gas ignition
• Embedded UNIC C3 automation system
• Efficiency of >40% in gas mode
Wärtsilä 20DF
Cylinder bore / stroke [mm] 200 / 280
Engine speed [rpm] 1000 / 1200
Output per cylinder [kW] 146 / 176
Available cylinder configurations 6L, 8L, 9L

23 © Wärtsilä 19 November 2010


Wärtsilä dual-fuel (DF) engine portfolio
20DF 6L20DF 1.0 MW

8L20DF 1.4 MW

9L20DF 1.6 MW  Paper s #95,


#112, #212
34DF 6L34DF 2.7 MW

9L34DF 4.0 MW

12V34DF 5.4 MW

16V34DF 7.2 MW

20V34DF 9.0 MW

50DF 6L50DF 5.85 MW Higher output for 60Hz / Main engines

8L50DF 7.8 MW

9L50DF 8.8 MW

12V50DF 11.7 MW

16V50DF 15.6 MW

18V50DF 17.55 MW
0 5 10 15
24 © Wärtsilä 19 November 2010
Wärtsilä 34SG spark ignited engine

• The cylinder output of the Wärtsilä 34SG raised to 500kW/cyl.


• With this new C2-output stage the cylinder output is on a par
with the Wärtsilä 32 power plant diesel engine
• Available in 9L, 16V and 20V cylinder configurations for a
maximum unit output of 10 MW

Wärtsilä 34SG
Cylinder bore / stroke [mm] 340 / 400
Engine speed [rpm] 720 / 750
Output per cylinder [kW] 480 / 500
Available cylinder configurations 9L, 16V, 20V

25 © Wärtsilä 19 November 2010


Wärtsilä 34SG spark ignited engine

• The Wärtsilä 34SG-C2 engine applies closed-loop cylinder


pressure control for control and monitoring of firing pressure,
knocking and
combustion quality
• Benefits:
– Improved detection of
knocking and misfiring
– 30% reduction in peak
pressure fluctuations
– Future potential to
support automatic power
and de-rating control as
well as improved
diagnostics for
preventive maintenance

 Papers #95, #106

26 © Wärtsilä 19 November 2010


Automation & Controls

UNIC – an integrated automation platform


for embedded applications
UNIC population by 2010
• Introduced in 2004, meanwhile fully rolled out Systems
on all Wärtsilä medium speed engines 2000
UNIC C3: 150 inst.
UNIC C2: 600 inst.
• Based on experience with WECS 2000 - 8000 1000
UNIC C1: 1300 inst.

• Developed and optimized for demanding


Year
industrial machinery, for robustness, capacity 2002 2004 2006 2008 2010

and flexibility
• Validated in rig tests (HALT = Highly Reliability improvement
accelerated lifecycle test), full scale engine Failures
tests in the laboratory and field installations per
reference
• Prepared for future developments period

Year
2002 2004 2006 2008 2010

 Paper #10,
#207, #209

27 © Wärtsilä 19 November 2010


Wärtsilä Common Rail Injection
CR2 – the next generation common rail system to meet
future requirements

Injector with integrated Capability for 1800 bar


accumulator and flow pressure and multiple
fuse injections

Benefits of CR2:
Multi cylinder pump  No servo oil circuit, reduced complexity
 Less pressure oscillation
 Increased robustness of the concept
 Improved flexibility and performance
optimisation potential

 Paper #119 Mini rail with safety and circulation valve

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Emission reduction focus

Different options to comply with emission legislation schemes

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Wärtsilä NOx reduction package for IMO Tier 2 / 3




IMO TIER 2

Improved combustion system
Valve timing optimization (Miller timing)
High-efficiency turbo charging system Reference vs. Miller


TDC BDC

Similar concept for 2-stroke and 4-stroke

Roller lift
300,0
300,0 320,0
320,0 340,0
340,0 360,0
360,0 380,0
380,0 400,0
400,0 420,0
420,0 440,0
440,0 460,0
460,0 480,0
480,0 500,0
500,0 520,0
520,0 540,0
°CA
Reference

IMO TIER 3 (Emission Controlled Areas)


• SCR catalyst and scrubbers for exhaust gas
aftertreatment
• Different alternative concepts under
evaluation:
2-stage turbocharging + flexible valve timing
+ exhaust gas recirculation (EGR) or wet
technologies (e.g. charge air humidification)
• Gas as a marine fuel (DF / SG engines)

30 © Wärtsilä 19 November 2010


2-stage turbocharging on medium-speed engines

Validation results of the first 2-stage turbocharging installation on a


full-scale Wärtsilä 20V32 engine

Power output kW/cyl 500

BSFC g/kWh -8

NOx Vol-ppm 576

Exhaust gas deg C < 540


temperature
before turbine
Turbocharging % < 74
efficiency

 Paper #73, #82, #210

31 © Wärtsilä 19 November 2010


Emission aftertreatment technologies

Development of emission aftertreatment and efficiency technologies


in Delivery Center Ecotech

Emission reduction:
NOx CO and HC Catalysts: SCR, oxidation catalysts
reduction

Emission reduction:
SOx and PM
Flue gas desulphurisation (scrubbers),
reduction electrostatic precipitators

Emission reduction:
Emission Emission monitoring systems
monitoring

Total economy:
Energy
Energy efficiency: combined cycles, combined
efficiency heat and power, chillers

32 © Wärtsilä 19 November 2010


Test results from the Wärtsilä SOx scrubber

Wärtsilä scrubber on Neste Oil MT “Suula” with a


4R20 auxiliary engine rated at 680 kW
• Tests in 2008-2009, including certification
• Tests on HFO with 3.4% sulphur and HFO of
1.5% sulphur

Test results:
• SOx removal > 99% in all operating
conditions
• Particle matter reduction: 30 – 60%

33 © Wärtsilä 19 November 2010


Discussion Items

- Strategy - How we see the future

- Engine development and trends

- Concluding remarks

19 November 2010
Thank you for your kind attention

40 © Wärtsilä 19 November 2010