Dual fuel engine development and design
Mika Ojutkangas Senior Manager Wrtsil Ship Power Merchant
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Wrtsil Mika Ojutkangas
Dual-fuel engine - operating principle
Gas mode:
Otto principle Low-pressure gas admission Pilot diesel injection
Ex.
In. Ex.
In. Ex.
In.
** * * *** * * * * *** *
* * * **** *
Intake of air and gas
Compression of air and gas
Ignition by pilot diesel fuel
Ex.
In. Ex.
In. Ex.
In.
Diesel mode:
Diesel principle Diesel injection
Intake of air
Wrtsil Mika Ojutkangas
Compression of air
Injection of diesel fuel
Wrtsil Dual-Fuel Engine Portfolio
20DF 6L20DF 1.0 MW 8L20DF 9L20DF 34DF 6L34DF 9L34DF 12V34DF 16V34DF 20V34DF 50DF 6L50DF 8L50DF 9L50DF 12V50DF 16V50DF 18V50DF 0
Wrtsil Mika Ojutkangas
1.4 MW 1.6 MW 2.7 MW 4.0 MW 5.4 MW 7.2 MW 9.0 MW 5.85 MW 7.8 MW 8.8 MW 11.7 MW 15.6 MW 17.55 MW 5 10 15
Higher output for 60Hz / Main engines
Dual-fuel engine characteristics
20DF
High efficiency Low gas pressure Low emissions, due to:
High efficiency Clean fuel
34DF
Lean burn combustion
Fuel flexibility
Gas LFO (DF) Bio Fuel HFO (TF)
50DF
Double wall gas piping
The engine room is a gas safe area
Three engine models
Wrtsil 20DF Wrtsil 34DF
Wrtsil Mika Ojutkangas
Wrtsil 50DF
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Wrtsil Mika Ojutkangas
DF Gas Trip (GAS -> MDO) on 100% load - instantaneous
No loss of power or speed at sudden transfer from gas to MDO (example 18V50DF, 17.1MW)
Wrtsil Mika Ojutkangas
Dual-Fuel advantages
Main advantages of the Dual-Fuel 4-stroke engine compared to SG (spark ignited): Simple mechanical propulsion application Full power available in both fuel operation modes Load application capability Load application capability is equal between dual-fuel and SG Dual-fuel can change to liquid fuel in case instant abnormal high load / unload requirement (no shut-down) Changeover point can be programmed to suit application
Improves safety
100 90 Engine 80 speed 70 60 50 40 30 20 10 0
DF & SG Normal load application
DF change to liquid mode
DF Big instant load application (trips to liquid) SG Instant, abnormal high load application
DF & SG Instant load application
SG
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DF
Time
The DF vessel concept
The DF engines provide safety and redundancy, inherent reliability of the diesel engine allows a simple installation
Single gas tank and gas feed system allowed
No duplicate (diesel) gensets for main propulsion
LNG
MDO
Wrtsil Mika Ojutkangas
Emissions Reduction Future Pathway
Win + Win Emissions & Cost Reduction
Best Available Technology
Paradigm Shift: Market moves to emissions reduction as key owner selection size criteria and away and cost from historical efficiencies based on heavy fuel.
Mid Term Both paths are not selected to the same vessel due to SCR PM Trap Other Long Term Fuel Cell, New technology
Wrtsil Mika Ojutkangas
Marine Fuel for Emission Control Areas (ECA)?
Wrtsil Mika Ojutkangas
The DF vessel concept
The DF engines will only use gas fuel inside ECA areas Safety and reliability of the traditional diesel engine remain No SCR unit, Tier III compliant No SOx Scrubber, No sulphur in fuel MDO as backup fuel
LNG
MDO
Wrtsil Mika Ojutkangas
The DF vessel concept, outside ECA
The DF engines can be run on HFO outside ECA areas No SCR unit No SOx Scrubber Optional HFO flexibility when allowed
LNG
MDO
Wrtsil Mika Ojutkangas
The DF vessel concept, outside ECA
HFO can be used to extend range ensure availability of fuel improve total economy
Optional HFO flexibility when allowed
LNG
MDO
Wrtsil Mika Ojutkangas
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Wrtsil Mika Ojutkangas
Wrtsil is a system integrator
SYSTEM INTEGRATION
Wrtsil Mika Ojutkangas
Wrtsil LNGPac
A complete and modularized solution for LNG fuelled ships
A. Storage tanks B. Evaporators C. Dual-Fuel Main engine D. Dual-Fuel Aux engines E. Bunkering station(s) F. Integrated control system
Wrtsil Mika Ojutkangas
A C
What is a gas valve unit?
The main functions of the GVU: Pressure regulation to the engine, according to engine load. One unit is required per engine. Safety (block valves, filters, inerting and venting) A GVU is located between the LNG storage system and the engine Max. recommended distance from engine is 10 m
Wrtsil Mika Ojutkangas
Installations today
Forced ventilation Single wall fuel gas pipe Double wall fuel gas pipe Gas safe area Gas hazardous area
Engine room, gas safe area Air in *
GVU room, Ex Zone 1 Fuel Gas Tank GVU
Air out
* to double wall fuel gas feed pipe annular space
Wrtsil Mika Ojutkangas
Conventional GVU installed in a separate space
A separate GVU room add complexity and installation costs:
Require dedicated compartment, including explosion duct from the room Lightning and other equipment has to be Ex Zone 1 compatible Airlock is required between GVU room and surrounding space Recommended maximum distance from GVU to engine 10 m, difficult to achieve in practice
Wrtsil Mika Ojutkangas
Gas Valve Unit in enclosure
Main features
Can be located in the same engine room still being compliant with IGC and (future) IGF codes. Integrated ventilation system when combined with LNGPac Compact design and easy installation Lower total investment cost compared to a conventional GVU installation Is delivered in a containerized form (plug-and-play concept)
T E
P T
P T
P T
T E
P T
P T
P T
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Installation with GVU enclosure
Forced ventilation Double wall fuel gas pipe Gas safe area Enclosure
Engine room, gas safe area Air in G V U
Saved space: -GVU room -Airlock between the GVU room and the engine room Savings -Less Ex certified equipment -Easy installation at yard, ready module
Fuel Gas Tank
Wrtsil Mika Ojutkangas
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Wrtsil Mika Ojutkangas
TARBIT PROJECT
Vessel delivery date Vessel typology Owner Ship Builder Flag Class 17.09.2007 25'000 dwt Chemical tanker Tarbit Shipping AB Shanghai Edward Shipbuilding Co Ltd Sweden Germanischer Lloyd
2011
DWT GT Displacement Length p.p. Length o.a. Keel To Mast Height Draught Breadth Extreme Breadth Moulded Speed
24783 ton 17757 ton 33788 ton 166.99 m 177.02 m 44.85 m 9.7 m 26.3 m 26 m 16 kn
Main facts
Vessel owned by Tarbit Shipping AB (Sweden)
Operated under time charterer by Statoil
Sailing in Norwegian waters
Conversion partially financed by Norwegian Nringslivets Hovedorganisasjon (Confederation of Norwegian Business and Industry) Designed by Wrtsil Ship Design (former Skipskonsulent )
Built by Edward Shipbuilding Co Ltd (Hudong-Zhong JV)
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Main engine conversion TODAY
2 x W6L46B 5850 kW each
CPP PTO 1500 kW
WRTSIL 8L20 1200 kW
CPP WRTSIL 8L20 1200 kW
PTO 1500 kW
Tomorrow
2 x 6LW50DF 5700 kW each
Wrtsil Mika Ojutkangas
Many different firsts
First Dual-Fuel engine in Mechanical drive application First LNGPac delivered by Wrtsil First Gas Valve Unit in enclosure
First Dual-Fuel engine marine conversion
First Dual-Fuel single main engine approval
LNGPac LNG
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Scope of conversion Scope of supply
Ship Design Engine conversion Gas tanks; LNGPac system (2 x 500m3) Gas piping (single and double walled) Bunkering system Gas supply units Torque meter for power measurement Exhaust system Fire-fighting upgrade Gas detection system Electrical system
Additional
NOx measurement during sea trial DF and LNGPac training for personnel
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Placement of equipment
LNG tanks
Wrtsil Mika Ojutkangas
Placement of equipment
NG pipes
Water/Glycol
LNG tanks
Cold box
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Placement of equipment
Ventilation
NG
GVU
Wrtsil Mika Ojutkangas
Placement of equipment
GVU
GVU
Wrtsil Mika Ojutkangas
References
Sold engine conversions worldwide
Project Name
Tintrofa Almeida Tearfil Century Power Denizli Cerestar Batamindo I Batamindo II Batamindo III Arenko Crescent Textile Mills Bilag Lucky Cement Lucky Cement Gera Manuara Christino Roha Aksa Takna Cengiz
Country
Portugal Portugal Portugal Pakistan Turkey German Indonesia Indonesia Indonesia Turkey Pakistan India Pakistan Pakistan Brazil Brazil Brazil Turkey Peru Turkey
Year
2004 2004 2005 2005 2006 2006 2005 2006 2007 2006 2007 2007 2008 2008 2009 2009 2009 2009 2009 2010 1x 1x 1x 3x 1x 1x 5x 7x 4x 2x 1x 1x 3x 7x 5x 5x 5x 6x 4x 7x
Conversion type
12V32 HFO 12V34SG 12V32 HFO 12V32DFc 12V32 HFO 12V32DFc 12V32 HFO 12V32DFc 16V46 HFO 16V50DF 16V46 HFO 16V50DF 18V32 HFO 18V32DFc 18V32 HFO 18V32DFc 18V32 HFO 18V32DFc 18V32 HFO 18V34SG 16V32 HFO 16V32DFc 18V32 HFO 18V32DFc 12V46 HFO 12V50DF 18V32 HFO 18V32DFc 18V46 HFO 18V46GD 18V46 HFO 18V46GD 18V46 HFO 18V46GD 18V46 HFO 18V46GD 18V32 HFO 18V34SG 18V46 HFO 18V50DF
Status
Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Finalized Ongoing Ongoing Ongoing Ongoing Finalized Ongoing
Wrtsil Mika Ojutkangas
Contents DF Technology The DF advantage News The Tarbit project Viking Line
Wrtsil Mika Ojutkangas
Viking Line 2800 Pax Cruise Ferry
The industry's most environmentally sound and energy efficient large passenger vessel to date.
Main particulars: Overall length: Breadth, moulded: Cruising speed Passengers: Class: Ice class: In service: Shipyard: Ship Owner: 214.0 m 31.8 m 22 knots 2800 LR 1A 2013 STX Finland Oy Viking Line
Wrtsil Mika Ojutkangas
Viking Line 2800 Pax Cruise Ferry
Wrtsil integrated scope of supply:
Main Engines: 4 x Wrtsil 8L50DF (DE) Total output: 4 x 7600 kW GVU in enclosure Natural gas is the most environmentally sound fuel today and with Wrtsil's dual fuel engines this ferry will be able to sail without restrictions in SECAs and NECAs. LNGPac 200 2 x 200 m3 Integrated tank and aux. rooms Bunkering system, Safety systems Cold recovery for HVAC The cold recovery system brings operational savings and overall increased vessel efficiency.
Wrtsil Mika Ojutkangas
Viking Line 2800 Pax Cruise Ferry
Wrtsil integrated scope of supply: FPP (Stainless Steel) 2 x 10 500 kW Shaft lines, Seals & Bearings Bow Thruster 2 x 2 300 kW Stern Thruster 1 x 1 500 kW The propellers are designed with the lowest possible pressure impulses for superb vibration control.
Compact Silencer System (CSS) Silent operation is important for passenger comfort, but also for the sailing route; through the islands of the Turku and Stockholm archipelagos.
Wrtsil Mika Ojutkangas
Dual-Fuel engines - References
New orders announced Sept. 2010
Power plant 28 installations 84 engines >640 000 running hours LNG carriers >68 installations 254 engines > 900000 running hours OSV - FPSO 8 installations 28 engines >226 000 running hours
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Summary
Wrtsil DF technology benefits Simple installation due to inherent redundancy; No need to install separate backup power. Possible to use a single gas tank on small vessels. Saved space, time and money with enclosed gas valve unit; No separate GVU room needed. Market leading, proven technology.
Wrtsil Mika Ojutkangas
WRTSIL
Mika Ojutkangas mika.ojutkangas@wartsila.com
Wrtsil Mika Ojutkangas
