yanmar's innovation and new product development …...yanmar's innovation and new product...
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Yanmar's Innovation and New Product Development for
“Beautiful Harmony with Global Environment”
Development Department
Large Power Products Operations Division
Feb. 13, 2015
© YANMAR Co., Ltd.
Development Concept
Strategic Approach to the Environment Regulation
Challenge to the Ultra Low Fuel Consumption
Reduce GHG Optimized SCR for Engine Noise & Vibration Technology Flexible Fuel Strategy
Cycle efficiency Improvement Variable Technology Electronic Fuel Injection
Innovative Improvement of Engine Performances
Improvement of reliability Reduce Maintenance Cost Making to High power Down sizing
Boosting the "Life Cycle
Value" for Customers
Beautiful Harmony with
Global Environment
Concept
Policy
© YANMAR Co., Ltd.
Research and Development Organization
© YANMAR Co., Ltd.
Environmental Regulation Trend
© YANMAR Co., Ltd.
Technologies to Reduce Fuel Consumption
2-Stage Turbo Charging
© YANMAR Co., Ltd.
Miller Cycle : Early Suction Valve Close
吸入 空気
Suc.
Sucking in Fresh Air
吸入 空気
吸入 + 膨張 空気
圧縮 空気
Decrease of Cylinder Air Temperature just before Combustion
Exh. Suc. Exh. Suc. Exh. Suc. Exh.
Early Suc. Valve Close
Adiabatic Expansion Cooling
Compression
Nox Reduction
© YANMAR Co., Ltd.
Tier2
IMO_Tier2 Spec.
F.O.C
IMO
NO
x Strong Miller
SCR
Tier3
The Great Effect of the Strong Miller Cycle
Drastically Improved FOC
Small Size Less Urea Consumption
© YANMAR Co., Ltd.
T/C
Com
pre
ssio
n R
ati
o
Δ=20゜
2-Stage T/C
The Relationship between Miller timing and Required Compression Ratio
Miller Timing (Suction Close Timing)
Tier1
Tier2
Earlier Suc. Close (Stronger Miller)
Stronger Miller timing requires higher
compression to suck in enough suction air.
© YANMAR Co., Ltd.
I/C SUC
T
EXH
C I/C
1bar、25℃ 8bar、320℃
1bar、25℃ 4bar、200℃
4bar、50℃
8bar、140℃
×8
×4 ×2
SUC
T
C
T EXH
I/C C
Single Stage
2 Stage T/C
Turbo Charging System Layout
Described Temperature,Pressure are example
© YANMAR Co., Ltd.
Test Result (F.O.C – NOx 75%Load)
Conventional Engine
2 Stage T/C System
5gkWh
© YANMAR Co., Ltd.
Performance in Acceleration
© YANMAR Co., Ltd.
2 Stage Turbocharging System to Reduce FOC
© YANMAR Co., Ltd.
Technologies to Reduce Fuel Consumption
Electronic Unit Pump System
© YANMAR Co., Ltd.
Minor Modification from Conventional Engine Minimum Electronic Device, Easy Maintenance
Electronic Unit Pump System
© YANMAR Co., Ltd.
Main electronic control parts
© YANMAR Co., Ltd.
1) Further improvement of FOC-NOx trade-off 2) Smoke reduction (Start, Low load, Acceleration) 3) Ship handling improvement when ships come alongside the pier or leave the pier.
Merit of EUP System
© YANMAR Co., Ltd.
Engine Performance Comparison
© YANMAR Co., Ltd.
6EY22W
6EY26W
1000 2000 Output(kW)
Electronically Controlled Engine Line-Up
3000
8EY26W
© YANMAR Co., Ltd.
Development of Marine Gas Engine
© YANMAR Co., Ltd.
Gas engine merit for ships
No item description effect
Tasks to be solved NOx SOx PM CO2
1 SCR NOx deoxidation by the catalyst ◎ - - -
・Urea cost, maintenance ・Prevention of ammonia leakage
2 Scrubber Removing SOx by seawater wash △ ◎ ◎ - ・Purification of polluted
seawater
3 EGR Exhaust gas recirculation ○ - × × ・Engine durability ・Efficiency drop recovering
4 Emulsion Combustion temperature decrease by emulsion fuel ○ - ○ -
・Mass pure water production device ・Engine durability
5 Gas engine
Operation by natural gas ◎ ◎ ◎ ◎ ・Fuel supply infrastructure ・Fuel storage in ships
Gas engine is the most effective solution to reduce all exhaust emissions simultaneously.
Remarks:◎ excellent ○ good
△ not so bad × bad
© YANMAR Co., Ltd.
YANMAR gas engine history
© YANMAR Co., Ltd. Large power products operation division
YANMAR gas engine history
Start from 1983
Total 650 engines sales
■ stoichiometric combustion system
■ lean burn combustion system
■ super lean burn combustion system
© YANMAR Co., Ltd.
Development Policy of Marine Gas Engine
© YANMAR Co., Ltd.
Pure Gas Engine
© YANMAR Co., Ltd.
Specification
Engine name 6EYG26L
Engine type 4cycle water cooled
Cycle Lean burn miller cycle
Ignition Spark ignite
Bore mm 260
Stroke mm 385
Speed min-1 720
Rated output KW 1350
Fuel Natural gas
© YANMAR Co., Ltd.
Marine gas engine profile (6EYG26)
© YANMAR Co., Ltd.
Marine gas engine profile (6EYG26)
Thermal efficiency
Diesel Pure Gas Engine
© YANMAR Co., Ltd.
Marine gas engine profile (6EYG26)
6EY26 LW
6EYG26
Exhaust gas characteristic
△30%
6EYG26
△89%
NOx CO2
NO
x e
mis
sio
n r
ate
(g
/kW
h)
(D/E) (G/E) CO
2 e
mis
sio
n r
ate
(g
/kW
h)
Environmental impact material reduction of 89%
GHG gas reduction of 30%
(D/E) (G/E)
6EY26
© YANMAR Co., Ltd.
Key technology development for marine gas engine
In gas engine, fuel gas is mixed with air in the intake port. The mixture concentration would vary when the load is varied. The mixture concentration variation would strongly influence combustion stability. Yanmar developed the fuel mixture concentration control technology.
-150
-100
-50
0
50
100
150
0 30 60 90 120 150 180
時間 [sec]
推進
出力
変動
[k
W]
推進出力変動 kWLoad
Load r
ate
[%]
100
90
80
70
60
50
40
Time [sec]
© YANMAR Co., Ltd.
Fuel Rich Condition Excess Air Condition Air-Fuel Ratio
Knocking Zone Missfire Zone
En
gin
e O
utp
ut
Theo
reti
cal A
ir-F
uel
Rat
io
Rapid Deceleration
Rapid Acceleration
Combustion Characteristics of Gas Engine
© YANMAR Co., Ltd.
Engine
Throttle Valve By-pass Valve
Silencer
Inter cooler
Exhaust
Air – Fuel Ratio Control System
© YANMAR Co., Ltd.
Time(sec)
0 500 1000 1500 2000 2500 3000 3500
By-pass Valve
Throttle Valve
By-pass Valve Throttle Valve
Gen. Output
Engine
Speed
Gen
. O
utp
ut(
kW
)
En
gin
e S
pee
d(m
in-1
)
By-p
ass
Val
ve
Po
siti
on
(%)
Thro
ttle
Val
ve
Po
siti
on
(%)
By-pass Valve Position
Throttle Valve Position
By-pass
Valve
Throttle Valve
Air Fuel Ratio Control by Throttle Valve and Bypass Valve
Prompt Air Fuel Control at Load fluctuation
Air – Fuel Ratio Control
© YANMAR Co., Ltd.
Air-Fuel Ratio
E
ngin
e O
utp
ut
60
70
80
90
100
110
38 39 40 41 42 43 44 45 46 M
ethan
e N
um
ber
Norway
Alaska
Shale Gas
Qatar
Malaysia
Brunei
Indonesia
Total Calorific Value (MJ/Nm3)
Knocking Zone
Misfire Zone
Knocking Zone
Misfire Zone
Knocking Zone
Misfire Zone
A B
C
Air Fuel Ratio Control against the NG Property Variation
Technology to Compensate the NG Property Variation
© YANMAR Co., Ltd.
Effect of Fuel Calorie on Engine Performance
© YANMAR Co., Ltd.
Development of Yanmar SCR System
© YANMAR Co., Ltd.
0
2
4
6
8
10
12
14
16
18
20
0 200 400 600 800 1000 1200 1400 1600 1800 2000
IMO Regulation for NOx
80% (E.C.A)
15~22%
IMO Tier3
(IMO Tier3 Apply from 2016)
Engine Speed [min-1]
NO
x [
g/k
Wh
]
IMO Tier2
IMO Tier1
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
E.C.A Global
80%NOx Reduction:
15-22%
(Tier2)
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
E.C.A Global
80%NOx Reduction:
15-22%
(Tier2)
© YANMAR Co., Ltd.
’07 ’08 ’09 ’10 ‘11
Basic Technology Development
Catalyst Rig Test Real Engine Bench Test
SCMD PJ
Basic Technology Development
Real Ship Demonstration
Super Clean Marine Diesel PJ
© YANMAR Co., Ltd.
Rig Test Model gas mixture unit Water addition unit Temperatures control unit Reacting furnace FT-IR
Catalyst Rig Test Equipment
Optimum Catalyst Searching
Real Engine Bench Test
Reacting furnace
© YANMAR Co., Ltd.
SCR System Bench Test(6EY18ALW+SCR)
Injection Nozzle
Engine Outlet
6EY18AL
Mixer
Reactor
Urea Water
Supply Unit
Controller
© YANMAR Co., Ltd.
Prevention of the Urea deposition
Reliability Improvement
Mixer
Inner wall of exhaust pipe
Adequate Temperature
© YANMAR Co., Ltd.
NH3/NOx ratio
NO
x R
ed
uct
ion
Rat
io
%
Air Assist
Airless
(Urea Atomization ⇒Promoted Decomposition to NH3)
Test Results Example
Air Assist Injection ・Downstream Direction Injection ⇒ Spacelike Uniformity ・Continuous Injection ⇒ Timelike Uniformity
Improvement of the NOx Reduction efficiency
© YANMAR Co., Ltd.
Compact Structure
Easy Installation in Shipyard
By-Pass Integrated Structure
By-Pass
Mixer
Injector
Damper
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
E.C.A Global
80%NOx Reduction:
15-22%
(Tier2)
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
[指定海域] [一般海域]
NOx:80%減 NOx:2次規制値
E.C.A Global
80%NOx Reduction:
15-22%
(Tier2)
© YANMAR Co., Ltd.
Optimum System for Plural Engines
NO.3 D/G NO.2 D/G
NO.1 D/G
Reactor Reactor Reactor
Inj. nozzle
Nozzle Unit Nozzle Unit Nozzle Unit
Inj. nozzle Inj. nozzle
Pump unit
Controller
The controller can controls urea water
injection amounts for 4 engines.
© YANMAR Co., Ltd.
Controller
Reactor
6EY22LW
Urea Water Tank
Bench Test of Total SCR System
© YANMAR Co., Ltd.
THANK YOU FOR YOUR ATTENTION.