Advanced Primary Measures Improve Diesel Emissions, Power and Consumption
In an ongoing development project MAN Diesel is achieving high power density and considerable reductions in both fuel consumption and exhaust emissions on its latest four-stroke, medium speed engines using only “primary measures”. In engine emission reduction technology primary measures denotes modifications to the basic, fully integrated features of any diesel engine – fuel injection, turbocharging, governing, valve timing, etc. Their variation influences the combustion process and hence power output, fuel consumption and the formation of noxious exhaust emissions. Part and parcel of the engine as delivered, combating emissions using primary measures involves neither additional work for the engine operator nor the use of additional equipment and consumables. NOx A major emphasis of all combustion engine emissions legislation is oxides of nitrogen (NOx). Since temperature peaks during combustion are responsible for over 90% of NOx formation, MAN Diesel’s work with primary measures targets the elimination of such areas in the combustion chamber without incurring fuel consumption penalties or, if possible, at improved fuel efficiency. Hence, in recent years, on engines with progressively lower NOX emissions, MAN Diesel has adopted a range of interacting primary measures targeting the combination of cooler combustion per se, making temperatures in the combustion chamber more homogeneous and cooling the combustion air entering the cylinder. To improve fuel air mixing the measures include improved re-entrant piston bowls; low swirl inlet ports; higher compression ratios; higher fuel injection pressures and improved injector nozzle spray patterns. Measures to reduce combustion temperatures comprise revised fuel injection timing, improved charge-air cooling and the combination of revised “Miller Cycle” valve timing and high efficiency, high pressure turbocharging. Technology Packages Central to MAN Diesel’s latest, very substantial reductions in NOx combined with improved power output and fuel consumption are further improvements in the interaction of separate measures thanks to advanced electronic control, and a further intensification of the “Miller Cycle” made possible by the introduction of two-stage turbocharging giving pressure ratios up to 7:1.

11 June 2009

MAN Diesel Group Teglholmsgade 41 DK-2450 Copenhagen SV DENMARK www.mandiesel.com Group Marketing Further information: Peter Dan Petersen Tel.: +45 33 85 14 70 peterd.petersen@man.eu Graphics and images: Mia Glarborg Tel.: +45 33 85 15 90 mia.glarborg@man.eu

 

 
6/2009

fuel injection equipment. MAN Diesel has all the strategic elements of engine development in-house. However. e. MAN Diesel has recorded reductions in NOx of over 30%.   6/2009 . electronic hardware and software for control.5 to 7.    Press Release Page 2 / 5 The Miller Cycle involves the early closure of the inlet valve. higher pressure turbocharging ensures that an equal – or in the case of MAN Diesel’s new technology package greater – amount of air can enter the cylinder in the shorter time available. MAN Diesel is developing two versions of the Miller Cycle engine based on differing technology packages. The technology packages are based entirely on in-house developed technology at MAN Diesel.g. The latter is necessary because at low loads. During trials using an intensive Miller Cycle under full load conditions and turbocharger pressure ratios of 6. reductions in fuel consumption as great as 8% and a 15% increase in specific power output. monitoring and diagnosis of engines and driven equipment and has now developed its own variable valve timing system. the shortened inlet valve timings in the intensive Miller Cycle can lead to increased smoke emissions. To counter this effect. the shorter inlet valve opening period would mean a lower mass of air combustion air entering the cylinder and hence reduced engine power and torque. MAN Diesel seeks to exploit the enhanced levels of control over diesel combustion possible using its advanced SaCoSone. and employs variable high pressure. Unique among builders of medium speed engines. All these technologies come together in the variable Miller Cycle package. two-stage high pressure turbocharging with variable turbine area (VTA) technology and variable valve timing (VVT). including large exhaust turbochargers. Two Versions To cover a full spectrum of applications. A variable Miller Cycle version with variable valve timing targets variable load (load following) applications. causing the air entering the cylinder to expand and cool and hence reduce temperature peaks during combustion. power supply to rolling mills or other variable load consumers or marine power generation or marine propulsion. where essentially. A version with fixed Miller valve timing. microprocessor safety and control system to manage common rail (CR) fuel injection. two-stage turbocharging complemented by common rail fuel injection and variable inlet valve timing. variable two-stage turbocharging and conventional fuel injection will cover baseload power generation applications.

duration and timing to be freely selected at all engine speeds and loads. the VVT system has enabled smoke emissions comparable with those of the standard 32/44CR engine with single stage turbocharging – i. which allows injection pressure. The second.e. As well as reductions in NOx emissions of over 30% and a maximum of 8% reduction in specific fuel oil consumption (SFOC). This gives the capability to optimise charge air delivery at all points on the engines performance map. VTA denotes “variable turbine area” control. In addition. Giving a similar level of parameter setting flexibility on the fuel injection side is MAN Diesel’s common rail fuel injection system. six cylinder version of MAN Diesel’s newest four-stroke engine. well within the visibility boundary.    Press Release Page 3 / 5 In the high pressure two-stage turbocharging system.has been tested with excellent results extensively on the inline.    6/2009 .e. fuel consumption and engine response to load changes. The favourable fuel consumption values are attributable to the increased air-fuel ratios above 20% rated output and the high efficiency levels of the two-stage charging system. This combination of technologies . Completing the package is MAN Diesel’s electronically controlled. employing cam followers on eccentric shafts to enable load dependent valve timing and hence vary the intensity of the Miller Cycle.the variable Miller Cycle . in-house developed VVT variable valve timing system. smaller turbocharger is fitted with the VTA control system to enable precise control of the charge air output. in part load operation. MAN Diesel states. a system which achieves regulation of turbocharger compressor output by means of turbocharger nozzle rings equipped with adjustable vanes instead of the fixed-vane rings used in MAN Diesel’s standard TCA (axial) and TCR (radial) turbochargers. it allows the quantity of charge air to be more precisely matched to the quantity of injected fuel to the benefit of emissions. the greater availability of combustion air in absolute terms has also allowed a considerable increase in cylinder output from 560 to 640 kW on the 6L32/44CR test engine. the all-electronic 32/44CR. two turbochargers are arranged in tandem with an intermediate charge air cooler. i. particularly to suppress engine smoke at part load. Adjusting of the vane pitch regulates the pressure of the exhaust gases impinging on the turbine to vary the output of the turbocharger compressor.

    Press Release Page 4 / 5 MAN Diesel 6L32/44CR inline six cylinder common rail engine under test with two-stage turbocharging including VTA technology and VVT.     6/2009 .

MAN Diesel is a company of MAN SE. MAN Diesel PrimeServ. generating sets. Denmark. The global after-sales organisation. France. 8.300 kW.000 staff. turbochargers. Ref no 6510-0136   6/2009 . supported by authorised partners. About MAN Diesel MAN Diesel is the world’s leading provider of large bore diesel engines for marine and power plant applications. which is listed on the DAX share index of the 30 leading companies in Germany. CP propellers and complete propulsion packages that are manufactured both by MAN Diesel and its licensees. The engines have power outputs ranging from 450 to 97. MAN Diesel employs approx. comprises a network of the company’s own service centres. The company designs two-stroke and four-stroke engines. the Czech Republic. primarily in Germany.    Press Release Page 5 / 5 Schematic arrangement of the MAN Diesel Variable Miller Cycle with two-stage turbocharging on the 6L32/44CR engine. India and China.

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