Technology for Marine Engines

®

E x c e l l e n c e o n B o a r dE x c e l l e n c e o n B o a r d

®

LEVERAGING ALL FOR MARINE.

ACERTfi Technology is the product of a $ 500 million investment structuredon the broadest product, application and manufacturing base in the indus-try. No other marine engine supplier can draw on an 11 kW to 16,000 kWproduct experience, combined with internal fuel systems, manufacturingand internal electronic controls design. This broad and solid base allowsCaterpillar to make the building blocks of ACERTfi work better togetherthan they would as stand alone components.

LESS SMOKE AND NOISE.

The investment paid off when Caterpillar made landmark breakthroughs in the science of fuel combustion. ACERTfi Technology allows the combustionprocess to be shaped and managed with an extremely high degree of precision. The end result is an engine that meets emissions requirementsquietly and with less smoke.

Advanced combustion has been a goal of engine researchers for decades.But only Caterpillar has the expertise, resources and technology base with proprietary electronic controls, fuel systems and air managementsystems to make it a reality.

PROVIDES BETTER PERFORMANCE.

What makes ACERTfi Technology good for the environment also makesACERTfi good for performance. Efficient combustion reduces engine wear and maximizes the amount of fuel energy applied to the propeller or generator. Instead of seeing the black smoke of partially burnt fuelescape out your exhaust system, ACERTfi drives the combustion system to pull the maximum amount of energy from each injection.

Technology to Decrease Exhaust Emissions

Cat and MaK engines with ACERTfi Technology deliver excellent performance, efficiency and durability,

while offering a highly effective emissions reduction solution. ACERTfi combines proven systems with

innovative new technologies to enhance the combustion process to such a high degree that it optimizes

total engine performance. And it is flexible enough to apply across the entire Cat and MaK product lines.

Only Caterpillar has ACERTfi Technology because only Caterpillar has the resources, dedication and history

of excellence to make it a reality.Dr. George Lustgarten

Director, Power Systems Engineering

Caterpillar Inc.

Developing ACERT® Technology

A CLEAR FUTURE.

As worldwide emissions standards tighten,ACERTfi Technology won t be left behind.Unlike other emissions solutions, ACERTfi

offers a clear direction for future regulatory compliance.

ACERTfi building block technologies can beadded as needed, and they re being con-stantly refined to enhance their effective-ness. Caterpillar is also developing newtechnologies that may be applied to ACERTfi

in the coming years.

ACERTfi Technology is the right solution for marine power today. And you can counton it to meet the challenges of tomorrow.

WHAT MAKES ACERTfi TECHNOLOGY SO ADVANCED?

Any company can purchase off-the-shelftechnology and call it innovation, but onlyCaterpillar has the breadth of product line,application experience, manufacturingcapabilities and design expertise to createa comprehensive, long-term emissions andperformance solution. ACERTfi Technology sadvanced design utilizes a number ofbuilding block technologies. Each is

optimized to work in a highly integratedway with other ACERTfi building blocks toproduce better results than as individualcomponents.

And ACERTfi is already proving itself indemanding applications. Thousands of Cat engines with ACERTfi Technology arenow logging miles in on-highway trucks or cruising the world s oceans and customerreaction has been outstanding.

WHAT MAKES ACERTfi TECHNOLOGY SO SIMPLE?

Because ACERTfi is primarily a combustiontechnology, there is no external plumbing to clutter cramped engine rooms. ACERTfi

also avoids the complications and costs ofwater injection systems and urea-basedcatalysts.

And when you specify an engine, ACERTfi

building block elements are included onlyas needed, so you get a solution optimizedfor your application.

Building Blocks of ACERT®

AIR MANAGEMENT

Cat engines with ACERTfi Technology use avariety of refined air management technolo-gies, including crossflow cylinder headsand wastegate turbochargers. They also take advantage of several newinnovations:Variable Valve Timing uses electronically-controlled hydraulic actuators to governwhen valves open and close to let air in andexhaust out of the combustion chamber.Series Turbocharging uses two smaller tur-bos together to reduce lag time while main-taining high airflows. Lower shaft speedsalso enhance reliability and service life.MaK Flex Cam Technology offers anotherway to precisely control valve timing. Thistechnology allows MaK engines to exceedcurrent IMO emissions requirements usingan easy-to-maintain internal solution.

COMBUSTION DESIGN

To optimize the flexibility of these new sys-tems, Caterpillar utilized advanced predic-tive modeling software that incorporatedfactors such as aerodynamics, thermody-namics, spray penetration, fuel vaporiza-tion, ignition, combustion and emissionchemistry to select the best nozzle configu-rations and combustion cylinder geometry.

®

FUEL DELIVERY

Multiple injection fuel delivery introducesfuel into the combustion chamber in aseries of precisely-timed microbursts.

This allows control over many more vari-ables during the combustion process. Thecombustion cycle can be tailored to delivermaximum power and efficiency with mini-mum emissions for a wide range of enginespeeds and loads.

ELECTRONICS

The Cat ADEM electronic controller actsas the brains of ACERTfi . Pioneered byCaterpillar almost 20 years ago, the ADEMcontroller coordinates and enhances fueldelivery, air supply and other engine func-tions to maximize overall performance andreduce emissions output.

Caterpillar ACERT® Technology for EmissionReduction in Medium-Speed Marine Engines

For a few years now, Caterpillar has made ahuge investment to develop an emissionreduction technology now marketed asACERTfi Technology. After a successfuldemonstration in the on-highway high-speed engines, Caterpillar will now embarkon a stepwise migration of selected ele-ments of ACERTfi Technology across theentire product line and range of applica-tions. The broad range of Caterpillar’smarine program calls for a differentiatedapproach. Key criteria are: n Prevailing emission limits for the

respective power range and timing of their introduction.

n Customer expectations in terms ofengine performance, maintenance practices, fuel quality and mode of operation.

By adopting this technology for medium-speed engines, it is our goal to meet andexceed customer expectations by maxi-mizing product value through:n Superior reliability in heavy fuel

operation.n Best fuel efficiency in its class.n Lowest engine emissions at minimum

additional complexity.

Keeping in mind the high reliability expec-tations of customers, Caterpillar decidedto adopt a two step approach providingthe most effective solutions with lowestcomplexity.

n Low Smoke eliminates visible smokecompletely while complying with IMO I standards at all operating load points.

n Low NOx demonstrates capability to reduce the current IMO NOx limits by at least 30% (LEE = Low Emission Engine).

ACERTfi Step 1 for Medium-SpeedEngines

ACERTfi Step 1 Flex Cam Technology FCT

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0180 270 360 450 540 630

2 4 6 8 10 120

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NOx Emissions Cycle Value (g/kWh)

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IMO IIMO II

FCTCCR

Cat Common RailLow Smoke

Low NOx

IMO I

Invisible Smoke

Flex Cam Technology:Building upon the ACERTfi system integra-tion concept, Step 1 achieves synergy be-tween flexible fuel systems and advancedair systems leveraging to a maximum thecurrent engine design. While maintaininga high fuel injection pressure over thewhole operation range, fuel injection andinlet valve timing are load controlled andinfluenced by acting upon the position of

Step 1: ACERTfi WITH FLEX CAM TECHNOLOGY (FCT).The development objective is a rapid introduction of ACERTfi Technology into a commercially available product, whichleverages the current product base. FCT is flexible to be adjusted to the respectiveapplication:

a lever shaft which influences injection timing/pressure, and inlet valve events.Valve timing changes at part load raise theeffective compression and enhance com-plete combustion. In addition, shifting therelative position of the lever to the fuel camincreases injection pressure, producing afiner atomization of the fuel in a load rangewhere it is otherwise difficult to controlsmoke.

Retrofit kit for low emissions

Step 2: EXPANDED ACERTfi APPLICATION TO MEDIUM-SPEED ENGINES.The next step in migrating ACERTfi to themedium-speed marine product is alreadyon the way. The goals are:n Reduce emissions far beyond the

current IMO regulations and offer an attractive technology for emissions sensitive areas.

n Maintain or improve engine perform-ance leveraging the additional built-in flexibility and capability of the fuel and air systems.

n Add flexibility to adjust performance and emission levels to the specific mode of operation.

n Continue to meet the level of reliability in heavy fuel operation expected by our marine customers.

Caterpillar has started a program with theobjective to determine the optimum systemcharacteristics for each ACERTfi Techno-logy module (fuel, air systems, etc.). Theyare being used to finalize the design, whichwill meet performance and high reliabilityexpectations of our marine customers.

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0 2 4 6 8 10 120

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NOx Emissions Cycle Value (g/kWh)

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Step 2 Target Area

IMO IIMO II

FCTCCR

Low Smoke

Low NOxInvisible Smoke

ACERTfi Step 1 + Step 2 for Medium-Speed Engines

Customer Value Sequence of ACERTfi Steps

ACERTfi Step 1 Flex Cam Technology n Highest potential for NOx and

smoke reductionn Hardware changes to prepare for

IMO II sustainable investmentn Low complexity + fail safe functionn Technically lower risk application

of existing technology

ACERTfi Step 2 Flex Cam Technologyand Cat Common Railn Best combination for IMO II

lowest complexity/lowest costn No additional median CCR is retrofitable

Valve drive and camshaft

Actuatorfi

Plunger of injectionpump/Spacer conrod /Nozzle ring

Subject to change without notice.Leaflet No. 244e • 08.05 • L&S • VM3

For more information please visit our website:www.cat-marine.com or www.mak-global.com

Caterpillar Marine Power SystemsEurope, Africa, Middle East

Caterpillar MarinePower SystemsNeum hlen 922763 Hamburg/Germany

Phone: +49 40 2380-3000Telefax: +49 40 2380-3535

Caterpillar Marine AsiaPacific Pte Ltd14 Tractor RoadSingapore627973/SingaporePhone: +65 68287-600Telefax: +65 68287-624

Americas

MaK Americas Inc.

3450 Executive WayMiramar Park of CommerceMiramar, FL. 33025/USAPhone: +1 954 447 71 00Telefax: +1 954 447 71 15

Caterpillar Marine Trading(Shanghai) Co., Ltd.Rm 2309, Lippo Plaza222, Huai Hai Zhong Road200021 Shanghai/P. R.ChinaPhone: +86 21 5396 5577Telefax: +86 21 5396 7007

Asia PacificHeadquarters

Caterpillar MarinePower SystemsNeum hlen 922763 Hamburg/Germany

Phone: +49 40 2380-3000Telefax: +49 40 2380-3535