yanmar's innovation and new product development …...yanmar's innovation and new product...

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.


Thermal efficiency

Diesel Pure Gas Engine

© YANMAR Co., Ltd.


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

ＡＢ

Ｃ

Air Fuel Ratio Control against the NG Property Variation

Technology to Compensate the NG Property Variation

© 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



E.C.A Global

80%NOx Reduction：

15-22%

（Tier2）





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





E.C.A Global

80%NOx Reduction：

15-22%

（Tier2）





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's innovation and new product development …...yanmar's innovation and new product...

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