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The new 32/40PGI engine
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Agenda
Gas as fuel
Gas Engines Market requirements
Development goals
Gas Engines
Lean burn principle
PGI principle
V32/40PGI Design
V32/40PGI Validation/ Application
Summary
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Gas as fuel
Very low emission levels:
Clean burning
Relatively free of contaminations
Methane contains the highest amount of hydrogen per unit of energy of
all fossil fuels -> lower CO2 emissions
Lean burn Otto process provides very low NOx emissions
Natural gas compared to diesel:
CO emissions reduction approx. 75%
CO2 emissions reduction approx. 20% NOx emissions reduction approx. 80%
No SOx emissions
Less particle emissions
No visible smoke
C HH
H
H
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Gas Engines Market requirements
Power Generation with highest possible efficiency
High specific power output
Low emissions
Low Life cycle costs (LCC)
Gas flexibility
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MBD- Development goals
High power output
Lower emissions
Higher efficiency than
other gas engine
concepts
Own unique strategic
position
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Gas Engines Competition
Electrical Engine Output [kW]
Competition
750 rpm- class- Power Generation
0 2,500 5,000 7,500 10,000
RR Bergen B35:40G
V32/40PGI
W34SG
16VGCM34
MHI M30G
Technology
PGI
SI/PC
SI/PC
SI/PC
MP/PC
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Gas Engines Competition
750 rpm- class
specific power output
bmep [bar]
Competition
10,0 15,0 20,0 25,0
RR Bergen B35:40G
V32/40PGI
W34SG
16VGCM34
MHI M30G
+12.5%
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Gas Engines Lean burn principle
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Gas Engines Lean burn principle
Otto principle
Low-pressure gas
admission
Ignition either by spark
plug or Pilot diesel
injection
Ignition by
Spark plug
Ex.In.
Ignition by
pilot diesel fuel
Ex.In.
MP-Concept
SI-Concept
*
Intake of
air and gas
Ex.In.*****
***** *
****
***
*
Compression of
air and gas
Ex.In.
***
****
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Gas Engines Lean burn principle
Examples of lean burn gas engines - W34SG
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Gas Engines Lean burn principle
Weaknesses of SI/ MP-Concept:
Lifetime of spark plug decreases with increase in
bmep higher LCC with increase in output i.e.
component limit
Different fuel systems for Micro-Pilot concept with
diesel pilot fuel higher LCC and emissions
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PGI Principle
PGI - Performance Gas Injection
Lean burn principle
First monofuel combination of Diesel and Otto
process in a Gas Engine Micro-Pilot Injection with pilot gas, approx 1% pilot
quantity
Ignition of pilot fuel at a hot surface inside
prechamber
Lower LCC due to lower wear at ignition
components in comparison to competition (SI)
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Gas Engines PGI principle
Otto principle
Low-pressure gas
admission
Ignition by Pilot gas
injection
PGI-Concept
PGI-Core element
*
Intake of
air and gas
Ex.In.*****
***** *
***** *
**
Compression of
air and gas
Ex.In.
***
****
Ignition by
pilot gas fuel
Ex.In.
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PGI Principle
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PGI Performance features
PGI The gas engine without spark plugs
High Power Output comparable to diesel
engines
Highest thermal efficiency combined withextremely low emissions
Long lifetime for ignition system no spark
plugs
Lower maintenance cost for the PGI engine
Gas flexibility
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V32/40 PGI Technical Data
Combustion process: Lean-burn
Number of cylinders: 12V 18V
Power output5400 kW 8100 kW (750 rpm)
5160 kW 7740 kW (720 rpm)
Cylinder bore: 320 mm
Piston: 400 mm
Engine speed: 720/750 rpm
Mean piston speed: 9.6/10.0 m/s
Mean effective pressure: 22.4 bar
Frequency: 60/50 Hz
Specific energy consumption: 7740 kJ/kWh
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Design of the new V32/40PGI
piston
charge air
exhaust gas
valve train
turbo charger
gas admission valvegas pipe
Ignition system
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V32/40 PGI Detail Design
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V32/40 PGI Detail Design
Gas supply pipe
Solenoid gas
valve
Charge air pipe
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32/40PGI
Engine Management System
Pilot Gas
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32/40PGI
Engine Management System
Individual control of
each cylinder
Efficient operation in small
operating window
Safe margin to knocking
and misfiring limit
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PGI Development process
Basic-Development
DesignPrototype/Series
Validation
Field
engineeringDevelopment-Project
Project Start / ReleaseSeriesSales
PGI Concept
Study on single
cylinder Transfer to
Prototype
Application in
MBD-CHP-
Plant
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V32/40PGI Test phase
Engine test on development test
bench
Continuous operation
in power plant
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V32/40PGI CHP-Application at MBD
Power output
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Summary
The PGI-Gas Engine has a completely new ignition concept
The PGI concept is a combination of Diesel and Otto process
The specific power output is comparable to diesel engines
The PGI engine has very low emissions
The PGI engine has a high efficiency with these low emissions
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