Injection systems for dual fuel applications
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1 Injection systems for dual fuel applications Robert Bosch, Large Engines (René Schimon) 1 ELE5 - Dr. Schimon 1/14/2015 Robert Bosch AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
2 Introduction Large Engine (LE) Engine categories HD-truck derivative High speed Medium speed Low speed (2-strokeengine) cyl.-volume (dm³): cyl.-output (kw): speed (min -1 ): < 2,5 < 120 > ,5-6 < 230 > < 500 < < > < <450 FIE in 2006 FIE in 2015 UP, CRS CRS PF, IP, CRS CRS UI, UP, PF, IP CRS, PF, UP PF CRS, PF PF PF, CRS Application: C&I Generator, Marine Locomotive Generator Marine Marine Generator CRSN HFO - CRS UI = Unit Injector UP = Unit Pump IP = Inline Pump CRS = Common Rail System PF = Single plunger pump Marine 2
3 Line up product portfolio Large Engine (LE) natural dual fuel Diesel / HFO LE-GV * CRSN HFO Conventional UI/UPS Large Engine Gas Valve Common Rail System CV Modular CRS for Large Engines Heavy Fuel Oil mechanical components Unit Injector / Unit Pump Syst. CP3.3 -LE CP9.1-LE -LE-22- HFO # PF-Pump Inline pump EUI Modular Set of LE valves * in development phase EDC17CV41 EDC17CV41 CP9.2 HFO # # tasting, no development yet NHA UPS Sensors: Marine Certification: Denoxtronic - SCR w/ urea [..] Temp. Sensor Knock sensor Speed sensor 3
4 Content of speech: BOSCH Concept for Dual Fuel Systems Double Injector Concept for Dual Fuel Applications Single Injector Concept for Dual Fuel Applications Comparison of single and double injector concepts Outlook and Summarize 4
5 Otto combustion cycle Gas monovalent Premixed, admission into intake manifold Premixed, admission into intake manifold Dual Fuel Premixed, admission into intake manifold Diesel combustion cycle Diesel Diesel injection ignition via spark plug ignition via pilot diesel injection by additional CR injector ignition via diesel injection (variable substitution) Diesel diffusion combustion spark plug 2x diesel 2x diesel 1x diesel 1x diesel diesel for medium speed engines only only 5
6 Double Injector Dual fuel concept: Main=conv. appl. Pilot=LE or Combinations: bore diameter [mm] MAIN PILOT conventional up to 400 conventional LE + 2nd FIE micro pilot 100% 100% power output Optional: ~100% mode OR ~100% diesel mode possible (variable substitution) 2x diesel 2x diesel Commercial vehicle () injector allows very small pilot quantities and is optimized for ideal fuel penetration during mode For bore diameters > 400 mm and central pilot injector position injector designed for pilot quantities Critical topic: nozzle tip temperature which can lead to fuel deposits for medium speed engines for Ø<400 mm LE for Ø>400 mm 6
7 Double Injector Dual fuel concept: Main=conv. appl. Pilot= LE + 2nd FIE micro pilot 100% 100% power output 2x diesel Commercial Vehicle Injector w/ top feed and side feed High pressure pump CP3.3 w/ gear pump ZP 7
8 Double Injector Dual fuel concept: Main=conv. appl. Pilot= Variants of mounting proposals: LE + 2nd FIE micro pilot 100% 100% power output 2x diesel System Engine bore diameter [mm] Systempressure [bar] Qe (inj. Quant.) [mm³ / stroke] Q hyd nozzle flow [cm³/30s] CRSN CRSN NSP 8
9 Double Injector Dual fuel concept: Main=conv. appl. Pilot= LE + 2nd FIE micro pilot 100% 100% power output 2x diesel System Engine bore diameter [mm] Systempressure [bar] Qe (inj. Quant.) [mm³ / stroke] Q hyd nozzle flow [cm³/30s] MAN 51/60DF CR NSP 9
10 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% 10
11 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: Standard 22 Injector in Dual fuel application w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% -high flow requires large flow area -large needle lift necessary lower penetration for low Qe 11
12 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: Standard Injector in Dual fuel application w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% 12
13 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: Standard Injector in Dual fuel application w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% -low flow requires low flow area -small needle lift possible higher penetration even for lower Qe ⅔ ⅓ 13
14 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: Stability of pilot injection quantities w/ micro pilot 0-100% lim. pilot inj. 0-70% 0-30% 0-100% 1% injection quantity requirement lead for single injector concepts to an injection in the ballistic area of the injector ⅔ ⅓ 14
15 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: Consequence of different requirements w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% Nozzle layout Qhyd: ~30% Nozzle layout Qhyd: 100% pressure [bar] pressure [bar] time [ms] time [ms] / 15
16 Single Injector Dual fuel concept: ( or ) Requirements and behavior of the Injector: Consequence of different requirements w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% 16
17 Single Injector Dual fuel concept: ( or ) Minimum pilot injection quantity: w/ micro pilot 0-100% 0-30% lim. pilot inj. 0-70% 0-100% 17
18 Summarize: pros and cons of each concept Challenge for new concept of single dual fuel injector: lim. pilot inj. Nozzle layout Qhyd: 100% pressure vapor fraction velocity velocity lift 0-70% 0-100% 18
19 Summarize: pros and cons of each concept Dual Fuel double injector concepts single injector concepts 2x diesel 2x diesel 1x diesel 1x diesel optimized for small pilot quantity optimized for diesel combustion + advantages of both injectors (small pilot quantity and 100 % diesel operation) + stable pilot quantity and ideal spray penetration - 2 injector (complexity of systems increases) - higher costs - complex control concept - complex packaging in cylinder head - main injector uncooled during mode % implementation of diesel packaging + standard CR control concept + lower costs (1 Injector only) -Either small pilot quantities and limp home diesel operation max. 30 load or 100% diesel mode with currently 70 % substitution rate Optimization will increase substitution rate ( 95%) 19
20 Summarize / Outlook: For medium speed engines the double injector concept is a proven stable solution for applications with bore diameters from 200 up to 510 mm For single injector concepts substitution rates of 70% are applied without modification of the fuel injection system Target for 2 nd generation DF engines: 22 Injector with a substitution rate 95% 20
21 Thanks for your attention 21 ELE5 - Dr. Schimon 1/14/2015 Robert Bosch AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
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