Technology for Marine Engines

Technology for Marine Engines Excellence on Board

Technology to Decrease Exhaust Emissions LEVERAGING ALL FOR MARINE. ACERT fi Technology is the product of a $ 500 million investment structured on the broadest product, application and manufacturing base in the industry. No other marine engine supplier can draw on an 11 kw to 16,000 kw product experience, combined with internal fuel systems, manufacturing and internal electronic controls design. This broad and solid base allows Caterpillar to make the building blocks of ACERT fi work better together than 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. ACERT fi Technology allows the combustion process to be shaped and managed with an extremely high degree of precision. The end result is an engine that meets emissions requirements quietly 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 management systems to make it a reality. PROVIDES BETTER PERFORMANCE. What makes ACERT fi Technology good for the environment also makes ACERT fi 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 fuel escape out your exhaust system, ACERT fi drives the combustion system to pull the maximum amount of energy from each injection. Cat and MaK engines with ACERT fi Technology deliver excellent performance, efficiency and durability, while offering a highly effective emissions reduction solution. ACERT fi 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 ACERT fi 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 WHAT MAKES ACERT fi SO ADVANCED? TECHNOLOGY Any company can purchase off-the-shelf technology and call it innovation, but only Caterpillar has the breadth of product line, application experience, manufacturing capabilities and design expertise to create a comprehensive, long-term emissions and performance solution. ACERT fi Technology s advanced design utilizes a number of building block technologies. Each is optimized to work in a highly integrated way with other ACERT fi building blocks to produce better results than as individual components. And ACERT fi is already proving itself in demanding applications. Thousands of Cat engines with ACERT fi Technology are now logging miles in on-highway trucks or cruising the world s oceans and customer reaction has been outstanding. A CLEAR FUTURE. As worldwide emissions standards tighten, ACERT fi Technology won t be left behind. Unlike other emissions solutions, ACERT fi offers a clear direction for future regulatory compliance. ACERT fi building block technologies can be added as needed, and they re being constantly refined to enhance their effectiveness. Caterpillar is also developing new technologies that may be applied to ACERT fi in the coming years. ACERT fi Technology is the right solution for marine power today. And you can count on it to meet the challenges of tomorrow. WHAT MAKES ACERT fi SO SIMPLE? TECHNOLOGY Because ACERT fi is primarily a combustion technology, there is no external plumbing to clutter cramped engine rooms. ACERT fi also avoids the complications and costs of water injection systems and urea-based catalysts. And when you specify an engine, ACERT fi building block elements are included only as needed, so you get a solution optimized for your application.

Building Blocks of ACERT FUEL DELIVERY Multiple injection fuel delivery introduces fuel into the combustion chamber in a series of precisely-timed microbursts. This allows control over many more variables during the combustion process. The combustion cycle can be tailored to deliver maximum power and efficiency with minimum emissions for a wide range of engine speeds and loads. ELECTRONICS The Cat ADEM electronic controller acts as the brains of ACERT fi. Pioneered by Caterpillar almost 20 years ago, the ADEM controller coordinates and enhances fuel delivery, air supply and other engine functions to maximize overall performance and reduce emissions output. AIR MANAGEMENT Cat engines with ACERT fi Technology use a variety of refined air management technologies, including crossflow cylinder heads and wastegate turbochargers. They also take advantage of several new innovations: Variable Valve Timing uses electronicallycontrolled hydraulic actuators to govern when valves open and close to let air in and exhaust out of the combustion chamber. Series Turbocharging uses two smaller turbos together to reduce lag time while maintaining high airflows. Lower shaft speeds also enhance reliability and service life. MaK Flex Cam Technology offers another way to precisely control valve timing. This technology allows MaK engines to exceed current IMO emissions requirements using an easy-to-maintain internal solution. COMBUSTION DESIGN To optimize the flexibility of these new systems, Caterpillar utilized advanced predictive modeling software that incorporated factors such as aerodynamics, thermodynamics, spray penetration, fuel vaporization, ignition, combustion and emission chemistry to select the best nozzle configurations and combustion cylinder geometry.

Caterpillar ACERT Technology for Emission Reduction in Medium-Speed Marine Engines For a few years now, Caterpillar has made a huge investment to develop an emission reduction technology now marketed as ACERT fi Technology. After a successful demonstration in the on-highway highspeed engines, Caterpillar will now embark on a stepwise migration of selected elements of ACERT fi Technology across the entire product line and range of applications. The broad range of Caterpillar s marine program calls for a differentiated approach. Key criteria are: n Prevailing emission limits for the respective power range and timing of their introduction. n Customer expectations in terms of engine performance, maintenance practices, fuel quality and mode of operation. By adopting this technology for mediumspeed engines, it is our goal to meet and exceed customer expectations by maximizing 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 expectations of customers, Caterpillar decided to adopt a two step approach providing the most effective solutions with lowest complexity. Step 1: ACERT fi WITH FLEX CAM TECHNOLOGY (FCT). The development objective is a rapid introduction of ACERT fi Technology into a commercially available product, which leverages the current product base. FCT is flexible to be adjusted to the respective application: max. Soot Emissions (FSN) 2,0 1,5 1,0 0,5 0 0 Invisible Smoke CCR Cat Common Rail 2 4 6 8 10 12 NO x Emissions Cycle Value (g/kwh) Flex Cam Technology: Building upon the ACERT fi system integration concept, Step 1 achieves synergy between flexible fuel systems and advanced air systems leveraging to a maximum the current engine design. While maintaining a high fuel injection pressure over the whole operation range, fuel injection and inlet valve timing are load controlled and influenced by acting upon the position of IMO II n n Low NO x Low Smoke eliminates visible smoke completely while complying with IMO I standards at all operating load points. Low NO x demonstrates capability to reduce the current IMO NO x limits by at least 30% (LEE = Low Emission Engine). FCT IMO I IMO I Low Smoke 14 ACERT fi Step 1 for Medium-Speed Engines a lever shaft which influences injection timing/pressure, and inlet valve events. Valve timing changes at part load raise the effective compression and enhance complete combustion. In addition, shifting the relative position of the lever to the fuel cam increases injection pressure, producing a finer atomization of the fuel in a load range where it is otherwise difficult to control smoke. ACERT fi Step 1 Flex Cam Technology FCT Valve Lift 16 12 8 4 0 90 180 270 360 450 540 630 Crank Angle ( ) Plunger Speed Crank Angle

Step 2: EXPANDED ACERT fi APPLICATION TO MEDIUM-SPEED ENGINES. The next step in migrating ACERT fi to the medium-speed marine product is already on 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 performance leveraging the additional built-in flexibility and capability of the fuel and air systems. ACERT fi Step 1 + Step 2 for Medium-Speed Engines max. Soot Emissions (FSN) 2,0 1,5 1,0 0,5 0 Invisible Smoke Step 2 Target Area CCR IMO II 0 2 4 6 8 10 12 NO x Emissions Cycle Value (g/kwh) n n Low NO x Add flexibility to adjust performance and emission levels to the specific mode of operation. Continue to meet the level of reliability in heavy fuel operation expected by our marine customers. Caterpillar has started a program with the objective to determine the optimum system characteristics for each ACERT fi Technology module (fuel, air systems, etc.). They are being used to finalize the design, which will meet performance and high reliability expectations of our marine customers. FCT IMO I Low Smoke 14 Customer Value Sequence of ACERT fi Steps ACERT fi Step 1 Flex Cam Technology n Highest potential for NO x and smoke reduction n Hardware changes to prepare for IMO II sustainable investment n Low complexity + fail safe function n Technically lower risk application of existing technology ACERT fi Step 2 Flex Cam Technology and Cat Common Rail n Best combination for IMO II lowest complexity/lowest cost n No additional media n CCR is retrofitable Retrofit kit for low emissions fi Valve drive and camshaft Actuator Plunger of injection pump/spacer conrod / Nozzle ring

Caterpillar Marine Power Systems Headquarters Europe, Africa, Middle East Americas Asia Pacific Caterpillar Marine Power Systems Neum hlen 9 22763 Hamburg/Germany Phone: +49 40 2380-3000 Telefax: +49 40 2380-3535 Caterpillar Marine Power Systems Neum hlen 9 22763 Hamburg/Germany Phone: +49 40 2380-3000 Telefax: +49 40 2380-3535 MaK Americas Inc. 3450 Executive Way Miramar Park of Commerce Miramar, FL. 33025/USA Phone: +1 954 447 71 00 Telefax: +1 954 447 71 15 Caterpillar Marine Trading (Shanghai) Co., Ltd. Rm 2309, Lippo Plaza 222, Huai Hai Zhong Road 200021 Shanghai/P. R. China Phone: +86 21 5396 5577 Telefax: +86 21 5396 7007 Caterpillar Marine Asia Pacific Pte Ltd 14 Tractor Road Singapore 627973/Singapore Phone: +65 68287-600 Telefax: +65 68287-624 For more information please visit our website: www.cat-marine.com or www.mak-global.com Subject to change without notice. Leaflet No. 244e 08.05 L&S VM3