Rene Schimon Bosch

Injection systems for dual fuel applications
Robert Bosch Diesel Systems, Large Engines (René Schimon)
Diesel Systems
1 ELE5 - Dr. Schimon | 1/14/2015 | © Robert Bosch AG 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Injection Systems for Dual Fuel Application
Introduction Large Engine (LE)
Engine HD-truck High Medium Low speed

(2-stroke-
categories derivative speed speed engine)
cyl.-volume (dm³): < 2,5 2,5-6 4 – 32 33 – 290 134 - 1.800

cyl.-output (kW): < 120 < 230 < 500 < 2.100 < 7.760
speed (min-1): > 1.400 > 1.400 < 1.400 > 450 <450
FIE in 2006 UP, CRS PF, IP, CRS UI, UP, PF, IP PF PF
FIE in 2015 CRS CRS CRS, PF, UP CRS, PF PF, CRS
Application: C&I Locomotive Marine Marine

Generator, Generator Generator
CRSN Marine
MCRS Marine HFO - CRS
UI = Unit Injector UP = Unit Pump IP = Inline Pump
CRS = Common Rail System PF = Single plunger pump
Diesel Systems
2 Dr. René Schimon | 1/14/2015 | © Robert Bosch AG 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
Line up – product portfolio Large Engine (LE)

natural gas Diesel / HFO
dual fuel
LE-GV * CRSN MCRS 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.
CRIN-LE-22-
HFO # EUI
Inline pump
CP3.3
CRIN PF-Pump
CRIN-LE CP9.1-LE
CP9.2 HFO # UPS

Modular Set of
LE gas valves NHA
# tasting,
* in development phase EDC17CV41 no development yet
EDC17CV41
Sensors: Marine Certification: Denoxtronic - SCR w/ urea
[..]
Temp. Sensor Knock sensor Speed sensor
Diesel Systems
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
Diesel Systems
Otto combustion cycle Diesel combustion cycle

Gas monovalent Dual Fuel Diesel
Premixed gas, admission Premixed gas, admission Premixed gas, admission
Diesel injection
into intake manifold into intake manifold into intake manifold
ignition ignition via pilot ignition via diesel Diesel

via diesel injection by injection (variable diffusion
spark plug additional CR injector substitution) combustion
spark plug 2x diesel 2x diesel 1x diesel 1x diesel diesel
gas gas gas gas gas
for medium speed engines CRIN only MCRS only

Diesel Systems
Double Injector Dual fuel concept: Main=conv. appl. Pilot=LE or CRIN
•Combinations: LE + 2nd FIE

micro pilot
bore diameter [mm] MAIN PILOT Gas Mode:
≈ 100% power
400 - 510 conventional MCRS
Diesel Mode: output
up to 400 conventional CRIN ≈100%
•Optional: ~100% gas mode OR ~100% diesel mode CRIN MCRS

possible (variable substitution) 2x diesel 2x diesel
•Commercial vehicle (CRIN) injector allows very small

pilot quantities and is optimized for ideal fuel penetration
during gas mode gas gas
•For bore diameters > 400 mm and central pilot injector

position  MCRS injector designed for pilot quantities
•Critical topic: nozzle tip temperature which can lead to
for medium speed engines
fuel deposits
CRIN for Ø<400 mm LE for Ø>400 mm
Diesel Systems
Double Injector Dual fuel concept: Main=conv. appl. Pilot=CRIN
LE + 2nd FIE
micro pilot
Gas Mode:
≈ 100% power
Diesel Mode: output
≈100%
2x diesel
gas
Commercial Vehicle Injector High pressure pump CP3.3

w/ top feed and side feed w/ gear pump ZP
Diesel Systems
Double Injector Dual fuel concept: Main=conv. appl. Pilot=CRIN

Variants of mounting proposals: LE + 2nd FIE
micro pilot
Gas Mode:
≈ 100% power
Diesel Mode: output
≈100%
2x diesel
gas
System Engine bore Systempressure Qe (inj. Quant.) Qhyd nozzle flow NSP
diameter [mm] [bar] [mm³ / stroke] [cm³/30s]
CRSN3-18 350 1600 30 ... 150 350 4-5
CRSN2-16 200 1100 - 1600 20 ... 60 200 - 310 2-3
Diesel Systems
Double Injector Dual fuel concept: Main=conv. appl. Pilot=MCRS
LE + 2nd FIE
micro pilot
Gas Mode:
≈ 100% power
Diesel Mode: output
≈100%
2x diesel
gas
MAN 51/60DF
System Engine bore Systempressure Qe (inj. Quant.) Qhyd nozzle flow NSP
diameter [mm] [bar] [mm³ / stroke] [cm³/30s]
CR 450 - 510 1050 70 - 280 800-900 4
Diesel Systems
Single Injector Dual fuel concept: only one FIE (CRIN or MCRS)
Requirements and behavior of the Injector: only one FIE only one FIE
w/ micro pilot lim. pilot inj.
Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
Diesel Mode: Diesel Mode:
≈0 - 30% ≈0 - 100%
1 x diesel 1 x diesel
gas gas
CRIN MCRS
Diesel Systems
Standard MCRS 22 Injector in Dual fuel application Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
-high flow requires large flow area

-large needle lift necessary
gas gas
lower penetration for low Qe
CRIN MCRS
Diesel Systems
Standard CRIN Injector in Dual fuel application Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
gas gas
CRIN MCRS
Diesel Systems
Standard CRIN Injector in Dual fuel application Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
-low flow requires low flow area

⅔
-small needle lift possible
gas gas
 higher penetration even for lower Qe
CRIN MCRS
Diesel Systems
Stability of pilot injection quantities Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
1% injection quantity requirement lead for 1 x diesel 1 x diesel

single injector concepts to an injection in
the ballistic area of the injector
⅔
gas gas
CRIN MCRS
Diesel Systems
Consequence of different requirements Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
Nozzle layout Qhyd: ~30% Nozzle layout Qhyd: 100% 1 x diesel 1 x diesel
pressure [bar]
pressure [bar]
gas gas
time [ms] time [ms]
CRIN / MCRS CRIN MCRS
Diesel Systems
Consequence of different requirements Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
gas gas
CRIN MCRS
Diesel Systems
Minimum pilot injection quantity: only one FIE only one FIE
Gas Mode: Gas Mode:
≈ 0 - 100% ≈ 0 - 70%
≈0 - 30% ≈0 - 100%
gas gas
CRIN MCRS
Diesel Systems
Summarize: pros and cons of each concept

Challenge for new concept of single dual fuel injector: only one FIE
lim. pilot inj.
Gas Mode:
≈ 0 - 70%
pressure velocity Diesel Mode:
Nozzle layout Qhyd: 100%
≈0 - 100%
1 x diesel
velocity
gas
vapor
fraction
lift
MCRS
Diesel Systems
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
optimized for diesel

gas gas gas gas
combustion
quantity
CRIN MCRS
+ advantages of both injectors + 100 % implementation of diesel packaging

(small pilot quantity and 100 % diesel operation) + standard CR control concept
+ stable pilot quantity and ideal spray penetration + lower costs (1 Injector only)
- 2 injector (complexity of systems increases) -Either small pilot quantities and limp home diesel
- higher costs operation max. 30 load or 100% diesel mode with
- complex control concept currently 70 % substitution rate
- complex packaging in cylinder head Optimization will increase substitution rate
- main injector uncooled during gas mode (≥95%)
Diesel Systems
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 2nd generation DF engines:

 MCRS 22 Injector with a substitution rate ≥ 95%
Diesel Systems
Thanks for your attention
Diesel Systems
21 ELE5 - Dr. Schimon | 1/14/2015 | © Robert Bosch AG 2015. All rights reserved, also regarding any disposal, exploitation, reproduction, editing,

Rene Schimon Bosch

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Injection systems for dual fuel applications

Robert Bosch Diesel Systems, Large Engines (René Schimon)

Introduction Large Engine (LE)

Engine HD-truck High Medium Low speed

cyl.-volume (dm³): < 2,5 2,5-6 4 – 32 33 – 290 134 - 1.800

Application: C&I Locomotive Marine Marine

Line up – product portfolio Large Engine (LE)

LE-GV * CRSN MCRS HFO Conventional UI/UPS

CP9.2 HFO # UPS

Sensors: Marine Certification: Denoxtronic - SCR w/ urea

 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

Otto combustion cycle Diesel combustion cycle

ignition ignition via pilot ignition via diesel Diesel

spark plug 2x diesel 2x diesel 1x diesel 1x diesel diesel

gas gas gas gas gas

for medium speed engines CRIN only MCRS only

Double Injector Dual fuel concept: Main=conv. appl. Pilot=LE or CRIN

•Combinations: LE + 2nd FIE

•Optional: ~100% gas mode OR ~100% diesel mode CRIN MCRS

•Commercial vehicle (CRIN) injector allows very small

•For bore diameters > 400 mm and central pilot injector

Double Injector Dual fuel concept: Main=conv. appl. Pilot=CRIN

Commercial Vehicle Injector High pressure pump CP3.3

Double Injector Dual fuel concept: Main=conv. appl. Pilot=CRIN

Double Injector Dual fuel concept: Main=conv. appl. Pilot=MCRS

-high flow requires large flow area

-low flow requires low flow area

1% injection quantity requirement lead for 1 x diesel 1 x diesel

time [ms] time [ms]

CRIN / MCRS CRIN MCRS

Summarize: pros and cons of each concept

Summarize: pros and cons of each concept

optimized for small pilot

optimized for diesel

+ advantages of both injectors + 100 % implementation of diesel packaging

 For medium speed engines the double injector concept is a proven

 For single injector concepts substitution rates of 70% are applied

 Target for 2nd generation DF engines:

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