Wärtsilä applies new technologies that cross traditional scientific disciplines and conventional industrial boundaries to solve product development tasks, thus producing added value for its customers. Wärtsilä’s R&D organization creates the basic elements that make a product both desirable and competitive. Wärtsilä’s R&D activities focus on products and applications that are reliable, self-diagnostic, cost-efficient to operate, and that produce minimal environmental impacts throughout their lifecycles. The company takes a proactive approach to managing its intellectual and industrial rights through incentive schemes for its employees that encourage innovation and initiative. A paramount priority in Wärtsilä’s R&D activities is to develop and safeguard the company’s critical areas of expertise. Wärtsilä’s research organization has long-term co-operation agreements with research institutes, engineering consultants, licensees, and other corporate partners in fields that are of crucial importance to the well-being of society and the conservation of the environment.
Product development is based on effective work process management to ensure that the set targets are reached. These boundary conditions form the hub of the process around which a reliable and cost-effective product is developed. The performance of the products and their features are verified through simulations and tests. Wärtsilä actively develops the compatibility of its products and common technology platforms, as well as designing products that are easy to manufacture. A substantial proportion of the company’s investments in product development is targeted at reducing environmental impacts. Total R&D expenses are shown in the ‘Wärtsilä and Sustainability’ section of this report.
The most important areas of R&D for Wärtsilä in recent years have included the application of common-rail technology to its engines, reducing emissions, improving efficiency, and broadening the range of suitable fuels. Major R&D programmes during 2007 were related to the HERCULES project, the Advanced diesel generating set project, and the development of fuel cells. Wärtsilä also co-operates with a number of leading European universities conducting research into engine technologies.
The HERCULES project
The HERCULES (High Efficiency Engine R&D on Combustion with Ultra Low Emissions for Ships) project, funded by the EU Commission, was closed in September 2007. A primary goal of this project, the origin of which was a common initiative from the two leading engine designers and manufacturers, Wärtsilä and MAN Diesel, was to develop new technologies to reduce gaseous and particulate emissions from marine engines. A second objective was to increase engine efficiency and reliability, which in turn will reduce specific fuel consumption, carbon dioxide emissions, and lifecycle costs. Successive objectives for improvements to be available onboard ships have been set for 2010 and 2020.
The R&D within HERCULES has been most successful. Methods taking us even considerably beyond the goals of the project have been identified and validated. New technologies enabling a reduction in emissions, for example a 50% NOx reduction without need of external abatement methods while maintaining or even improving efficiency, have been developed. In long-term projects, such as particulate removal technologies, new insights could be gained.
Platforms for advanced engine R&D, including further exploitation of results from the HERCULES project, have been developed. Both the Extreme Value Engine (EVE) and the testing environment in the Internal Combustion Engine Technology laboratory at the Helsinki University of Technology, have been entirely renewed. A new test facility based on a high-temperature spray combustion chamber for combustion research on large-bore diesel engines, has been built in close co-operation with the Federal Technical University in Zürich. Further research activities in related areas, such as intelligent turbocharging, advanced technologies for NOx reduction, and fundamental research of particulate formation, yielded new results that will lead to the application of new technologies on future Wärtsilä engines.
A follow-up project has been defined and a proposal has been submitted to the EU for acceptance within the 7th framework programme. Continuation of research under this framework would ensure the exploitation of the created partnerships and the first HERCULES project, and would penetrate into new areas.
Advanced diesel generating set (GENSET)
The main aim of this project, which is funded by Tekes, the Finnish Funding Agency for Technology and Innovation, is to develop a compact and highly competitive diesel generating set by exploiting the benefits offered by permanent magnets and axial flux technology. The plan is also to make an inventory of the know-how available at a number of Finnish research institutions in order to create concepts for future fuel injection systems, valve actuating systems, and turbocharging systems.
Validation of a prototype diesel generating set commenced at the Vaasa engine laboratory in May 2007. The generating set, which has been subject to extensive performance and endurance tests, had accumulated more than 1,000 hrs by the end of 2007.
The validation of the GENSET-concept will continue in 2008. The intention is not only to expose the generating set to further endurance tests, but also to test new technologies having the potential to support engine performance improvement and emission reductions. The new technologies, which include solutions developed both by domestic research institutions and external industrial partners, will be implemented and tested in a systematic step-by-step approach, allowing anyone evaluating the outcome of the tests to clearly identify the influence of each and every added technical feature.
Development of fuel cell technology
A fuel cell is a clean, efficient and reliable method of producing energy, making it a highly attractive option for commercial power production. Wärtsilä has been developing fuel cell technology for decentralized power generation and marine applications since the year 2000. The company’s fuel cell development team is focusing on developing, designing and manufacturing a solid oxide fuel cell (SOFC) system. In this work Wärtsilä is taking advantage of its extensive know-how in combined heat and power generation, and the company’s in-depth knowledge of its marine customers’ needs.
Part of the R&D programme covers the development of the WFC20 alpha prototype, a 20 kW SOFC unit, which was successfully started in October 2007. Wärtsilä plans to introduce its first demonstration units in the 20 kW range during 2008. Within the next year or two, the company is planning to introduce pre-commercial units in the 20 to 50 kW range. Commercialization of fuel cell units for onshore and offshore power plant applications will start at the beginning of the next decade. In 2008 Wärtsilä is participating in three major EU-funded development projects in which three fuel cell units developed by Wärtsilä will be built and tested.
