Two-stage Turbocharging Technology

Klaus Payrhuber
Product Line Management
GE Energy
Jenbacher Gas Engines

Commitment to Customer Value

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In an effort to deliver the highest customer value, GE Energy has developed its Jenbacher gas engines
with a focus on high electrical efficiency and high specific output. GE’s commitment to ongoing research
and development and investment in advanced technology ensures meeting industry requirements and
maintaining its leadership position by generating measurable customer benefits.

Innovative Technology
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The design concept of GE’s Jenbacher type 6 gas engine is based on a pre-chamber ignition system,
favorable combustion chamber geometry, nominal piston speed of 11 meters per second (m/s), and
separation of the cool mixture from the hot exhaust gas through a cross flow 4-valve cylinder head,—a
combination that has enabled continuous performance improvements over time. Since 1994, the
electrical efficiency of our type 6 gas engines has been increased from 38 percent (at 12 bar brake
mean effective pressure; BMEP) to 45.6 percent in 2009 (at 22 bar BMEP), while maintaining adherence
to TA Luft requirements (German regulations for air quality).

Introduced in June 2010, GE’s new J624 with two-stage turbocharging has a maximum electrical
efficiency of 46.5 percent and produces 4.4 MW (at 24 bar BMEP). Improvements in output and efficiency
are a demonstration of the steady and continuous development path of the type 6 engine. One of the
new J624 gas engines with two-stage turbocharging has been in operation since September 2010.

GE’s new J920 9.5 megawatt large gas engine, introduced in October 2010, includes the proven two-
stage turbocharging technology employed in the new J624. As a result, the J920 will benefit from all
previous field experience with two-stage turbocharging on other engines.

New technology blocks, like two-stage turbocharging, are required to push the limits of current and
new engines. Two-stage turbocharging has led the way to more advanced Miller valve timing and an
optimized lean-burn combustion process, which enables higher efficiency levels. Combined with the
optimized MORIS high-energy ignition system, along with refined control strategies and algorithms, the
new technology blocks facilitate a sufficiently wide operating band between the knock and misfire
limits.

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Figure 1. Two-stage turbocharging concept:

Highly-advanced Miller valve timing reduces the knock tendency; however, it also increases the required
charging pressure. To meet the required charging pressure, the required compressor pressure ratio (>6)
can be achieved only by using special turbocharger features, which reduces the charging efficiency
dramatically to a value below 60 percent. In response, two-stage turbocharging is used to increase
charging efficiency to more than 75 percent. The newly developed charger module consists of a low-
pressure compressor with subsequent intercooling, a high-pressure compressor also with intercooling,
and the corresponding high- and low-pressure turbocharger turbines on the exhaust side. Power
control of the engine is achieved using a compressor bypass.

Customer Benefits
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- Higher electrical efficiency

- Higher total efficiency of 90 percent or more—about 3 to 4 percent points more than single-
stage turbocharging

- Full output at tropical, hot ambient conditions

- Full output at high altitudes

- Higher allowable mixture temperature enabling higher cooling water temperature for
independent power production

- Higher allowable return water temperature enabling higher flexibility for combined heat and
power

Interested in more information on GE’s J920? Visit www.ge-J920gasengine.com or contact our

HU UH

dedicated Sales team jenbacher.j920sales@ge.com .

HU UH