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June 2016 www.coalage.com 53 engine technology continued Eisenblätter." This technology has been applied throughout our 1600 and 2000 Se- ries engines, and it again provides us with a unique selling proposition for the mining market." Eisenblätter likened the design of the company's latest engines displayed at bau- ma to the preparation of a fine meal: "Ev- erybody knows the basic ingredients that go into a great dish — the secret to success is how these ingredients are combined," he said. "In our case, we have several prin- cipal ingredients in engine design, such as two-stage regulated turbocharging with intercooling, exhaust gas recirculation, an advanced engine controller and optimized piston design for efficient combustion, and maximum fuel pressure. All of these technol- ogies are well known in the industry, but our engineers — our 'cooks' — know how to use them in the right combination, and to only use what's needed and not more. That's the secret of our success in this area." MTU also unveiled at bauma its Emis- sion Flex Package, which enables customers to operate engines in countries where very different emission requirements may apply and available fuel has a high sulphur con- tent. Using software designed specifically for the purpose, the engine's exhaust gas af- tertreatment system and SCR system can be deactivated; no hardware modifications are required. This solution also means that new vehicle designs will not require additional changes to the installation space needed to accommodate the engine. Initially the Emission Flex Package will be offered as a retrofit solution for Series 900, 460 and 500 engines designed to meet EU Stage IIIB and Tier 4 Interim specs. The package is designed for EU Stage IV and Tier 4 compliance on new engines. MTU mentioned that earlier this year its Capacitor Power System (CaPoS) had been installed for the first time, on three trucks operating in a mine in South Afri- ca. An MTU spokesman said, "By install- ing CaPoS, we have been able to operate trucks equipped with Series 4000 engines using just four batteries instead of the usual eight, supplemented by two CaPoS modules. The customer is very pleased and can now reduce operating costs sig- nificantly with our product." CaPoS is a "maintenance-free" starter system that employs supercapacitors and replaces the vehicle's starter batteries; it is claimed to improve battery service life fivefold. The system — which includes an integrated battery charger — is compact, less expensive, and has a higher degree of protection against dirt, grease and other contaminants, said MTU, and has been developed specifically for the demands of the mobile off-highway sector. Liebherr's New Line With its D96 and D98 engine series, Liebherr is launching two new diesel mod- el lines in the range of 700 kW to 4,500 kW (940–6,000 hp). The first of the D96 series is a V20 unit rated at up to 1,500 kW (2,000 hp), compliant with EPA Tier 4 Final ex- haust emission limits and available with SCR exhaust gas aftertreatment. Liebherr said it also is developing a nat-gas en- gine for stationary applications, based on D9620 design elements and with a power output of 1,070 kW. Production of the gas engines will start at the end of 2017. Liebherr said its D98 series engines have the highest power density available in their market segment, providing up to 43.5 kW per liter. The D98 series will be available in three different cylinder layouts: a V12 that will be the first of the series to enter the market, followed by V16 and V20 configurations. As with the D96 series, an available SCR sys- tem will enable the D98 engines to comply with Tier 4 Final emission limits. Produc- tion of these new engines will start at the end of 2016 in Colmar, France, and Bulle, Switzerland. Liebherr's ECU3 engine control unit has been completely revised for the new generation of 11.2 common rail sys- tems. Now an all-in-one system, it in- cludes all control functions for the engine, the common rail system and exhaust gas aftertreatment. Volvo Penta: Maximum Versatility Volvo Penta stated that its new 16-liter en- gine, designed for maximum flexibility in mobile applications, offers a wide range of benefits and features including improved fuel consumption, increased torque and a new turbocharger. The TAD1643VE-B was developed in answer to customer requirements for a reliable, more compact off-road industri- al powerplant, according to the company. OEMs and end users expressed a desire to find an alternative engine choice that is more suitable for the latest generation of mobile applications, where engine dimen- sions, weight and installation space are concerns. The new 565-kW (750-hp) unit is based on Volvo Penta's TAD1643VE, but with modified features that enable it to be in- stalled in a wider range of machines. Those features include: Meeting Stage V Regulations The Stage V regulations to be introduced by EU countries will bring extremely stringent emissions regulations for construction, mining and material handling equipment, commencing January 1, 2019. The key re- quirement for Stage V is a particulate num- ber (PN) count of 1012/kW-hr — the maxi- mum amount emitted for each kW of engine output per hour. The amount of particulate matter (PM) emitted by weight will drop to 0.015 g/kW-hr. Taken together, the PN count and PM weight requirement in effect eliminate 99.9% of all PM, which requires the use of a diesel particulate flter (DPF). Additionally, oxides of nitrogen (NOx) emissions will be set at the ex- tremely low level of 0.4 g/kW-hr, requiring the use of Selective Catalytic Reduction (SCR) af- tertreatment. Engines above 751 hp (560 kW) are included in the Stage V regulations, but do not require the PN count. Liebherr's D98 series diesels will be avail- able in three versions: a V12, shown here, followed by V16 and V20 configurations.