Comparative Assessment of the Thermal Load of a Marine Engine Operating on Alternative Fuels

The decarbonization of the operational fleet through the implementation of renewable and low-carbon fuels (LCFs) is considered a key factor in achieving the regulatory greenhouse gas (GHG) reduction targets set by the IMO and the EU. In parallel with optimizing engine energy efficiency and emission characteristics during retrofitting for LCF operations, it is equally important to assess and ensure the reliability of engine components under permissible thermal and mechanical loads. This study investigated the key factors influencing thermal and mechanical stresses on the cylinder–piston assembly components as the engine’s operation shifts from diesel to biodiesel, natural gas, methanol, or ammonia. The methodological foundation of this research was an original comparative analysis method that evaluates the impacts of thermal stress and combustion cycle energy efficiency factors. The combustion cycle energy parameters were modeled using a single-zone mathematical model. The thermal load factor was determined based on the ALPHA (αgas) coefficient of heat transfer intensity and the average combustion gas temperature (Tavg). The optimization of the combustion cycle during retrofitting was simulated without changes to the engine structure (or without “major” modernization, according to IMO terminology), with modifications limited to the engine’s combustion adjustment parameters. A key characteristic of the transition from diesel to LCFs is a significant increase in the maximum cycle pressure (Pmax), a factor influencing mechanical stresses: ammonia, +43%; LNG, +28%; methanol, +54–70%; biodiesel, no significant changes. This study confirms the adopted strategy to maintain thermal load factors for engine components equal to Dmax conditions. It is emphasized that, after ensuring Pmax-idem conditions, the thermal load during LCF operation aligns closely with the characteristic diesel level with minimal deviation. The thermal load reduction is associated with an increase in the excess air coefficient (λ) and a controlled reduction in the compression ratio within an allowable variation of ±1 unit. Based on statistical correlations, a rational increase in λ was identified, reaching up to 2.5 units. Considering the real-world operational load cycle structure of marine engines, further research will focus on analyzing thermal and mechanical stresses according to ISO 81/78, as well as E2 and E3 operational cycles.