Medium-speed MaK diesel engines up to 16 MW are being recognised for reliability, performance, good fuel efficiency and innovative emission reduction technology. To this end it is indispensable to adjust the engine at each operating point in an optimum way to the requirements. The Flexible Camshaft Technology (FCT) and flexible injection system developed by Caterpillar specifically for MaK engines have a key function in these endeavours. One of the big challenges was the reduction in development time without affecting reliability and service life. Success factors to achieve this were new development tools, improved test procedures, and consequent project planning. In the following years considerable efforts to improve environmental compatibility will be required. For maritime application the emission regulations of IMO (MARPOL 73/78) are binding worldwide. Furthermore, there are separate requirements of diverse authorities whose limits are below those of IMO. To meet these challenges Caterpillar has created the so-called ACERT program in order to enhance engine performance and drastically decrease emissions by measures internal to the engine. One means of increasing the engine power output is to increase the swept volume. An increase in mean effective pressure strongly depends on the availability of a higher charging pressure. The increasing use of the Miller cycle allows to decrease NOx emission by decreasing the gas temperature, but requires an increased charging pressure to compensate the attendant lack of air. MaK has set itself ambitious emission goals in order to meet future requirements and at the same time to enhance customer value. For the engine process this means that all emission relevant areas of the engine must be included in the development. Essentially, these are the Miller cycle and the increase in compression. To decrease NOx and soot emission at the same time, FCT and CCR (Caterpillar Common Rail) will become necessary as support measures. In the year 2002 this technology was demonstrated on a MaK 12 M 43 engine as an example. For the NOx emission a cycle value of about 8 g/kWh was reached and the FCT technology allowed to kept soot emission below the visibility limit over the entire operating range.


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