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Underpinning lower emissions with two-stage turbocharging
Everllence’s TCT is its latest generation of axial blower, offering improved performance to support lower engine emissions
As shipowners prepare to transition to lower carbon intensity fuels, Everllence is developing lighter weight, more powerful, more easily maintained and longer-lasting turbochargers.
One that has been specifically designed for IMO Tier III two-stroke marine engines is the TCT, one of the newest generation axial blowers. It is a technology that the enginebuilder says works equally well on high-performance power plants with two-stage turbocharging.
Everllence launched the TCT turbocharger series in 2019, starting with the TCT40, and subsequently adding the TCT30, TCT50 and TCT60. Ultimately, the series will comprise six frame-sizes, including TCT70 and TCT80 units.
Japan’s Mitsui E&S, an Everllence turbocharger licensee since 1981, produced its first TCT 40 unit in September 2025. One of the world’s largest manufacturers of two-stroke marine engines, Mitsui E&S intends to progressively add other sizes in the TCT range. These turbochargers will be installed on Everllence two-stroke engines that are manufactured by the Japanese OEM.
Ecocharge
Married to Everllence’s Ecocharge, the introduction of the TCT means two-stage turbocharging can achieve efficiency levels of up to 80%, a market-leading accomplishment, according to the group. Suitable for high- efficiency, medium- and high-speed engines, Ecocharge implements two blowers in a series to achieve a higher-pressure ratio than could be achieved by a single-stage turbocharger.
“Tests show a 5% improvement in charging efficiency”
Other benefits of Ecocharge include an improved environmental performance because of higher scavenging air pressures. And, in the age of increasingly stringent emissions penalties, the technology is compatible with a wide range of engines and fuel types that mean operators can use smaller engines for a given power output or, should they wish, lower emissions and fuel consumption by using the same engine.
Whatever the type of the engine, there is a blower to match. The Everllence range covers outputs from 600-30,000 kW per turbocharger. For instance, with compliance with Tier III regulations being uppermost in the mind of many operators, the long-established TCR range of blowers was created to handle engines fuelled by HFO, MDO, biofuels and gas across the widest possible output: 350 kW to 7MW.
ETB model
Turbochargers are constantly evolving. The latest-generation TCRs are made from more advanced materials that enable them to be more efficient and reliable, while also being more powerful and lighter. With lower cost of running in mind, the new materials mean less maintenance and a longer working life.
As Everllence’s ETB model illustrates, turbochargers are specifically designed to match every engine, in this case for EcoEGR applications in which the blower runs continuously in Tier III and Tier II Eco mode. Introduced some six years ago, EcoEGR has since been widely deployed in marine engines in the interests of lower emissions.
The ETB range was designed from the outset to marry up with the EGR system, a breakthrough in engine tuning. Under EGR, fuel consumption and NOx emissions are reduced in large turbocharged diesel engines so that the performance of the engine and blower are re-optimised. Typically, the blower runs continuously in both Tier III and Tier II Eco mode. Real-world tests show a 5% improvement in charging efficiency, a 10% increase in specific airflow and, especially impressive, a 25% gain in charging pressure.
“The TCF blower reduces emissions”
These increases in performance are achieved in a much more compact design than previous turbocharger series. Weight is down by roughly 40% and overall size by 30%.
Radial blower
Everllence’s TCF radial blower, optimised for maximum flow, is designed to function at part load. As tests have proved, a TCF retrofit and engine modification package improved fuel consumption in the relevant operating range by 4.5%. The TCF blower also reduces emissions to help meet regulations such as the Energy Efficiency Existing Ship Index (EEXI). The modular construction of the TCF makes for easy installation. In two-stage applications the TCF series works as the low-pressure turbocharger, a configuration that helps reduce the size or number of blowers required in ways that cut costs.
And as demand for retrofits grows, the TCFs are designed for quick and easy replacement because of the modular construction and standard connection dimensions. The range is also known for easy maintenance and extended periods between overhauls.
Heritage
Everllence’s latest designs build on a long heritage. Its first turbochargers were installed some 80 years ago and quickly built up a loyal following for their reliability. Today, they run on 65,000 engines in what amounts to a giant real-world laboratory that underpins a constant improvement.
The TCP range, for instance, is a product of that mindset, enabling output increases of about 20% that operators can exploit in their own way. Everllence explained: “That translates to increased power at a similar cost, or a smaller engine, or fewer cylinders for the same output.”
The numbers tell the story. Current one-stage blowers typically deliver pressure ratios of well above 5.0, while the TCPs achieve stable operating points as high as 6.7. These figures result from a complete reworking of the aerodynamic stages on the compressor and turbine sides. In other numbers, overall efficiency levels are improved by about 70%, dynamic behaviour in the form of the rotor moment of inertia is down by 25%, and specific engine costs by 20%. Maximum permissible temperature is 650-750C. And in the interests of ease of installation, the TCPs are plug-and-play because the flange connections are the same as existing turbochargers. The range is suitable for hydrogen, ammonia and methanol, as well as conventional fuels.
Blowers are some of the hardest-working items in the engineroom and even the most robust turbochargers can suffer failures. Everllence offers its PrimeServ 24/7 year-round troubleshooting service. Technicians are always available to deal with questions from the engineroom and get the blowers back up and working. In the worst case, OEM spare parts are only 24-hours away. Everllence prides itself on rapid deliveries and that is useful when downtime costs US$22,000 a day and often much more. With strategically placed hubs around the world, PrimeServ’s technicians can adjust on the spot if a ship misses a routine maintenance stop because of a changed route.
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