Experience innovations in turbocharger technology!

Single-stage turbocharging up to a pressure ratio of 6:1

Today's exhaust-gas turbochargers for the single-stage turbocharging of combustion engines are standard technology. They are usually a core component of large engines to satisfy a wide range of requirements. New advances in engine development are hardly feasible without optimising the exhaust-gas turbocharging process.

One example: the charging pressure of up to 6:1 that is needed for dual-fuel engines can only be achieved by further developing the present ST27-EP series.

Figure: ST27 compressor performance
Figure: ST27-EP compressor performance

Our development priorities:

  • High charging pressures for the highest engine efficiency, especially in diesel, gas and dual-fuel applications
  • Optimisation of the turbocharger performance
  • Modification of the components for very high exhaust-gas temperatures
  • Extension of the maintenance intervals and service life for all of the components
  • Reduction of noise emissions

Your benefits:

  • High engine efficiency
  • Reduced fuel consumption
  • Lower exhaust-gas and noise emissions
  • Reduced maintenance costs and time
  • Longer service intervals and shorter downtimes during maintenance

Please refer to our individual products for more details of our single-stage turbochargers.

Two-stage turbocharging up to a pressure ratio of 12:1

Compared to single-stage turbocharging, two-stage exhaust-gas turbocharging allows a significant increase in the maximum charging pressure. In conjunction with adapted engine's valve control times (Miller cycle timing), the engine's efficiency can be further increased with a simultaneous drop in fuel consumption and emissions. Turbocharging efficiencies of more than 75 percent can be achieved thanks to intermediate cooling.

Engine with KBB turbocharger
Figure: 6DL36 engine (with HPA7000 & HSR6 K2B turbocharger)

Our development priorities:

  • High charging pressures for the highest engine efficiency, especially in diesel, heavy fuel oil, gas and dual-fuel applications
  • High turbocharger performance for turbocharging efficiencies of more than 75 percent
  • Engine and operation-specific adaptation of the closed- and open-loop control strategy
  • Extended maintenance intervals and very short downtimes during servicing work
  • Low noise emissions

Your benefits:

  • System solutions for the integration of a two-stage turbocharging system that are perfectly matched to your engine
  • The highest power density for your engine
  • Reduced fuel consumption
  • Lower exhaust-gas and noise emissions


Please refer to our individual products for more details of our two-stage turbochargers.

Exhaust-gas turbochargers for exhaust-gas recirculation (EGR)

Exhaust-gas recirculation can be used to reduce nitrogen oxides in both single-stage and two-stage turbocharged diesel engines. Part of the engine's exhaust gas is thereby returned to the combustion process. Using an exhaust-gas recirculation system allows you to opperate without exhaust-gas aftertreatment such as SCR. The requirements of the turbocharging system will vary depending on the chosen EGR system (e.g. high-pressure EGR).

High-pressure EGR with single-stage exhaust-gas turbocharging
High-pressure EGR with single-stage exhaust-gas turbocharging
High-pressure EGR with two-stage exhaust-gas turbocharging
High-pressure EGR with two-stage exhaust-gas turbocharging

Our development priorities:

  • Development of exhaust-gas turbochargers (e.g. ERT20) for single-stage turbocharged diesel engines with high-pressure EGR in the output range between 500 kW and 2 MW
  • Modification of exhaust-gas turbochargers for two-stage turbocharged diesel engines with EGR in the output range between 500 kW and 5 MW
  • Optimisation of coatings and use of alternative materials to prevent damage from corrosion, sooting and particle impacts
  • Substitution of casing materials for intake temperatures up to 140 °C
  • Optimisation of thermodynamics and flow path on the compressor and turbine side
  • Application-specific modification of bearings, shaft sealing and oil supply with both the EGR mode switched on and off

Your benefits:

  • Use of exhaust-gas turbochargers especially adapted to EGR operation
  • Sound support to adapt the EGR system and exhaust-gas turbocharging process
  • Reduced particle emissions
ERT20 – AGR turbocharger for single-stage turbocharged diesel engines and high-pressure EGR

Condition-based Maintenance (CBM)

Intelligent, continuous monitoring of exhaust-gas turbochargers entails much more than just checking the speed and charging pressure. For example, it also enables targeted service depending on the real stresses to which the components are exposed and in response to unforeseen operating conditions (condition-based maintenance). This type of monitoring is ideal in applications that are characterised by high partial-load shares or greatly varying load profiles.

Online monitoring of an exhaust-gas turbocharger
Figure: Online monitoring of an exhaust-gas turbocharger

Our development priorities:

  • Prevention of unforeseen failures and severe turbocharger damage through the targeted monitoring of all important components
  • Optimization of the compressor and turbine washing processes
  • Extension of turbocharger monitoring with a focus on customized servicing solutions
  • Turbocharger data management for systems with several single-stage and two-stage turbocharged combustion engines

Your benefits:

  • Monitoring of the turbocharger's performance and operating condition
  • Adapted compressor and turbine washing intervals and washing sequences
  • Service intervals based on use and operation
  • Reduced service and operating costs thanks to flexible service intervals depending on the stress to which the components are exposed

Any questions about our activities in innovative fields?

If so, don't hesitate to ask our experienced engineers or simply send us an enquiry via our contact form. Feel free to contact Dr. Silvio Risse for more information on technical details: you can call him on +49 351 4085 622 or send an e-mail to silvio.risse@kbb-turbo.com.

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