Hydraulically supported fuel valves
HYDRAULICA
Less fuel. Cleaner combustion. Longer intervals.
HYDRAULICA keeps the fuel valves of your diesel engine steady when they close. The fuel burns completely, even at part load. For 2- and 4-stroke engines on ships and in power plants.
How it works
A steady valve makes the difference
A standard fuel valve is designed for 85 to 100 % load. At part load the needle bounces after closing and fuel drips into the combustion chamber. HYDRAULICA applies a defined hydraulic oil pressure to the fuel valve. The needle stays closed, no fuel drips after the injection and combustion is complete.
Before: standard fuel valve, the needle bounces after closing.
After: with HYDRAULICA, after-dripping is almost completely avoided.
The system
Four components, one clear setup
The system is added to your existing engine. No IMO-relevant components are changed.
System layout on a V-type diesel engine, top view: HPU, VPC and SBC supply the modified fuel valves through high-pressure pipes, single- or double-walled. Dimensions in cm.
Hydraulic Pump Unit (HPU)
Oil tank, operating and standby pump for redundancy and all electrical equipment. The oil is the same as the engine lubrication oil. One unit can supply several engines.
Variable Pressure Controller (VPC)
Distribution block, proportional valve and calculator. It sets the right pressure for each operating point.
Separation Block Cabinet (SBC)
Installed as close to the engine as possible. It shuts off the supply and monitors the pressures.
Modified fuel valves
Lube oil holds the opening pressure on top of or inside the spring chamber. Best done during a scheduled valve overhaul.
What you gain
Savings you can calculate
2 to 8 %
less fuel
0.65 to 1.69 years
payback in five business cases
Less CO₂
and visibly fewer particles
Longer TBO
fewer spare parts, fewer service hours
Business cases
Five ships, five calculations
Calculated with the average values of the last twelve months and an MGO price of 532 € per tonne. Lower maintenance and spare part costs are not included, so the real benefit is higher.
| Ship | Main engine | Fuel saving | Saved per year | Investment | Payback |
|---|---|---|---|---|---|
| Container ship, 812 TEU | 1 × MaK 9M43, 8.4 MW, 4-stroke | 6 % | 339 t · 180,450 € | 160,000 € | 0.89 years |
| Container ship, 862 TEU | 1 × MaK 9M43C, 8.5 MW, 4-stroke | 5 % | 280 t · 148,726 € | 160,000 € | 1.08 years |
| Container ship, 2,272 TEU | 3 × Götaverken, 58 MW, 2-stroke | 2 % | 1,400 t · 744,958 € | 485,000 € | 0.65 years |
| Coastal tanker | 1 × 6 MW, 4-stroke | 4 % | 173 t · 91,949 € | 155,000 € | 1.69 years |
| RoRo ferry | 2 × Pielstick PC 2.5, 12 MW, 4-stroke | 8 % | 450 t · 239,289 € | 330,000 € | 1.38 years |
Budget prices including parts and service, as of February 2022. Your result depends on engine maker, setup and operating profile.
Proven principle
Proven before, made new
The principle behind HYDRAULICA ran on more than 120 diesel engines: 45 installed directly between 1989 and 1995, and around 80 more by a larger licensee from 1996. In 2001 the system was shelved because it competed with OEM spare part sales. In 2025 we relaunched it, technically upgraded and ready for newer engine types.
RoRo cargo ship. Two Pielstick 12V PC2.5 main engines: high fuel savings, less CO₂ and visibly fewer particles.
2-stroke engine. Installation on a Sulzer RND90 with double-walled lube oil supply pipe.
DNV. Letter of No Objection in principle for diesel engines.
RINA. Class approval for diesel engines.
How we work
From your data to real savings
1 · Share your data
Engine type, operating profile and fuel consumption in our customer data sheet.
2 · Business case
We calculate savings and payback for your engine.
3 · Install
Fuel valves are modified during a scheduled overhaul, HPU, VPC and SBC are added.
4 · Measure
You see the savings in your own fuel figures.
Questions we hear
Your questions, answered
Which engines does HYDRAULICA work with?
2- and 4-stroke diesel engines, on ships and in power plants. We check your engine type before we make an offer.
Are certified engine components changed?
No. No IMO-relevant components are changed. DNV has issued a Letter of No Objection in principle and RINA a class approval.
Which oil does the system use?
The same oil as the engine lubrication oil. No extra consumables are needed.
Can one unit supply several engines?
Yes. The pump capacity of the HPU can be chosen for several engines.
Can I combine it with blueEGR?
Yes. HYDRAULICA and our exhaust gas recirculation can be installed together.
Contact
Get your savings calculation
Send us your engine type, your operating profile and your fuel consumption. We calculate what you could save and when it pays back.
All data on this page is non-binding and from individual projects. Every project is assessed individually.
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