CONTINUOUS EMISSION MONITORING SYSTEMS (CEMS)

Transcription

1 CONTINUOUS EMISSION MONITORING SYSTEMS (CEMS) SHIPPINGInsight, October 2018 Hinrich Brumm // Markus Haas Strategic & Technical Industry Management Maritime October 2018

2 THIS IS SICK INTENTION OF FOUNDER MR. ERWIN SICK We are developing optic electronic sensors to bring benefit and protect human beings and the environment 2

3 CONTINUITY USING INNOVATIVE SENSORS BRINGS YOU COMPETITIVE ADVANTAGE First photoelectric switch based on autocollimation principle First light curtain for accident prevention 1956 First flue gas monitor 1978 First in-situ gas measurement device 1989 First distance determination with laser light on the pulse time-of-flight principle 1993 First safety laser scanner based on pulse time-of-flight principle High-speed 2D code reader Ultrasonic gas flow meter 2009 Navigation based on natural landmarks 2013 Cost-saving cascading of safe switches and sensors within a machine 2015 MARSIC300 Gas analyzer for Maritime Industry with self- calibration filter 2016 SICK AppSpace for creating and managing tailormade application solutions 3

4 NEW GENERATION OF ANALYZERS USING INNOVATIVE SENSORS BRINGS YOU COMPETITIVE ADVANTAGE MCS100EHW MARSIC200 MARSIC Q More than 300 installations on ships Q >3.000 MCS100E HW installations on land More than 250 installations of NEW MARSIC 4

5 THIS IS SICK BENEFIT FOR MANKIND AND NATURE 5

6 THIS IS SICK GERMAN SITES Hamburg Hamburg Dresden Dresden Freiburg Karlsruhe Waldkirch, Reute Donaueschingen Überlingen Überlingen 6

7 MARITIME SERVICES CONTINUOUS EMISSION MONITORING SYSTEMS Who are we: SICK started in 2009 with maritime CEMS Today more than 300 Installations Two different devices MARSIC200 and MARSIC300 Most certified solutions with seven Type Approval Certificates New Production site with more than 5,000m² Second new production site in operation 7

8 ALWAYS CLOSE TO YOU SHORT DISTANCES SAVE YOU TIME AND MONEY Germany Sweden China Italy USA Japan Malaysia Hungary Singapore Subsidiaries and representative offices Agencies Production Regional Competence Centers Development 8

9 SICK PRESENCE IN THE US A GLOBAL COMPANY WITH LOCAL SUPPORT! Bloomington, MN. 287 Employees Stoughton, MA. 110 Employees Houston, TX. 85 Employees

10 INTRODUCING SICK AG Wide Portfolio of more than 40,000 Products. We provide Solutions for: Factory Automation Yards, Machining, Robotics, Automotive, Logistics Automation Ports, Cranes, Industrial Vehicles, Traffic Process Automation Oil & Gas, Power, Metal and Steel, Maritime, 10

11 DNV GL CHINA TECHNICAL COMMITTEE Why Measure Emissions aboard? 2. CEMS Technology 3. Flow and dust measurement 4. Remote Control aboard a Ship 5. Approvals 6. Practical Impressions 11

12 WHY MEASURE MARITIME EMISSIONS? Vessel Operation Compliance (Mandatory) Economical Incentives (Optional) Ecological Incentives (Optional) Others (Optional) International -MARPOL Annex VI (Reg 13 (NOx) -MARPOL Annex VI (Reg 14 (SOx) National (e.g.) -EU Directive 94/25/EC -EU 2015/757 (MRV) -River Rine Regulation -Shenzen Port / China -Port of L.A. -Other Local Incentives -Norway Regulation (NO X Tax) -Swedish Regulation (SJÖFS) -other Performance optimization -Engine performance -CH 4 -Slip on DF -Ammonia Injection Control -Other Environmental Certification - Blue Angel -Green Ship -Green Image -Other -Prove Contracts -Retrofit -Control of Catalysts -R & D -Other 12

13 WHAT EMISSIONS TO BE MEASURED Measurement of SO X emission At scrubber in-/outlet Measurement of NO X emission at SCR in-/outlet No x monitoring as an on Board Verification Procedure (OBVP) Measurement of NO X emission to safe harbor fees Improve engine efficiency by measuring emissions (NOx, CO, CO 2, O 2 ) CH 4 slip control at LNG / DF engines Measurement of CO 2 according to EU Regulations 2015/757 13

14 Sulphur in FO [%] MARPOL ANNEX VI AND MEPC.259(68) MARPOL Annex VI and MEPC.259(68) limits the maximum Sulphur content in Fuel Oil Low Sulphur fuel to be used or HFO and exhaust gas treatment (Scrubber) This require daily or continuous exhaust gas measurement of SO 2 and CO 2 Ratio SO 2 /CO 2 is the compliance parameter 5 4,5 4 Global ECA Max 3.5% Sulphur in Fuel or (SO 2 /CO 2 )<152 After Max 0.5% Sulphur in Fuel or (SO 2 /CO 2 ) < 22 3,5 3 2,5 Max 0.1% Sulphur in Fuel or (SO 2 /CO 2 ) < ,5 1 0,

15 ONE SOLUTION: SCRUBBER Why Invest in Scrubber? Business case for installing EGCS Impact of the IMO decision on Scrubber Installation The number of ships with scrubbers increases disproportionately till ) Number of Scrubbers and also CEMS Will increase rapidly in the next years IFO380 : 380$/mt LSFO / MGO:540$/mt Δ: 160$/mt 1) Cumulative representation of the officialimo fuel availibility study 15

16 DNV GL CHINA TECHNICAL COMMITTEE Why to Measure Emissions aboard? 2. CEMS Technology 3. Flow and dust Measurement 4. Remote Control aboard a Ship 5. Approvals 6. Practical Impressions 16

17 EMISSION MONITORING ANALYZER HAS TO BE : Suitable for maritime Application Easy to Operate and service Approved & Accepted Reliable Robust Design to resists again: -Vibrations -Temperatures -Power fluctuation -Dirt/Dust Made for Application -VOC from HFO (very high dew point, sticky) -High PM load -SO 3 reacts with moisture to H 2 SO 4 (Sulfuric Acid), -NH 4 reacts with SO 3 and moisture to (NH 4 )2SO 4 -High Water content aft. Scrubber -droplets and dust -High cross sensitivity in IR-Spectrum Easy to Operate -Calibration without gas -Leakage test without tools Easy to Service -Global service network -Modular design for easy module replacement -Accessible Easy to Access -Remote Infrastructure Statutory -MARPOL (Drift, noise, etc) - Other regulations Class Requirements -Vibrations, EMC, etc Approved, that the analyzer will work under conditions aboard (vibrations, power fluctuation, etc. Approved, that the analyzer will not bring the ship into danger (flammability, disturbing bridge radio,etc) Without a CEMS, compliance of vessel incl. scrubber cannot prove! 17

18 CEMS TECHNOLOGY: IN-SITU AND EXTRACTIVE Two Philosophies: In-Situ: Measures direct in Process Extractive: Measures outside the Process -Hot-Wet Extractive (Gas analyzed in hot/wet condition) -Cold-Dry Extractive (Gas to be dried before analysis) All Technologies based on optical effects (Absorption) 18

19 CEMS-TECHNOLOGY: IN-SITU Situation -very compact, less Space -Scrubber exit very close to exhaust outlet -weather impact at sampling points In-Situ -Vibrations as mounted on stack -Harsh Environment -Less accessibility Extractive -Analyzer placed in better environment -Good accessibility (service/maintenance) Graphic (without CEMS): Wärtsilä 19

20 CEMS-TECHNOLOGY: IN-SITU In-Situ (Cross-Duct or Probe) Fast response time Detector Detector Light Source Easy to Install No sampling condition needed Light Source Mirror Sensitive to vibration and heat alignment Contact surfaces (windows) sensitive for water droplets Calibration with gas not practical Maintenance always on top of stack (inconvenient) 20

21 CEMS-TECHNOLOGY: IN-SITU WITH TDSL High Selectivity Spectral Resolution : nm Error, when H 2 O concentration not measured and corrected Typical range 0 20 Vol-%, after Scrubber: 40%! Error, when temperature drifts -> Spectrum is moving Sensitive to vibration NH 3 H 2 O 21

22 CEMS-TECHNOLOGY: COLD-DRY EXTRACTIVE Filter Extractive (Cold-dry) 180 C (wet) Cooler Pump -Extracted from Stack/Process -Analyzer in a safe environment -Low Investment for standard -Sulfuric Acid handling (SO 2 + H 2 O -> H 2 SO 3 / H 2 SO 4 ) -Sampling condition needed (cooler, pumps, ) -Moisture in gas must be removed -Maintenance required -Calibration Gas required 4 C (dry) Pump 50 C (dry) Out 22

23 CEMS-TECHNOLOGY: COLD-DRY EXTRACTIVE SO 2 -Measurements in UV or IR IN IR Spectrum, SO 2 is overlapped by water Water content must be absolute stable SO 2 H 2 O IN UV Spectrum, no water cross-sensitivity No stable dew point needed 23

24 CEMS-TECHNOLOGY: HOT-WET EXTRACTIVE Filter Extractive (Hot-Wet) -Extracted from Stack/Process -Analyzer in a safe environment -No movable parts, no mechanical pump -Absolute minimum maintenance -Internal ref.-filters, no cal.-gas needed -Highest availibility 200 C (wet) 200 C (wet) Ref.-Filter Ejector pump Ejector Air 24

25 CEMS-TECHNOLOGY: HOT-WET EXTRACTIVE Hot extractive principle, no condensation of H 2 O, H 2 SO 4, HNO 3 Sample gas at no point below 200 C No condensation of components possible No deposition with salts on surfaces SO 2 and NH 3 measurement also in raw gas at high concentrations. Cell of MARSIC300 Gold coated mirrors with ceramic overlay Optical path length: of 8.4 m: So longer the path length, so more absorption will result. More absorption, mean lower detection limits! Lowest Range for SO 2 of 30ppm Ref.-Filter 25

26 DUAL FILTER WAVELENGTH TECHNOLOGY Dual Wavelength Technique Absorbance = - log (U Sample/URef) Due to ratio measurement (Sample/Ref.) all alteration effects (beamer, detector, windows) are compensated. Typical components: CO 2, SO 2, NO, NO 2, H 2 O 1, 0 0, 5 Infra-Red Spectrum Sample.-Filter Ref.-Filter 7, 0 7, 5 8, 0 8, 5 9, 0 9, 5 1 0, 0 µ m 26

27 SO 2 Concentration (ppm) CEMS-TECHNOLOGY: HOT-WET EXTRACTIVE Filter wheel (component specific wavelength) Filter wheel (internal calibration filter) Cuvette SO 2 SO 2 SO 2 SO 2 SO 2 Light Source SO 2 SO 2 SO 2 SO 2 SO 2 SO 2 Detector SO 2 SO 2 0. MARSIC300 in measurement mode 1. flushing the cuvette with instrument air Measuring value 2. Setting signal zero 3. Swing in of specific calibration filter (or fill with gas) 4. Setting span point calibration Calibration curve for SO 2 5. Swing of specific calibration filter 6. Switch back to measurement SO 2 raw signal 27

28 DNV GL CHINA TECHNICAL COMMITTEE Why to Measure Emissions aboard? 2. CEMS Technology 3. Flow and dust Measurement 4. Remote Control aboard a Ship 5. Approvals 6. Practical Impressions 28

29 MEASUREMENT OF EXHAUST GAS FLOW - FLOWSIC NO X -Measurements needs to be not only concentration (ppm) but mass flow (kg/h) / (g/kwh) Option 1: Carbon Balance Method (MARPOL Annex VI) Option 2: Measuring the mass flow (kg/h) Must be measured for calculation: -CO, HC, CO 2 content of the raw exhaust gas -TC intake air conditions (h,p,t) -Uncorrected brake power of engine -Fuel oil consumption -FO composition must be known (S / C / H / O / N) Only NO X + Flow + Power gives NO X in g/kwh 29

30 DUST MEASUREMENT - DUSTHUNTER Dust measurement as indication for engine performance or to prove contracts Temperature: C Pressure: hPa Dust concentration: > 200mg/m³ Type of Dust: Soot Type of Fuel: HFO / MDO / Gas Diameter of duct: 0,8 1,5m 30

31 DNV GL CHINA TECHNICAL COMMITTEE Why to Measure Emissions aboard? 2. CEMS Technology 3. Flow and dust Measurement 4. Remote Control aboard a Ship 5. Approvals 6. Practical Impressions 31

32 REMOTE PLATTFORM INFRASTRUCTURE Customer Meeting Point Server 1 Remote Service Center Customer SICK Meeting Point Server SICK Meeting Point Router 32

33 REMOTE PLATTFORM INFRASTRUCTURES Monitoring Emissions prove compliance Condition Based Maintenance Maintenance, when needed Encrypted connection Increased security Predictive Maintenance safe time & money Experts global available fast reaction & competence Well maintained CEMS Increased availability 33

34 BLUEMON COMPLIANCE TRACKING MARSIC and BlueMon provide An environmental fingerprint of a ship Visualization of SO 2, CO 2, etc. tracked in ECA marked maps Powerful reporting for port state control, flag state and class Alarms crew due in time to take action by heading into sensitive areas 34

35 DNV GL CHINA TECHNICAL COMMITTEE Why to Measure Emissions aboard? 2. CEMS Technology 3. Flow and dust Measurement 4. Remote Control aboard a Ship 5. Approvals 6. Practical Impressions 35

36 TYPE APPROVAL OF MEASURING SYSTEMS Statutory Rules and Guidelines must be fulfilled: MARPOL Annex VI Regulations for Prevention of Air Pollution from Ships NTC2008 NOx Technical Code General regulation related to NOx (MEPC 177(58) Guidelines for exhaust gas cleaning systems Details for regulation 14 from MARPOL (MEPC 259(68) Appendix III Specifications for Analyzers to be used in the determination of gaseous components of marine diesel engine emissions: -Measuring principle for NO/NO2 is CLD NDIR resp. NDUV for CO2/SO2. -Accuracy -Precision -Drift -Linearity -Gas drying -Sampling system (probes/tubes) -Leakage tests -Calibration with span gases -Interferences (H2O and CO2 to HCLD, CO2 to CO, etc.) All tests included to grant, that the product is able to measure the emissions in the quality and reliability as required by MARPOL Annex VI. 36

37 TYPE APPROVAL OF MEASURING SYSTEMS Equivalence test is a challenge NOx Technical Code, Chapter 5.4.2:. Other systems (then ref.-systems) may, subject to the approval of the Administration, be accepted if they yield equivalent results to that of the equipment referenced in (e.g. CLD/HCLD for NO/NO 2 ) ISO 8178: The correlation testing is to be performed at the same laboratory, test cell, and on the same engine. The tests should be run concurrently. The equivalency shall be determined by F-test and t-test statistics, with outliers excluded, obtained under the laboratory cell and the engine conditions described above. Equivalence tests have been performed successful for MARSIC200 and MARSIC300 at the engine test bed of the University of Rostock under surveillance of a DNV GL. 37

38 TYPE APPROVAL OF MEASURING SYSTEMS When Measuring SO 2, what measuring range should be used? NTC2008 Appendix VIII Pt The analyzer range should be such that the measured emission value is within 15% - 100% of the range used. Typical SO 2 after a scrubber: 6ppm You can t measure 6ppm SO 2 in a range of ppm! 38

39 TYPE APPROVAL OF MEASURING SYSTEMS Class Rules and Guidelines must be fulfilled At least, Tests to be performed: -Power supply failure -Energy supply fluctuations -Cold -Dry heat -Damp heat -Vibrations -Declination -Flammability -Insulation resistance -High voltage -Electrostatic Discharge -Electromagnetic Fields -Conducted fast transient (Burst) -Conducted radio-frequency interference -Conducted impulse voltages (surges) -Conducted low-frequency interference (harmonics) -Conducted Emissions All tests to grant, that no danger is caused by the product to the vessel and its crew (EMV to bridge radio, electricity, flammability, etc.) AND that the product is able to work aboard a vessel (high vibrations, voltage fluctuation, etc). 39

40 TYPE APPROVAL OF MEASURING SYSTEMS Vibration resistance is a challenge General At Stack Near Engine 40

41 TYPE APPROVAL OF MEASURING SYSTEMS 41

42 TYPE APPROVAL OF MEASURING SYSTEMS EMV is a challenge, too 42

43 TYPE APPROVAL OF MEASURING SYSTEMS Environment Location closed area or open deck Temperatures Humidity Vibration 43

44 DNV GL CHINA TECHNICAL COMMITTEE Why to Measure Emissions aboard? 2. CEMS Technology 3. Flow and dust Measurement 4. Remote Control aboard a Ship 5. Approvals 6. Practical Impressions 44

45 INSTALLATION MARSIC300 FOR TWO PRIOR- AND AFT SCRUBBER 45

46 DRY SCRUBBER SAMPLING POINT Exhaust Gas Condition after Dry Scrubber Sampling Point after a dry scrubber Massive load of Calcium hydroxide In-Situ was not able to measure reliable Replacing an In-Situ analyzer with a hot-wet extractive system 46

47 GOOD ANALYZER POOR INSTALLATION Good Product - Good solution? How to work here? 47

48 GOOD ANALYZER POOR INSTALLATION -Ambient Temperature >70 C - Temp-Inside 120 C Solved by add. A/C 48

49 GOOD ANALYZER GOOD INSTALLATION Installation Location inside the funnel DECK12,5 MARSIC300 & I-Air Preparation unit Well and constant ambient air conditions Best access for staff and services 49

50 PRACTICAL IMPRESSIONS 50

51 SAMPLING FILTER UNITS ON STACK AND OPACITY MEASUREMENT 51

52 SAMPLING FILTER UNITS ON STACK AND FLOW MEASUREMENT (EXHAUST T/H) 52

53 PRACTICAL IMPRESSIONS 53

54 PRACTICAL IMPRESSIONS: REDUNDANCY 54

55 CERTIFICATES AND CONFORMITIES MARSIC300 Full Term Type Approval Certificates from Det Norske Veritas Germanischer Lloyd American Bureau of Shipping Chinese Classification Society Class NK, Japan Bureau Veritas (MARSIC300) Lloyd s Register Certified according to MARPOL Annex VI and NTC 2008 Basic rules for classification Societies IACS E-10 (EMC, vibrations, cold, ) DeSOx-Guideline MEPC.259(68), MEPC.184(59) MARSIC300 DeNOx-Guideline MEPC.198(62) MED (Marine Equipment Directive) by DNV GL 55

56 ANY QUESTIONS? 56

57 Markus Haas Technical Industry Manager Maritime