LOW SULFUR FUELS & SCRUBBERS. Dr.VIS - VISWA GROUP

Transcription

1 LOW SULFUR FUELS & SCRUBBERS Dr.VIS - VISWA GROUP

2 ABOUT VISWA Viswa Lab is the 2 nd largest Global fuel testing lab Viswa Lab is certified to ISO and the highest level certifications for a Fuel Analysis and Survey organization Viswa Lab is also audited by ASTM and Dept of Defense USA Viswa Lab has 5 PhDs, 10 Marine Engineers/Master Mariners and over 12 Masters Degree Holders Viswa Lab carries out big data analytics and has identified several algorithms to identify problem fuels Viswa hold patents 8 patents in the field of bunker fuels Viswa Lab has developed 5 new instruments

3 VISWA CUSTOMER BASE Serves 8,500 ships - Nearly 80,000 samples - Over 620 customers

4 VISWA WHAT IS NEW? Selected as one of the four IMO approved testing labs New lab opened in Redcar, UK New lab opened in Fujairah, UAE Joined Intertanko Bunker Sub-Committee BQS hubs opening in Panama, ARA and Fujairah to join existing operations in Singapore, Houston and China Developed onboard instrumentation In-house for Energy Efficiency monitoring (VEEMS) and Scuffing detection through acoustic emission and advance detection of filter blocking and others

5 VISWA LAB PHILOSOPHY 5 There are 3 kinds of labs. First is those that test and give results. The 2nd level labs test and tell the customer about potential problems. VL belongs to the 3rd category We test, identify potential problems and also PROVIDE SOLUTIONS. Solutions are based on past experience in problem solving, use of additives

6 VISWA LAB FIRSTS 6 First to Identify Organic Acids in NOLA fuel in 1994 First to Identify H2S & Mercaptan sulfur in St.Petersburg fuels in 2007, causing catastrophic engine damage First to Identify cause of Piston Ring Breakage using bunker fuel algorithm PFIN First to Benchmark Fuel Quality using Ignition and Combustion Properties True Worth Index (TWI) First to Benchmark Fuel Quality using ISO 8217 tests Engine Friendliness Number (EFN) First to Benchmark Fuel Quality & Quantity Bunker Purchase Efficiency (BPE) and Bunker Quantity Index (BQI)

7 FBTN PAPER PRESENTED AT CIMAC CONGRESS 2013 SHANGHAI

8 NECN PAPER PRESENTED AT CIMAC CONGRESS 2013 SHANGHAI

9 VISWA A GREEN LAB Solar Installation in Houston 9

10 AREAS OF EXPERTISE 10 Bunker fuel oil analysis Additional tests including Chemical Screening, FT-IR, FBTN etc. Lubes and Cylinder lubes analysis Tribology and particle morphology studies Purifier Efficiency Studies Ignition & Combustion studies Material Failure analysis Corrosion Prevention Studies Bunker Quantity, Sludge, ROB and Forensic Surveys Energy Efficiency VEEMS Instrument Emission Control Viswa Scrubber

11 BUNKERS IN 2015 THE CURRENT STATUS IEA has predicted HSFO to MGO supplied ratio will change from 80:20 to 70:30 in Price Difference between HSFO and LSMGO has remained same even with drop in bunker prices. Price Difference will increase as MGO demand increases Experts predict price difference will go beyond $450/MT This makes the ROI for scrubbers much more attractive New hybrid 0.1% LSHFO only available in a few ports New HSFO desulfurization techniques are coming from R&D but will not be widely available to meet market demand VL in-house R&D has managed 15% sulfur reduction in HFO

12 NEW 0.1% FUELS - ISSUES TO CONSIDER More than 12 suppliers have announced products to meet the 0.10% Sulfur requirement for the 2015 ECA s Pricing between $10 and $50/MT less than LSMGO prices. Buyers are demanding $100/MT New 0.1% LS fuels may not be attractive since the price is not much less than MGO price and limited availability. Also may have other problems related to compatibility, tankage, pipelines etc. Effects of long term storage Not Known

13 SPECS FOR NEW LS FUELS AS TESTED FUELGRADE HDME50 SHELL ULSF 0.1% TOTAL MARINE VERTEX CHEM OIL BUNKPORT ANTWERP ROTTERDAM MOBILE HOUSTON SUPPLIER EXXON MOBIL SHELL MARINE TOTAL MARINE VERTEX CHEM OIL DENSITY(kg/m3) C(cSt) UPPERPOURPOINT( C) WATER(%m/m) MICROCARBONRESIDUE(%m/m) SULFUR(%m/m) TSP(%m/m) CATFINES(ALUMINUM+SILICON) VANADIUM(ppm) < 1 NETCALORIFICVALUE(Mj/kg) CCAI LUBRICITY(μm) ACID NUMBER EstimatedCetaneNumber

14 COMPATIBILITY ISSUES NEW 0.1% LS fuels in general are highly paraffinic, making compatibility of these fuels with any other fuel difficult. Permissible mixing 2% to 5% Exxon Mobil HDME50 shows poor compatibility with MGO. They now say that ring formed is due to the color of the fuel HDME50 fuel blocks filters of 5 microns or less by itself or blended with diesel or blended with heavy fuel (tested by Viswa Filter Blocking Tendency Number). Sample run through 5 µ filter FBTN number Fuel that does not choke filter < 1.4 HDME HDME 50 (95%)+MGO (5%) 4.33 HDME 50 (95%)+RMG 380 (5%) micron and higher sizes do not have any filter choking problem both by itself and when blended with MGO

15 WHAT IS VISWA FBTN (FILTER BLOCKING TENDENCY TEST)? Instrument to identify if fuels will cause filter choking in actual onboard conditions Fuel is subjected to temperature and pressure conditions similar to onboard conditions Filter size, temperature and pressure can be adjusted If FBTN value is < 1.4, no filter choking problems experienced If FBTN value is > 1.4, filter choking problems expected Higher the FBTN value, more serious filter choking problems FBTN LAB SETUP

16 FBTN Algorithm Test Results 16

17 FUEL QUALITY ISSUES DISTILLATES Problem cases increasing 17 # Machinery Problem # of Cases Common Problem Ports Probable Causes Tests to Identify 1 Filter Choking due to Bacteria > 30 Singapore, Rotterdam, US Gulf Bacterial Contamination Bacteria/Algae/Fungal grown test 2 Filter Choking due to high CP/CFPP > 25 European Ports Fuels with higher wax content Cloud Point/Cold Filter Plugging Point 3 Fuel Pump Problems > 5 Some US ports (ULSMGO supply) Low Lubricity/Viscosity HFRR Lubricity Test 4 Acidic Wear and Filter Choking > 10 Malaysia/Some US ports FAME (Biodiesel Contamination) FAME/GCMS

18 PROBLEMS WITH DISTILLATE FUEL BACTERIAL GROWTH Choked Filters

19 PROBLEMS WITH DISTILLATE FUEL WAX DEPOSITS (HIGH CP, CFPP)

20 EMISSION REGULATIONS IMPORTANT DATES 20 Most Important date is 2020 when Global Sulfur limit will drop to 0.5% This will be decided by IMO in 2018 However, Viswa Lab believes that this date will not change from 2020 since EU has clearly declared that In EU waters outside ECAs, the current 3,50% m/m fuel sulphur limit will change to 0.5% m/m from 1 January 2020 irrespective of any delay agreed by IMO in relation to the corresponding MARPOL Annex VI requirement

21 SCRUBBERS THE CURRENT STATUS Over 100 fitted scrubbers with over 40 on order 75% of orders on vessels younger than 10 years Bulkers at 3% account for 22% of orders 18% of orders from offshore and 50% from cruise and ferries Prices dropped considerably on all models Models Open Loop; Closed Loop; Hybrid Most Popular model is Inline Scrubber with one venturi or no venturi Best Performance Twin venturi (Highest SOx removal) Best Future Ready Twin venturi (Highest PM removal)

22 SCRUBBER ROI* THE CURRENT STATUS RETROFIT NEW BUILD Engine Size (MW) Days in ECA ROI (Years) Days in ECA ROI (Years) < months Scrubber will be incredibly attractive after the global switch to 0.5% sulfur whether it occurs in 2020 or *Data source from EGCSA member

23 Self-financing SCRUBBER FINANCING OPTIONS Complete financing from outside agency who will take the differential pricing towards repayment with NO UPFRONT FEES VS can finance scrubber manufacture with earnest deposit from ship-owner and installation cost. Owner pays full amount when the scrubber is functionally approved Consider having it co-funded by charterer since they are also beneficiaries as a joint venture

24 SCRUBBER SELECTION CRITERIA FINANCIAL CONSIDERATIONS Total Cost/Time Lifetime CAPEX OPEX Financing See separate slide Lifetime Maintenance and Special survey costs Metallurgy of the scrubber Connecting Aux Engines, boilers, Incinerators Off hire + Positioning voyage for installation Staff requirement and training

25 OWNER & CHARTERER CAN BENEFIT FROM SCRUBBER Ship Information Scrubber capacity 12MW Scrubber cost (illustrative) $3.2 Million Fuel savings from Scrubber = 40*150*$250 = $1.5 Million/Year {Fuel use 40 MTPD; 150 days of sailing in ECA & fuel SPREAD $250/MT} TO BE SHARED BETWEEN OWNER & CHARTERER 67/33 CHARTERER GAINS $0.5 Million/Year for handling the scrubber OWNER GAINS 0.8 Million/Year ($1 Million-$0.2 Million Operating Costs) PAYBACK = 3.2/0.8 = 4.0 YEARS

26 OWNER & CHARTERER CAN BENEFIT FROM SCRUBBER Scrubber CAPEX (12 MW) 50% in ECA 100% in ECA $3.2 Million $3.2 Million Scrubber fuel use, MTPD Days in ECA Fuel Spread (LSMGO- HSFO) $250/MT $250/MT Savings/Year $1.5 Million $3.0 Million OPEX costs by Owner $200,000/Year $400,000/Year Owner/Charterer benefits 67% 33% Owner/Charterer benefits $1.0 Million/$0.5 Million $2.0 Million/$1.0 Million Net benefits top Owner (who pays for the OPEX) $0.8 Million $1.6 Million Payback 4.0 Years 2.0 Years

27 PARTICULATE MATTER 27 Currently no regulation for Particulate Matter (PM) at this time PM particulates are classed into 2.5micron and 10micron 2.5 micron particulates are more harmful and they come from burning gasoline and diesel fuel 10 micron particulates come from burning heavy fuels and is easier to capture Total Particulate Matter 71,000 MT of fine particulate matter

28 VISWA SCRUBBERS SPECIAL POINTS No changes to main engine exhaust system or silencer. Only one damper sends exhaust to scrubber and one damper shuts off exhaust to atmosphere. Simple failsafe arrangement with spring loaded damper valves Very low electrical power requirement Low maintenance cost smaller components with lesser power requirements; low running cost No fresh water requirement for operation Low SW consumption works in Great Lakes and brackish water also Fully automated No user input required

29 VISWA SCRUBBERS SPECIAL POINTS Minimum sea water effluent discharge and can be stored onboard if required, suitable for post 2020 operations Improved Particulate Matter removal able to meet more stringent future regulations Most Economical scrubber in market Best value for the price Existing problems of current scrubbers on ships have been studied and Viswa Scrubber designed to avoid all such problems Payback time 1 year in ECA zone voyages; 2 years warranty with worldwide back up

30 Scrubber Flow Scheme

31 INLINE SCRUBBER Hybrid Operation Open Loop Hybrid Ready 3-Contact Stages Inside or Outside the funnel Trap to prevent water seepage into the engine Low pressure drop Optional ID Fan Proven Droplet Separation system INLINE SCRUBBER Dia. 2.4 M Height 12 M Weight 7 T 3- Stage Scrub bing Air Preheater Exhaust

32 Inline Option - Lower power needs ID Fan CEM Demister Figure 3: VS Hybrid-Inline SW Scrubber HYBRID CLOSED LOOP OPERATION Line Diagram Sea Water Scrubber/ Demister Cleaning System (FW) Caustic (50% NaOH) Tank & Feed System Caustic feed on ph control Aux E Exhaust PLC MCC Sea Water Supply on level control (CL) RecyclePump1 Recycle Tank Recycle Pump2 E-58 Filter with Back flush Sludge <18% Solids SW Pump (CL) E-57 E-56 Deaeration Tank ph, PAH & Turbidity Meter OvrBrd Discharge Waste Water Storage (CL only)

33 SCRUBBER SELECTION CRITERIA CONSIDERATIONS IN INSTALLATION Problems with retrofitting Time taken for installation Latest Techniques 3D virtual assembly Rack Mounted Scrubber Installation issues Inline V/S Twin Venturi Problems over the long term Typical Installation 3D View

34 SCRUBBER SELECTION CRITERIA TYPICAL SCRUBBBER PROBLEMS ENCOUNTERED Heavy vibration and noise from vortex formation Corrosion on piping, pumps, valves and casings due wrong material specifications; leakages due inadequate design for thermal expansion requiring retrofit design changes Crystallization of salts and soot deposits in scrubber components. Caustic leakage on decks. Deposits and sediments causing obstruction and leakage of pumps and nozzles Overflowing of internal collectors, excessive foaming, sludge not draining out - inadequate for harsh marine environment service Increased back pressure on main engine causing thermal overload and reduced speed (ID Fan in Twin venturi prevents this) Not enough space in exhaust uptake funnel for the maintenance of scrubber components

35 3D VIEW - SCRUBBER MODEL VIEW 1 Typical Installation 3D View

36 3D VIEW - SCRUBBER MODEL VIEW 2 Typical Installation 3D View

37 TWIN VENTURI ASSEMBLY 3D Drawing

38 IN CLOSING, CURRENT SCENARIO The Elite in Shipping are voluntarily accepting sulfur regulations. This earns them the credit as a Green Energy Organization A small percentage of suppliers, regularly adulterating fuels are now coming under pressure of criminal charges by agencies such as Dutch Police Hong Kong and Shenzhen have already announced a sulfur limit of 0.5%. It is a matter of time before more countries announce ECA's. Increased ECA improves viability of Scrubbers. R&D efforts for removing sulfur from the fuel are enjoying moderate success Regulations on Particle Matter can be expected though they are not currently in force. Crude oil and bunker fuel prices will remain stable for the next 3 years it appears right now Though this looks like a low point, Shipping will grow and bring profits to the stakeholders

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