CIMAC NMA Norway 27 January 2010

Transcription

1 CIMAC NMA Norway 27 January 2010 Ole Skeltved Head of the Marine Installation Department Marine Low Speed, Engineering < 1 >

2 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 2

3 NOx limits for new build engines 3

4 Emission Trend Emission restricted areas by IMO ECAs in 07/2009 Top Container Ports : 1. Singapore 2. China, Shanghai 3. China, Hong Kong 4. China, Shenzhen 5. South Korea, Busan 6. Netherl., Rotterdam 7. UAE, Dubai 8. Taiwan, Kaohsiung 9. Germany, Hamburg 10. China, Qingdao existing ECAs: Baltic Sea, North Sea Most used trading routes planned ECAs: Coasts of USA, Hawaii and Canada discussed ECAs: Coasts of Mexico, Coasts of Alaska and Great Lakes, Singapore, Hong Kong, Korea, Australia, Black Sea, Mediterranean Sea (2014), Tokyo Bay (in 2015) 4

5 Tier III candidate technology Tier III candidate technology: WIF (Water In Fuel emulsion) SAM (Scavenge Air Moistening) EGR (Exhaust Gas recirculation) SCR (Selective Catalytic Reduction) Turbocharger compressor outlet Seawater injectors Freshwater injectors WMC Flow change cyclone water separator Sea water drain Fresh water drain 5

6 How do the methods reduce NOx? EGR: recirculation of exhaust gas increases heat capacity and lowers O 2 content SAM & WIF: water vapour in combustion chamber increases heat capacity and lowers O 2 content High heat capacity and low O 2 in scavenge air gives low combustion temperatures Low combustion temperatures gives low NO x 6

7 NOx reduction technology Tier III Tier II Tier I (MFP/LDF4) *For SCR: SFOC is cost of urea. Corresponding to 7.5% SFOC increase if fuel is Diesel, 15% if fuel is HFO 7

8 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 8

9 Water In Fuel (WIF): Fuel Oil System From centrifuges Manual operated dumping valve Heavy fuel oil service tank Diesel oil sevice tank Duplex filter Main engine Viscotherm Mixing tank 1 Manual filter Air cooler Overflow valve Supply pumps Compressed air F.O.drain tank overflow tank Water oil measuring Preheater Circulating pumps Fresh water supply Homogenizer Auto filter Safety pump air operated 1 Dumping tank LEE4/OLS 9

10 WIF unit - Mechanical 10

11 Percentage NOx reduction NOx reduction versus load Test results from APL Singapore Load % OLS/

12 Fuel change % Fuel change versus water amount Test results from APL Singapore 2,0 Fuel consumption - Torque meters 1,0 0, ,0 75% load 50% load 25% load -2,0-3,0-4,0 % added water OLS/

13 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 13

14 Principal Sketch of the EGR Prototype System (NK/LDA) 14

15 EGR installation

16

17 MAN Diesel EGR Unit for MAN B&W Low Speed Engines EGR scrubber Exhaust gas into EGR scrubber from exhaust gas receiver Exhaust gas out of EGR scrubber, into EGR cooler EGR cooler EGR blower Exhaust gas out of EGR blower, into charge air pipe Cooling sea water to/from EGR cooler (LD/MZP) 17

18 MAN Diesel EGR Unit for 7S50MC.to reality: EGR gas pipes - scrubber to cooler EGR scrubber EGR shutdown valve EGR cooler & WMC Cooling water pipes EGR gas pipe/s - exhaust receiver to scrubber < 18 >

19 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 19

20 Expected Performance of Engine and Auxiliary System 8S60MC - 100% load and ISO ambient conditions 125,500 kg/h at C 2.5% Sea Water (16.0 m3/h x 20 C) Sea Water brine (10.9 m3/h x 66 C) SW Tank Salt Content: 3.2% 130,400 kg/h at 66.0 C 1.4 m3/h FW1 (8.0 m3/h x 59.0 C) FW1 (8.1 m3/h x 65.7 C) FW1 Tank Salt Content: 0.3% 130,300 kg/h at 65.7 C 1.3 m3/h FW2 (8.0 m3/h x 61.2 C) FW2 (9.3 m3/h x 61.2 C) FW2 Tank Salt Content: 0.02% 129,000 kg/h at 61.2 C (2432/PZS) 20

21 New SAM application versus normal cooler arrangement / (2100/KEA) 21

22 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 22

23 SCR Selective catalytic reduction Engine load Process computer NO X analyser Engine exhaust gas Mixer Urea solution storage tank SCR reactor Pump unit Cleaned gas Exhaust receiver Engine Turbo charger To stack 23

24 SCR Selective catalytic reduction 1 SCR reactor 2 Turbocharger bypass 3 Temperature sensor after SCR 4 Large motors for auxiliary blowers 5 Urea injector 6 SCR bypass 7 Temperature sensor before SCR 8 Additional flange in exhaust gas receiver Deck 4 6S35MC L/ /0801 (2160/PZS) 24

25 M/V Navion Dania with SCR catalytic reactor installed On the M/V Navion Dania, urea is used for NOx reduction. The urea is stored in hull tanks 25

26 Installation of SCR Before installation During installation After installation L/ /0801 (2160/PZS) 26

27 Nam Cheju, Korea, 40 MW 4 x MAN B&W 7K60MC-S, SCR Retrofit Installation Before After (3230/JH) 27

28 Nam Cheju, Korea, 40 MW Power Plant MAN B&W 12K80MC-S, SCR Installation Design temperature: 500 C Design pressure : 5 bar Inlet :Ø 2300mm, ASME SA 240, gr 316 Outlet :Ø 1800mm, ASME SA 387, gr 12, cl:2 Support tower : SM 400 M, JIL G (3230/JH) NO x after SCR : 260 ppm at 13 % O 2 Amonia slip : max 10 ppm NO x reduction efficiency: % 28

29 Two mode engines? Tier III only in Emission Control Area s different ways to reach two-tier limits, examples: Opt. Base engine IMO Global IMO ECA 1 optimisation Tier II After treatment 2 Fuel optimised (high NOx) After treatment, low 3 Fuel optimised (high NOx) After treatment, option 1 (eg WIF) After treatment, high After treatment, option 2 (eg EGR+WIF) 29

30 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 30

31 Sulfur % IMO & CARB Fuel-Sulphur Content Limits 5 4,5 4 3,5 Global: SECA: Global 3 2,5 CARB MGO: 1, (DMA) CARB MDO: (DMB) 2 1,5 SECA 1 0,5 CARB Phase 1 CARB Phase Year 31

32 Aalborg Industries & DFDS Exhaust gas scrubber retrofit project 20MW MAN B&W two-stroke engine Operating in SECA on MDO Exhaust gas scrubber permits HFO operation Expected payback time less than two years RO RO vessel M/V Tor Ficaria JPA / LEO 32

33 Development Schedule Test at MAN Diesel 2008 Ship installation July 2009 Service test Feb < >

34 DFDS Exhaust Gas Scrubber Project Re-heater (not shown ) Demister Absorber section Twin venturi inlet Swirl chamber Example of packing material in absorber JPA / LEO 34

35 Scrubber Principle Layout JPA / LEO 35

36 System solutions for reduction of exhaust gas emissions Agenda : NOx limitations WIF Water In Fuel emulsion EGR Exhaust Gas Recirculation SAM Scavenging Air Moistening SCR Selective Catalytic Reduction SOx limitations Scrubber WHR Waste Heat Recovery (LEE4 / OLS) 36

37 The WHR Principle Standard Engine Mechanical output: 48.5% Exh. gas 25.1% Charge air cooling: 17.8% Jacket water cooling: 4.8% Lub. oil cooling: 3.2% Radiation: 0.6% Mechanical output: 47.9% Engine with WHR system WHR elec. output 4.9% Condenser: 8.6% Exh. gas 14.7% Charge air cooling: 15.4% Jacket water cooling: 4.7% Lub. oil cooling: 3.2% Radiation: 0.6% Energy fuel: 100% Energy in Power-Turbine fuel: 100% (PT) in parallel with main engine turbochargers and / or Steam Turbine (ST) utilizing heat in the exhaust gas after the turbochargers Up to approx. 10% MCR power can be obtained with full WHR system (PT+ST) η standard 50% η WHR 55% η WHR+SAM 59% 37

38 Turbocharging Efficiency 38

39 WHR Applications 39

40 WHR Applications This means we will use 2 x MET71MA instead of 2 x MET83MA on a 8K80ME-C9 engine!! 40

41 Measured Influence on SFOC 41

42 Waste Heat Recovery Systems Options for exhaust Gas Utilisation Power Turbine Stand Alone PTG Power Turbine Generator Steam Turbine Stand Alone STG Steam turbine generator Combined Turbines Steam turbine Power turbine 42

43 Schematically sketch of PTG 43

44 STG Diagram (LEE4/CDL) 44

45 The WHR Principle Reproduced with permission from OSS 45

46 Combined SFOC in g/kwh at ISO conditions for 12K98ME-C6 Note: The total efficiency is dependent on the actual configuration of components and may therefore differ from this in an actual project. 46

47 CIMAC NMA Norway 27 January 2010 Questions? Ole Skeltved Head of the Marine Installation Department Marine Low Speed, Engineering < 48 >