Reducing Exhaust Emissions from Wärtsilä Marine Engines Moottoritekniikan seminaari Teknologiateollisuus ry 18 May 2010 Göran Hellén 1 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 1/29
Contents Marine Emission Legislation Update NOx Reducing Technologies Scrubber Technology for SOx Reduction Gas Fuel Alternative 2 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 2/29
Contents Emission Legislation Update 3 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 3/29
IMO Requirements on NOx Revised Marpol Annex VI NOx (g/kwh) 18 16 14 12 10 8 6 4 2 0-2.5 g/kwh ~20% -80% Wärtsilä engines 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 Rated engine speed (rpm) Tier I - 130 kw - New ships 2000 Tier II - 130 kw - New ships 2011 Tier III - 130 kw - New ships 2016 in designated areas 2000 Tier 1 limit (global) 17 11.3 g/kwh ISO NOx 2011 Tier 2 limit (global) 14.5 9.0 g/kwh ISO NOx 2016 Tier 3 limit 3.4 2.3 g/kwh ISO NOx Only NOx designated area (NECA) Existing areas: USA and Canada coastal waters; Expected areas: North Sea, Baltic Sea 4 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 4/29
IMO Fuel Sulphur Caps 4,5% 3,5% 1,5% 1,0% 0,5% 0,1% Global SECAs (USA and Canada coastal waters, Baltic Sea, North Sea, English Channel) Wärtsilä engines are designed to cope with any fuel sulphur content FGD (scrubber) alternative is allowed 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 5 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 5/29
IMO Emission Control Areas (ECAs) Main requirements on SOx Emission Control Areas Distillate fuel to be used from 2015 or scrubber Main requirements on NOx Emission Control Areas Tier 3 level (80% NOx reduction) from 2016 Existing SOx Emission Control Areas Baltic Sea North Sea and English Channel North American Emission Control Area Existing NOx Emission Control Areas North American Emission Control Area New Expected Emission Control Areas (discussed but no decisions taken yet): Baltic Sea (also for NOx) North Sea (also for NOx) Norwegian Sea (NOx and SOx) Tokio Bay (NOx and SOx) 6 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 6/29
Marine Fuel Sulphur Restrictions in California Regulation Applies Within 24 Nautical Miles of the California Coastline Regulation Applies to All Engines on Ocean-going Ships Mandatory use of Low Sulphur Marine Distillate Fuel: From 2009 Max 1.5% Sulphur in Marine Gas Oil (MGO) Max 0.5% Sulphur in Marine Diesel Oil (MDO) From 2012 Max 0.1% Sulphur in MGO and MDO Safety and technology demonstration exemptions FGD (scrubber) is not allowed 7 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 7/29
Marine Fuel Sulphur Restrictions in Europe Sulphur in Fuel caps in Europe: 0.1% (1000 ppm) from 2010 EU ports and inland vessels 1.5% (15000 ppm) in force for passenger ships in regular service to/from EU ports FGD (scrubber) is allowed 8 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 8/29
Marine Incentive / Penalty Schemes Norway: Environmentally differentiated tonnage tax system NOx fee for vessels operating in Norwegian waters 15 NOK/ kg NOx with some possibilities to discount Sweden: Differentiated fairway and harbour fee system Voluntary emissions control programs established by classification societies Port authorities emissions control programs 9 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 9/29
Contents NOx Reducing Technologies 10 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 10/29
Available and Potential NOx Reduction Technologies Extreme Miller and 2-stage TC (ca. NOx -40%) Low NOx combustion tuning (ca. NOx -10%) EGR system (ca. NOx -60%) Wetpac H - Charge air hum. (ca. NOx -40%) Wetpac E - Water Fuel Emulsion (ca. NOx -25%) Wetpac DWI - Direct Water Inj. (ca. NOx -50%) NOR (SCR) system (ca. NOx -80%) Gas engine (ca. NOx -85%) Tier 3 0% 20% 40% 60% 80% 100% NOx Reduction Potential 11 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 11/29
Effects of Miller Timing Shorter compression stroke compared to STD timing Expansion stroke remains unchanged => lower specific fuel consumption => process gas temperature lower lower NOx lower component temperatures lower cooling losses Higher boost required for unaffected power output turbocharger speed limitations Main reason for introducing 2-stage turbocharging along with the need for higher power output 12 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 12/29
Effect of Miller timing 4 stroke Engines Wärtsilä 6L20 with advanced Miller timing. Charge air pressure need and corresponding NOx emission reduction with constant firing pressure, constant injection timing and nominal 100% power & speed. 10 120 9 100 8 80 PIC 7 60 NOx (%) 6 40 5 20 4-90 -80-70 -60-50 -40-30 -20-10 0 0 Earlier IV closure 13 Reducing exhaust emissions from Wärtsilä marine engines 18 May 2010 Göran Hellén 13/29
Contents Wärtsilä NOR System for NOx Reduction 14 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 14/29
SCR catalyst operation principle NH 3 15 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 15/29
Wärtsilä NOR system overview Control system cables= Compressed air = SCR Sootblowing Urea piping = Dosing & Control unit Compressed air Urea tank Pump unit Wecs 16 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 16/29
Selection of NOR Reactor for Wärtsilä Engines WÄRTSILÄ NOR OVERALL DIMENSION TABLE W Size Engine Power kw Reactor W mm Reactor H mm Reactor L mm Flanges DN mm Dosing Unit Size W 1 1260 945 4505 3440 500 1 2 1261-2240 1260 4690 3440 700 1 3 2241-3500 1575 5045 3440 800 1 4 3501-5040 1890 5215 3440 1000 1 5 5041-6860 2205 5410 3440 1200 1 6 6861-8960 2520 5915 3440 1300 2 7 8961-11340 2835 6110 3440 1500 2 H L 8 11341-14010 3150 6485 3440 1600 2 9 14011-16950 3465 6685 3440 1800 2 10 16951-20170 3780 6885 3440 2000 2 NOR reactor will be selected according to engine power Other components will be selected according to the chosen reactor size The design principle is that all components are to be chosen according to exhaust gas flow 17 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 17/29
SCR System - Typical Consumables TYPICAL OPERATION COST DISTRIBUTION Catalyst replacement Urea 100% SCR power Catalyst eplacement SCR power Fuel Urea 100% 1. Reducing agent 2. Compressed air for reducing agent injection 3. Compressed air for soot blowing 4. Power for NOx monitoring, if used (not in standard scope ) 5. Air conditioning of cabinets 6. Catalyst element 7. Other 18 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 18/29
SCR References More than 200 Wärtsilä engines with SCR are in operation today, Marine and Stationary Power plants 4-stroke and 2-stroke 19 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 19/29
Contents Wärtsilä Scrubber System for SOx Reduction 20 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 20/29
SOx Reduction with SOx Scrubber Closed loop works with freshwater, to which NaOH is added for the neutralization of SOx. Exhaust Gas CLOSED LOOP = Zero discharge in enclosed area NaOH unit ph Scrubber ph Fresh water Water Treatment Cooling Process tank Holding tank Seawater Sludge tank 21 Environmental Wärtsilä This document Legislation the & property Technology of Wärtsilä Development Corporation and shall not 9-10.2.2010 be copied or reproduced Göran without Hellénthe consent 21/29 of the owner. Wärtsilä
Alkalinity in the Baltic Sea Finland Sweden Open sea alkalinity Surface data (0 15 m) Data from 2001-2005 22 Environmental Wärtsilä This document Legislation the & property Technology of Wärtsilä Development Corporation and shall not 9-10.2.2010 be copied or reproduced Göran without Hellénthe consent 22/29 of the owner. Wärtsilä
Scrubber Operation Cost Saving and Payback Time Scrubber operation cost saving and payback time 1,2 15 000 1,1 Operating cost savings [1000 / year] 13 000 11 000 9 000 7 000 1,0 0,9 0,8 0,7 0,6 0,5 0,4 Payback time [years] 5 000 0,3 300 350 400 450 500 550 600 650 700 750 800 850 900 Fuel price difference (MGO-HFO) [USD/t] 23 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 23/29
Test Results from Wärtsilä SOx Scrubber Wärtsilä scrubber on Neste Oil MT Suula with a 4R20 auxiliary engine rated at 680 kw. Tests in 2008-2009, including certification. Tests on HFO with 3.4% sulphur and HFO of 1.5% sulphur Test results SOx removal > 99% in all operating conditions (NOx reduction: 3 7%) (Particle matter reduction: 30 60%) 24 Environmental Wärtsilä This document Legislation the & property Technology of Wärtsilä Development Corporation and shall not 9-10.2.2010 be copied or reproduced Göran without Hellénthe consent 24/29 of the owner. Wärtsilä
Contents Gas Engine Alternative 25 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 25/29
Natural Gas as Fuel - Gas Engine Technologies Gas-diesel (GD) engines: Runs on various gas / diesel mixtures or alternatively on diesel. Combustion of gas, diesel and air mixture in Diesel cycle. High-pressure gas injection. Spark-ignition gas (SG) engines: Runs only on gas. Combustion of gas and air mixture in Otto cycle, triggered by spark plug ignition. Low-pressure gas admission. Dual-fuel (DF) engines: Runs on gas with 1% diesel (gas mode) or alternatively on diesel (diesel mode). Combustion of gas and air mixture in Otto cycle, triggered by pilot diesel injection (gas mode), or alternatively combustion of diesel and air mixture in Diesel cycle (diesel mode). Low-pressure gas admission. New releases 20DF, 34DF, Gas-diesel (GD) engines Dual-fuel (DF) engines Spark-ingnition gas (SG) engines 32DF, 50DF 34SG 32GD, 46GD 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 26 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 26/29
Gas Fuel Alternative Typiacl NOx, SOx and Particulates Emissions HFO versus Gas Fuel In gas mode the DF engine meets the IMO Tier III regulation already today 100% NOx (relative) 100% SOx (relative) 10-15% HFO Gas (DF engine) ~0% HFO Gas (DF engine) 100% Particulates (relative) 0-5% HFO Gas (DF engine) 27 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 27/29
Examples of gas (dual-fuel) engine references Petrojarl 1 FPSO Petrojarl 2x 18V32DF 2x 52 000 running hours Sendje Ceiba FPSO Bergesen 1x 18V32DF 38 000 running hours Viking Energy DF-electric offshore supply vessel Eidesvik Kleven Verft 4x 6R32DF 4x 49 500 running hours Stril Pioner DF-electric offshore supply vessel Simon Møkster Kleven Verft 4x 6R32DF 4x 46 500 running hours Provalys and Gaselys DF-electric LNG Carrier Gaz de France Alstom Chantiers de l Atlantique 2x 12V50DF + 2x6L50DF Total 92 000 running hours for 2 ships Gaz de France energy DF-electric LNG Carrier Gaz de France Alstom Chantiers de l Atlantique 4x 6L50DF Total 58 000 running hours British Emerald DF-electric LNG Carrier BP Shipping Hyundai Heavy Industries 2x 12V50DF + 2x9L50DF Total 54 000 running hours Totally 62 contracted dual-fuel engine powered LNG carriers whereof 30 delivered 28 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 28/29
Thank You for Your Attention! 29 Environmental Legislation & Technology Development 9-10.2.2010 Göran Hellén 29/29