PM/BC Reduction by DPF and wet-esp for marine ship engines: Recent R&D in Korea Sunho Park Associate Professor Department of Mechanical Engineering Dankook University Republic of Korea Sep. 19 th, 2018 ICCT s 5 th Workshop on Marine Black Carbon Emissions
Outline
1. Background Speaker s research at Dankook University Synthesis and Characterization of PM Animal Exposure VOC Removal by Plasma PM from ship(hfo) Flame Stabilization Optical Diagnostics: Soot in Flame Burner Design
1. Background Air pollutants from ship and their climate effects Why is Greenland's ice getting darker? 5 th Source: Atmospheric Sciences ICCT Workshop September 2018, SF
1. Background Particulate Matters Schematic of diesel PM [TEM image of particulate matters] Guan, 2015, J. Environ. Management Main fractions Solid fraction (SOL) Soluble organic fraction (SOF) Sulfate particulates(so 4 ) - Elemental carbon - Ash Sub-category - Organic material derived from L.O. - Organic material derived from Fuel - Sulfuric acid - Water Total particulate matter(tpm) = SOL + SOF + SO 4 Source : Diesel particulate filter, www.dieselnet.com
1. Background IMO PPR Agenda Consideration of the impact on the Arctic of emissions of Black Carbon from international shipping We finalized the definition for Black Carbon, We have been identifying appropriate methods for measuring black carbon emissions, and We are considering possible control measures that reduce black carbon emissions from international shipping.
1. Background: Global Projects Cleanest ship project DEECON project HERCULES project SCR Burner DPF Innovative After Treatment System for Marine Diesel Engine Emission Control Budget: 3.465 M Duration : 3 yr. (09/2011 ~ 08/2014) M/V Victoria (BP) Dimension: 69.96 X 11.44 X 4.25(LBD, m) M/E: MTU8V4000, 880 kw, 1,800 rpm Fuel - Low sulfur fuel Operation - Advising speed control After-treatment system DPF + SCR Contents NOx PM SOx Engine out emission Emission with reduction tech. Reduction rate(%) 8 0.15 0.81 0.2-2.2 0.004 0.004 72.5-90.0 97.3 99.5 Electrostatic Sea Water Scrubber(ESWS) SOx and PM removal Non-thermal Plasma Reactor NOx and VOC abatement SCR Removal of any residual NOx ESWS wash water treatment system Treatment of liquid by-products Budget: 86 M + 25 M Duration : 119 months + 36 months The objectives of the HERCULES-2 Fuel flexible engine New materials Adaptive power plant Near-zero emissions engine Work package 8 80% PM reduction with after-treatment system Adaptation and integration of after-treatment system(scr on DPF)
1. Background Recent government-supporting R&D in Korea Development of NOx reduction unit for 10,000 ps-class ship engines (2011~2017, Ministry of Oceans and Fisheries) Installation and proof of SOx scrubber for ships toward IMO global sulfur cap (2018~2021, Ministry of Oceans and Fisheries) EGCS for Tier Ⅲ regulation and 0.1%-sulfur fuel (2012~2014, Ministry of Trade, Industry and Energy)
2. R&D Overview Development of DPF and wet-esp for ships 2012-2018, Ministry of Oceans and Fisheries PM analyzer <2 st. diesel engine HHI-MAN B&W 6S46MC-c7> 400 kw marine diesel engine Gas analyzer Diesel particulate filter Back pressure sensor 1,500 TEU container WET EP (3 MW BC/SOx after-treatment system) 5 th ICCT Workshop <Inlet and outlet view in DPF system> September 2018, SF
2. R&D Overview Basic Principles Diesel Particulate Filter Gas from engine outlet Schematic Filtered gas Wet Electro-static Precipitator Schematic electrode adsorption corona discharge water film collector plate Electrode (-) particle charging electrode water film Regeneration necessary Collecting Plate (+) Flushing of collector plate necessary
2. R&D Overview Ship application characteristics and the R&D objectives Ship application characteristics - High sulfur content in fuel results in SO 2 in exhaust gas and a high sulfate fraction in PM : Sulfur poisoning of catalyst, Corrosion of ESP electrode, etc. - PM contains more SOF (soluble organic fraction) : Controlling regeneration of PM in DPF is harder, DOC functionality issue - Size of the after-treatment system is much greater than the system for land vehicles - Allowable back pressure is lower - Ship stability issue Objectives: Not only deal with the issues in the above, but also satisfy the following conditions ; Diesel Particulate Filter Wet Electro-static Precipitator 5 th ICCT Workshop on par with existing systems September 2018, SF
2. R&D Overview Test bench for marine engine emission and performance Low speed engine cell Korean Register Testing & Certification Center Gunsan, Korea High/midium speed engine cell Fuel : Bunker-A (0.29%S), high sulfur diesel(0.34, 0.05%S), ULSD(< 10 ppms) Engine : HHI-MAN 6S46MC(2-str., 7.4 MW), Doosan Infracore 4V158TIH(4-str., 403 kw) Test cycle : E2, E3 cycle from ISO 8178
2. R&D Overview PM emission from the test engines 2-st 7.4 MW engine 4-st 400 kw engine (ULSD) ULSD HSD Total PM Emission rate (g/h) Soot SOF <Comparision of SOF> ULSD HSD Sulfate E2 E2 E2 E2 E3 E3 E3 E3
3. DPF for 400 kw ship engine Part design and development Pore former and microstructure of the substrate Pore former Parameter Graphite A B C D PMMA Walnut shell Density [g/cm 3 ] 1.3 1.3 1.3 1.3 1.3 1.2 Porosity [%] 50.1 50.6 49.9 51.0 50.5 53.7 70 Air Flow Rate vs Back Pressure Compressive Strength vs Pore Former Cont.(%) Ave. pore size [ μm ] 6.7 6.7 6.8 7.7 8.0 10.7 Intrusion vol. [cc/g] 0.40 0.27 0.37 0.39 0.37 0.30 Pressure Drop(mbar) 60 50 40 30 20 5P 10P 15P 20P 25P 30P Active regeneration burner 10 0 0 20 40 60 80 100 120 Air Folw Rate (kg/h) Air flow controller Fuel injecting nozzle Flame control Ignition test Burner systemization
3. DPF for 400 kw ship engine Test results DPF system for 400 kw engine Experimental conditions (E2 & E3 cycle) Cycle E2 cycle E3 cycle Power [kw] 403 302 202 101 403 302 202 101 Speed [rpm] 1,800 1,800 1,638 1,440 1,134 Torque [Nm] 2,139 1,604 1,069 535 2,139 1,763 1,337 849 Mode 1 2 3 4 1 2 3 4 0.02 Gravimetric 1.4 FSN 10 Opacity Particulate mass [g/kwh] 0.015 0.01 0.005 0 Engine out emission 3 mode 4 mode 2 mode 3 mode 4 mode E2 cycle E3 cycle DPF downstream Ave. reduction: 84% Filter smoke number [-] 1.2 1 0.8 0.6 0.02 0.015 0.01 0.005 0 Engine out emission DPF downstream 3 mode 4 mode 2 mode 3 mode 4 mode E2 cycle E3 cycle Opacity [%] 8 6 4 2 0 Engine out emission DPF downstream 3 mode 4 mode 2 mode 3 mode 4 mode E2 cycle E3 cycle
4. Wet-ESP for 3MW ship engine Background research Electro-static precipitator Electrostatic precipitator Filter Smoke Number [-] 2 1.5 1 0.5 0 Engine out Downstream of ESP Mode 1 Mode 2 Mode 3 Mode 4 E3 cycle Soot concentration [g/m 3 ] 20 15 10 5 0 Engine out Downstream of ESP Mode 1 Mode 2 Mode 3 Mode 4 E3 cycle Particle number concentration [#/cm 3 ] 10 7 10 6 Engine out Downstream of ESP 10 5 10 4 1000 100 10 100 1000 D [nm] p 2-st 7.4 MW engine emission measurement 2-ST diesel engine HHI-MAN B&W 6S46MC-C7 Hydraulic dynamometer Number concentration(#/cm 3 ) 10 7 Mode1 10 6 Mode2 Mode3 Mode4 10 5 10 4 10 3 10 2 10 1 10 100 D p (nm) FSN 0.30 0.24 0.18 0.12 0.06 0.00 Mode1 Mode2 Mode3 Mode4 E3 Cycle 5 th ICCT Workshop 참조 : 최종보고서 September 내 pp. 336-341, 별책2018, 1 내 pp.199-235 SF
4. Wet-ESP for 3MW ship engine Installation and test 2 st. diesel engine HHI-MAN B&W 6S46MC-c7 Supporting frame installation Engine monitoring : P, T, atm, back pressure Hydraulic Dyno. Supporting frame installation Pipe connection between EP and MW engine WET EP (3 MW PM/BC aftertreatment system) Smoke meter MSS Measurement of engine out emissions
4. Wet-ESP for 3MW ship engine Test results FSN method Principle PSA method 1 st 2 nd 1 st 2 nd Principle 75% 75% Engine out 70% 82% Engine out 82% 86% Downstream of ESP Downstream of ESP PM/BC reduction - FSN method: 75-82% - PAS method: 82-86% Back Pressure Gaseous emissions SO 2 (ppm) 1 st 2 nd 1 st 2 nd SO 2 /CO 2 ~ 38 mbar rarely removed
4. Wet-ESP for 3MW ship engine Test result of the final product PM/BC reduction SO 2 reduction Smoke (FSN) 0.04 0.03 0.02 0.01 0.00 0.44 FSN method PSA method Engine out Test condition ESP downstream (66kV) 91.4 % 91.4% 저감 Dilution ratio : 10 Dilution ratio : 15 SO 2 concentration [ppm] SO 2 concentration [ppm] 1400 1200 1000 800 600 400 200 1500 1000 500 0 0 SO2: 601.7 (1 min. ave.) CO2 : 4.3 (1 min. ave.) SO2/CO2 ratio : 139.1 (3.213% S) SO2: 621.4 CO2 : 4.3 SO2/CO2 ratio : 143.1 (3.304% S) 97.7% 98.6% 96.9% SO2: 528.4 CO2 : 4..3 SO2/CO2 ratio : 121.8 (2.813% S) 97.3% 1200 1500 1800 2100 2400 Time [sec] SO2: 1160.0 (1 min. ave.) CO2 : 4.3 (1 min. ave.) SO2/CO2 ratio : 267.4 (6.176% S) 93.4% SO 2, Ave. reduction rate: 97% SO2: 611.9 CO2 : 4.3 SO2/CO2 ratio : 141.4 (3.265% S) SO2: 14.0 SO2: 8.9 SO2: 16.2 SO2: 16.3 95.5% SO2: 1266.6 CO2 : 4.4 SO2/CO2 ratio : 288.7 (6.668% S) SO2: 77.0 SO2: 57.6 SO2: 1441.8 CO2 : 4..4 SO2/CO2 ratio : 329.7 (7.616% S) 0 200 400 600 800 1000 Time [sec] 82.4% SO2: 253.7 Soot concentration (mg/m 3 ) 0.33 0.22 0.11 0.00 Engine out 95.3 % 저감 ESP downstream (66kV) 95.7 % 저감 95.3% 95.7% Performance of the final product - Back pressure: 31 mbar < 60 mbar - SOx reduction: 97% - PM/BC reduction: 91.4% > 90% 5 th Test condition ICCT Workshop September 2018, SF
5. Summary and future plan Summary and future plan DPF system for sub-mw class and wet-esp for MW class marine engine developed in Korea Real ship installation and proof will be performed soon. Real ship proof of the developed DPF system (2018-2021, Ministry of Oceans and Fisheries) Ship installation scheduled Development of SCR on DPF system for 500 kw marine engines (2018-2021, Ministry of Trade, Industry and Energy) SCR catalyst coated filter
5. Summary and future plan Control measures under consideration (IMO PPR CG) Fuel Type Fuel Treatment Exhaust gas treatment Diesel Particulate Filters (DPF) Electrostatic Precipitators (ESP) Selective Catalytic Reduction (SCR) with Diesel Particulate Filter (DPF) Covers both SCR combined with DPF in a serial connection, and SCR-F technology. The latter is a single device which has the functions of both SCR and DPF by coating SCR catalysts on a filter for DPF.
Thank you very much for your attention! Sunho Park Associate Professor of Mechanical Engineering Dankook University Republic of Korea E-mail: sunhopark@dankook.ac.kr