dryegcs® process - a.pmcdn.neta.pmcdn.net/p/xgen/community/events/2009/san_francisco/... · data...

Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms

Sus ta ina ble Shipping Confe re nc e 2009 in Sa n Fra nc is c o, U.S.A.Ra lf J ürge ns , Head of R & D, Couple Sy s te ms GmbH, Hamburg, Germany

1. For the Re duc tion of Sulphur a nd Pa rtic le s

DryEGCS® ProcessDry Ex ha us t Ga s Cle a ning Sys te m

2. Combination w ith SCR e a s ily pos s ible


Overview• Introduction• Exhaust Gas Composition (PM, NOx, CO2, SOX)

• The DryEGCS® Process• The economical side of the DryEGCS® Process• Summary


1. Singapore

5. South Korea, Busan

9. Germany, Hamburg

10. China, Qingdao

6. Netherl., Rotterdam

2. China, Shanghai

8. Taiwan, Kaohsiung

7. UAE, Dubai

3. China, Hong Kong

4. China, Shenzhen

e x is ting ECAs : Baltic Sea, North Sea

pla nne d ECAs : Coasts of USA, Hawaii and Canada

Top Container Ports :

dis c us s e d ECAs : Coasts of Mexico, Coasts of Alaska and Great Lakes, Singapore, Hong Kong, Korea, Australia, Black Sea, Mediterranean Sea (2014), Tokyo Bay (in 2015)

Mos t us e d tra ding route s

Emission restricted areas by IMO – ECAs in 07/2009, Source: MAN

IntroductionIntroduction


What does desulphurization really mean?

• New emission values and upcoming ECAs will increase the demand of LSFO and MDO signifcantly

• The production costs for Low Sulphur Fuel are extremely high if a desulphurization plant is operated on site of the refnery compared to the blending costs if regular crude oils and sweet oils are mixed

• The desulphurization process consumes high amounts of energy in the form of temperature, steam and pressure as well as huge quantities of hydrogen (H2)

• The carbon dioxide footprint for a desulphurization plant is quite large and is estimated to increase by more than 10 % if switched to MDO



process flow diagram for a diesel hydrotreaterprocess flow diagram for a diesel hydrotreaterprocess flow diagram for a diesel hydrotreater

Process fow diagram for a diesel hydrotreater



The fuel oil industry claims that inves tments in excess of $ 130 Bn are required to secure the supply of LSFO

• Appreciation of fuel prices• Supply bottleneck• In Europe it is diffcult by law to fnd sites for new

refneries• Time-consuming authorization procedure• What to do with app. 10 Mill. t of sulphur?



Price gap Oil to Gas has increased, HFO to Gas even reversed

data compiled by MAN, sources: BP, Bunker Bulleting daily, www.bloomberg.com

data compiled by MAN, sources: BP, Bunker Bulleting daily, www.bloomberg.com


In June 2009 the EU has estimated the price increase for 0,1 % @ $250 - $300 per ton!

http://www.bloomberg.com/


Conclus ion

• Simply switching to distillates as stipulated by some third parties appears to be not the single solution for lowering emissions

• Distillates are technically and economically not available to substitute app. 320 Mill. tons of HFO

• Actually a concept in which the oil industry supplies the shipping industry with a sulphur reduced fuel (1 to 1,5 % S) in combination with on board operated exhaust gas cleaning systems is discussed



A combination of sulphur reduced fuel and the operation of an EGCS offers many benefts :

• Cost effectiveness• Emissions comply with IMO• Secured supply with fuel• Can be put into action just now!


Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms Exhaus t Gas Exhaus t Gas

Compos itionCompos ition Source: Germanischer Lloyd

Exhaust Gas Composition of a 4-stroke Diesel Engine (propeller curve, MCR 75 %, with 2,2 % sulphur in fuel),


1. Characteris tics of particles

• Consist of sulphates, water combined with sulphates, oxide ash (heavy metal), organic compounds

• Size 10 nm to 10 µm• The d50 is < 1 µm

• Visible if concentration > 0,15 g/Nm³ • Only removable by applying a ceramic/metal flter, a

wet scrubber or a dry scrubber

Exhaus t Gas Exhaus t Gas Compos itionCompos ition


2. Characteris tics of Nitrogen Oxides (NOx)

• NOx is a generic term for mono-nitrogen oxides (NO and NO2)

produced during combustion, especially at high temperatures

• The NOx fraction of the exhaust gas of diesel engine usually consists of 95 % NO and 5 % NO2

• Tier I + II achieved by engine modifcations (FWE, HAM, EGR a.o.)

• TIER III achievable only by SCR technology (Selective Catalytic Reduction)Exhaus t Gas Exhaus t Gas

Compos itionCompos ition


3. Carbon Dioxide (CO2)

• 1 ton of fuel burned equates to 3,2 tons of CO2

• From a chemical point of view Carbon dioxide is a very slowly reacting compound and thus diffcult to be treated by an exhaust gas system

• CO2 can be dissolved physically in water but an increase of temperature and pressure release it back to the atmosphere

• The design of new ships with effcient engines and the optimized operation of ships can reduce the emission of CO2

much better than any EGCS



4. Characteris tics of Sulphur Oxides (SOx)

• Sulphur is a natural compound of crude oil• The sulphur is chemically bonded to the hydrocarbons of the oil• The binding energy is quite high which makes it so diffcult and

energy consuming to separate the sulphur from the hydrocarbons

• During combustion the sulphur is oxidized to SO2 (app. 95 to 98 %) and SO3 (app. 2 to 5 %).



1. DryEGCS® Process

• The large-scale proven processes for the desulphurization of exhaust gases are based these days on absorptive processes

• Normally lime based materials such as calcium carbonate (CaCO3), burnt lime (CaO) or hydrated lime [Ca(OH)2] are in use

• Beside the wet desulphurization process also dry processes utilizing limestone or calcium hydroxide are established sustainably on the market

• Practically both technologies, Wet Scrubbers and Dry Scrubbers, can be operated on board of a vessel




• The DryEGCS® Process is based on a technology known in land-based applications as “Chemisorption”

• Calcium hydroxide reacts with SO2 and SO3 and forms calcium sulfate = G Y P S U M

Ca (OH) 2 + SO2 → Ca SO3 + 2 H2O Ca SO3 + ½ O2 → Ca SO4

Ca (OH) 2 + SO2 + ½ O2 → Ca SO4 + H2O Ca (OH) 2 + SO3 + H2O → Ca SO4 + 2 H2O

The DryEGCSThe DryEGCS ®® Proce s sProce s s


3. DryEGCS® - Reducing Agent

Calcium Hydroxide Granulate“Calhydgran”• The calcium hydroxide is utilized in

the form of a granulate or pellets (spherical form)

• Diameter 3 mm – 8 mm• Bulk density 800 kg/m³• BET-Surface 18 – 20 m²/g


„Calhydgran“ = Ca(OH)2



• A two-stage construction has been selected for the exhaust gas cleaning

• The granulate of the frst stage is a sacrifcial layer• It removes the rough sooty particles and other residues from the

exhaust gas and acts quasi as a particle flter• Within the second stage the process of chemisorption takes place

and the sulphur oxide molecules react with the calcium hydroxide


Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The DryEGCSThe DryEGCS ®®

Proce s sProce s s


Proce s sProce s s

Ma in e ng ine2 x 8,6 Me ga w att

SCR for the re duc tion of NOx

Fix e d be d a bs orbe r For re mov a l of SOx a nd PM

18 m / 59 foot

Duc t w ork

Fa n

Exemplary design for the „Coastal Reference“, BC Ferrieswas possible!



• The dwell time of the exhaust gases in the granulate both stages is approximately 3,7 seconds, which guarantees an almost complete separation of sulphur oxides > 90 %

• Operation temperature from 240° C to 410° C

• In case a selective catalytic reduction (SCR) for the NOx removal of the exhaust gas is required this unit can be installed

downstream the DryEGCS® without any additional reheating




• No temperature dropping required• Perfect solution for the combination with SCR• SCR can be designed signifcantly smaller• No formation of aerosols at the funnel• No increase of the exhaust backpressure• Heat recovery possible and recommended




• Dry operation for the removal of PM and SOx

• Proven technology (more than 500 installations worldwide during the last 20 years on land)

• Robust and maintenance free system• Exploitable residues => cost free disposal• Low energy consumption (ca. 0,5 %)• No operating stuff required



Proce s sProce s s

DryEGCS® Pilot-Installation onMS TimbusMAK 3,6 MWat

October 26, 2009


Proce s sProce s s

Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The e conomy of the DryEGCSThe e conomy of the DryEGCS ®®

Proce s sProce s s

1. Inves tment Cos ts

• DryEGCS® Process 120 US-$ per kW• Peripheral costs (ship yard installation, pipeline, starting up, certifcation etc.) app. 100 US-$ per

kW • Calcium Hydoxide Granulate app. 24 US-$ per kW/

year Price/t 250 US-$, Exploitable residues => cost free disposal• Low energy consumption (app. 64 kWh/h) app. 0,15 US-

$/kWh• No operating stuff required app. 0,1 man

year• Maintenance maximum 2% of investment cost p.a.• Pos s ible los s of s ale s whe n cargo s pace is provide d for re ducing age nt

Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms SummarySummary

1. Robust and maintenancefree system2. Long-term proven system3. No corrosion of donwstream installed exhaust gas components4. No aerosol formation 5. Exploitable residues6. Installation of a small sized SCR without reheating 7. Combined particle precepitation8. No examination of the sewage quality required9. Very low energy consumption

10. No tra ns mis s ion of polluta nts from the a tmos phe re into the hydros phe re but tota l re mov a l from the bios phe re !


Thank you very much for your attention!

dryegcs® process - a.pmcdn.neta.pmcdn.net/p/xgen/community/events/2009/san_francisco/... · data...

Documents