emission rules nox, sox & co · man diesel & turbo author current topic 00.00.2012 < 2...

1< >MAN Diesel & Turbo Author Current topic 00.00.2012

Emission Rules

NOx, SOx & CO2

MAN Diesel & Turbo - 2-st Technical & Market SeminarUniversity of Piraeus, 25.11.2015

George Drossos

Head of Marine New Sales and Promotion

MAN Diesel & Turbo Hellas Ltd

George. [email protected]


Agenda – Emission RulesUniversity of Piraeus, 25.11. 2015

1 Emission Rules Overview

2

TIER III, SCR3

TIER III, MDT strategy

4

Comparison SCR versus EGR 5

TIER III, EGR

SOx Rules, Status 6

7 Conclusions


Agenda – Emission RulesUniversity of Piraeus, 25.11. 2015


2

TIER III, SCR3


4


TIER III, EGR

SOx Rules, Status 6

7 Conclusions


Emission Rules OverviewECO Ships development governed by today´s demands

ECO Ships

Inert Gas

EEDI

Vessel Design

Efficient Technology

ECA’s

SOx, NOx, PM

Ballast Water

NOx

EGR, SCR Vaporizer/Mixer

SCR Reactor

T/C by-pass

Cylinder by-pass

V1

V2V3

TIER III / ECA

SOx and PM

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

Fuel Sulphur Content

(Equivalent) [%]

2008 2010 2012 2014 2016 2018 2020 2022

NOx [g/kWh]

Tier I

Tier III

Tier II

in ECAs

in ECAs

General

0,1%

ECA

CO2

EEDI

Ship Recycling

IMO 2004

Oil

MARPOL 2011 SOLAS 1974

Hong Kong Conv.

New Clean Fuels

LNG, LPG,

MeOH, etc.

IMO

../../Rejser/Greece - Cuprus Week 38 2013/Technical Seminar Presentations/Environmental Table.pdf


Emission Rules OverviewTable of present legislation by IMO

Regulation Status Emission Limit Area Geographical Region

NOx TIER III 3.4 g/kWh NECA North Americas + Hawaii

SOx MARPOL

Annex VI

0.1 % Sulphur

(3.5 % globally)

SECA North Sea,

Baltic Sea, North

Americas + Hawaii

CO2 EEDI Gram CO2 /

(Ton x Nautical Mile)

Globally


Emission Rules OverviewExisting and Future ECA Areas

01.10.2014

Source: DNV GLMEPC 66, London, April 2014


Tier I Global Jan. 1st, 2000 17.0 g/kWh

Tier II Global Jan. 1st, 2011 NOx limit 14.4 g/kWh

Tier III NOx ECA Jan. 1st, 2016 3.4 g/kWh

Emission Rules OverviewNOx control, Date of keel laying of all new vessels


Emission Rules OverviewSOx control, all vessels

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

2005 2010 2015 2020 2025 2030

Su

lph

ur %

Year

Sulphur limits of marine fuelsMARPOL Annex VI

Global limit

SOx ECA

2018 review


Emission Rules OverviewEEDI in force Globally from 1. January 2013

EEDI - Energy Efficiency Design Index

Definition:

EEDI = CO2 emission = ΣP x CF x SFC

benefit of ship capacity x speed

Unit: Gram CO2 / (Ton x Nautical Mile)

Reference:

10%

20%

30%

DWT

EEDI

2012

201520202025


Increased Propulsion Efficiency

Optimise hull form & propeller Larger propeller → Reduced power requirement

Increased Engine Efficiency

Change of engine type Larger stroke/bore ratio → Reduced SFOC and RPM

De-rated engine Increased pressure ratio (pmax/pmep) → Reduced SFOC

Engine tuning Part- or low load tuning → Reduced SFOC at low load

Emission Rules OverviewEEDI – Reduction

- 5

- 3


Agenda – Emission RulesUniversity of Piraeus – 25.11.2015


2

TIER III, SCR3


4


TIER III, EGR

SOx Rules, Status 6

7 Conclusions


TIER III, MDT StrategyNOx Reduction Technologies

Available Methods Possible NOx Reduction

SCR, HP or LP

EGR, HP or LP

Emulsion fuel

Water injection

Engine tuning

After Treatment

Primary method

Tier III

SCR: Selective Catalytic Reduction System; EGR: Exhaust Gas Recirculation System

Combination of Methods also being pursued

0% 50% 100%

14< >MAN Diesel & Turbo Author Current topic 00.00.20123336719.2010.04.27 (NK/LDF)

EGR (Exhaust Gas Recirculation)

SCR (Selective Catalytic Reduction)

TIER III, MDT Strategy Two way standard Technologies


TIER III, MDT StrategyFrom focus on HFO to focus on Low Sulphur Fuel

Before 2014 After 2014

Full fuel flexibility solutions

EGR + SCR

HFO solution design status 2014

0.1% sulphur optimized solution

MEPC 66, London, April 2014

The North American NOx ECA is also a SOx ECA

No risk of retrofit demands in future N-ECA’s

Next possible NOx ECA earliest ~ 2017

Ship owners mostly expect SOx compliance by Low Sulphur Fuel

World map


SCR component Cost reduction potential Size/installation reduction potential

SCR catalyst elements Good (≈30-40%) Good

SCR Reactor Good (≈20%) Good

Mixer Vaporiser Limited Limited

Reducing agent dosing system None None

Soot blowing system Good (≈20%) Limited

SCR Valves None None

Heating/Venting system Limited Limited

Material choices None None

Control Systems incl. sensors Limited None

SCR pipes, compensators None None

TIER III, MDT StrategyHP SCR consequences High Low Sulphur fuel


TIER III, MDT StrategyExample of SCR reactor program, High versus Low sulphur fuel


EGR component Cost reduction potential Size/installation reduction potential

Blower Limited None

WTS Good(≈30%) Good

Control system None None

pH control system Limited Limited

Sensor system Limited None

Scrubber + pre-scrubber Good(≈30%) Good

Cooler Limited Good

Drainers, valves , pumps etc. Limited Good

Material choices Limited None

Overall unit sizes Good(≈30%) Good

TIER III, MDT StrategyEGR consequences High Low Sulphur fuel


HFO/HS (3.5%)Incl scrubber

LS (0.1%)Only pre-

scrubber

Change of Tier III strategy

TIER III, MDT StrategyExample of EGR unit on engine, High versus Low sulphur fuel


EGR SCR SCR

On-Engine High-pressure Low-pressure

(HP) (LP)

TIER III, MDT StrategyLow sulphur fuel focus includes low pressure SCR

http://marine.man.eu/two-stroke/project-guides

http://marine.man.eu/two-stroke/project-guides

http://marine.man.eu/two-stroke/ceas

http://marine.man.eu/two-stroke/ceas


TIER III, MDT StrategyEmission Reduction Control System (ERCS) Setup

ME-ECSERCS

ERCSMOPECS-MOP EMS-MOP

EGRCU

or

SCRCU

ACU-1

RCS/BMS

Bridge

Engine room

Engine control

room

MODBUS


TIER III, MDT Strategy

Revised Expected Market Penetration




2

TIER III, SCR3


4


TIER III, EGR

SOx Rules, Status 6

7 Conclusions


• Selective Catalytic Reduction, is a catalytic technology to reduce NOx emissions in exhaust

gasses. Standard technology used in Stationary and Automotive sector.

• NOx is removed over an SCR catalyst, when a reducing agent is added. Typically aqueous

solution of urea is used as reducing agent (as a carrier of ammonia NH3). The SCR reaction

produces harmless nitrogen and water. Added amount of reducing agent has to be controlled.

TIER III, SCRBasic principles

SCR reaction:

+ 0.5 O2 → N2 + 1.5 H2O

flow

NOx + NH3

1 g NOx ≈ 1.65 g Urea (40%)


TIER III, SCRControl of urea dosing is important

0

20

40

60

80

100

120

0

2

4

6

8

10

12

14

16

0 20 40 60 80 100 120

Am

mo

nia

slip

(p

pm

)

NO

x e

mis

sio

n (

g/k

Wh

)

Urea dosing (l/h)

Example of SCR Dosing control considerations

NOx emission (g/kWh

Ammonia slip

$

Dosing control

ABS

NH3

SO3

Cold

surface

http://www.google.dk/url?sa=i&source=images&cd=&cad=rja&docid=Nq-5w_6lGxRr3M&tbnid=VrEsdm1UZGVy9M:&ved=0CAgQjRwwAA&url=http://www.clker.com/clipart-2406.html&ei=HHFWUu7aD4bAtQbiq4D4BA&psig=AFQjCNGL_wBmljT5kf9KZXq7xt6FVj_5Bw&ust=1381483164294414

http://www.google.dk/url?sa=i&source=images&cd=&cad=rja&docid=Nq-5w_6lGxRr3M&tbnid=VrEsdm1UZGVy9M:&ved=0CAgQjRwwAA&url=http://www.clker.com/clipart-2406.html&ei=HHFWUu7aD4bAtQbiq4D4BA&psig=AFQjCNGL_wBmljT5kf9KZXq7xt6FVj_5Bw&ust=1381483164294414

http://www.google.dk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=xXy3fFWDbyZJpM&tbnid=cw_P_OlLK25_1M:&ved=0CAUQjRw&url=http://www.clipartof.com/gallery/clipart/sad_sailor.html&ei=sHFWUorwE8aO4AS9rICABg&bvm=bv.53899372,d.Yms&psig=AFQjCNEXVtPPrjAALC2hbLyuW2jAkWH9-Q&ust=1381483303047281

http://www.google.dk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=xXy3fFWDbyZJpM&tbnid=cw_P_OlLK25_1M:&ved=0CAUQjRw&url=http://www.clipartof.com/gallery/clipart/sad_sailor.html&ei=sHFWUorwE8aO4AS9rICABg&bvm=bv.53899372,d.Yms&psig=AFQjCNEXVtPPrjAALC2hbLyuW2jAkWH9-Q&ust=1381483303047281


TIER III, SCR Two layouts, High Pressure- and Low Pressure

LSF: max.:

0.1%S

(Low temp.)

LSF: 0.1%S (HSF

up to 3.5%S in

special cases)


TIER III, SCR Schematic layout HP and LP

HP SCR

•Tier II engine temperature 250*-500 °C

•HP SCR tuned Tier III engine: 285-500 °C

•Pressure 1-4.5 bara

LP SCR

•Typical Tier II engine temperature 200*-300 °C

•LP SCR tuned Tier III engine: 220 - 300 °C

•Pressure ~1 bara


TIER III, SCR SCR systems – scope of supply

HP SCR LP SCR

SCR system suppliers for HP and LP SCR have to be approved by MDT following FTA procedure

SCR system suppliers have to fulfil Requirements specified by MDT


TIER III, SCR Current status of approval

HP SCR from Hitachi Zosen

Approved

Shop test and service test completed

LP SCR from Doosan

Provisional approval

Shop test completed

Service test pending


TIER III, SCRERCS - Control parameters HP SCR & LP SCR

• Control of all SCR valves to ensure proper

engine operation

• Control of CBV as low load method to assist SCR

• Control dosing amount

• No control of SCR valves as these are controlled

by ”external” SCR control system

• Control EGB as low load method to assist SCR

• Control dosing amount

HP SCR LP SCRVaporizer/Mixer

SCR Reactor

T/C by-pass

Cylinder by-pass

V1

V2V3


ECS and ERCS HP SCR MOP

ME ECS MOP

TierII / TierIII command

Possibility to select Prepare SCR

ERCS MOP: Auto/Stop selection

Information of SCR system


ECS and ERCS LP SCR MOP

ME ECS MOP

TierII / TierIII command

Possibility to select Prepare SCR

ERCS MOP: Auto/Stop selection

Information of SCR system


TIER III, SCR Examples of SCR ship operation

12

34

1. Tier II operation. SCR system disengaged

and kept clean

2. Prepare SCR selected before arriving to

ECA zone (or Tier III cmd). Typically 1-2 hour

is needed from cold SCR system depending

on engine load

3. SCR system is ready. Tier III command

selected when arriving at ECA zone

4. Tier III operation, urea dosing

5. ECA port, engine stop. SCR system heat

retained

6. Leaving ECA port, engine start. Quick SCR

start-up

7. Leaving ECA area, Tier II selected. SCR

system disengaging and kept clean

5

6

7

http://www.google.dk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=4mZRV_OVwrKDFM&tbnid=mPccJ1uJNWLrOM:&ved=0CAUQjRw&url=http://www.marineinsight.com/marine/impact-of-north-american-emission-control-area-eca-on-the-u-s-and-the-shipping-industry/&ei=8WhXU8WJNcSlO-CngSA&bvm=bv.65177938,d.ZWU&psig=AFQjCNFI6vMMxErVN6HO8MVkwlkGShfKHQ&ust=1398323820018744

http://www.google.dk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&docid=4mZRV_OVwrKDFM&tbnid=mPccJ1uJNWLrOM:&ved=0CAUQjRw&url=http://www.marineinsight.com/marine/impact-of-north-american-emission-control-area-eca-on-the-u-s-and-the-shipping-industry/&ei=8WhXU8WJNcSlO-CngSA&bvm=bv.65177938,d.ZWU&psig=AFQjCNFI6vMMxErVN6HO8MVkwlkGShfKHQ&ust=1398323820018744


Installation

SCR reactor Vaporizer/mixer

M/V Santa Vista

TIER III, SCR Example of HP SCR installation


HP SCR programme example

Hitachi Zosen


Bypass of EGE boiler

Engine delivery

TIER III, SCR Example of HP SCR installation


SCR Engine room arrangement

182 K Bulk – 6G70ME-C

TIER III, SCR Example of HP SCR Outline


LP SCR on 6G60ME-C9.5 engine on test bed

Vaporiser

SCR

reactor

TIER III, SCR Test Installation with LP SCR


Low pressure SCR

TIER III, SCR Example of LP SCR Outline




2

TIER III, SCR3


4


TIER III, EGR

SOx Rules, Status 6

7 Conclusions


• 30- 40 % of the exhaust gasses are

recirculated to the scavenge air receiver.

• In this way, part of the oxygen is replaced by

CO2 from the combustion process.

• This replacement increases the heat capacity

of the scavenge air, thus reducing the

temperature peak of the combustion and the

formation of NOx.

• The NOx reduction is almost linear to the ratio

of recirculated exhaust gas.

TIER III, EGRBasic principles


TIER III, EGRERCS – Control strategy of EGR

Control of all valves

Measurement of O2 in scavenging air

Control of NOX reduction through exh. gas re-circulation

rate (EGR blower rpm), determining scavenging air O2

”Near limit” control of EGR to avoid smoke


EGR – By-pass matching EGR – Cut out matching

EGR

CBV

EGB

T/C

CBV

EGR

TIER III, EGR Schematic layout, By-pass Matching and Cut-out Matching


EGR

unit

EGR

unit

6G70ME-C9

EGR by-pass matching

7S90ME-C9

EGR cut-out matching

Cut-out T/C

TIER III, EGR Outline, By-pass Matching and Cut-out Matching


TIER III, EGRExample of EGR installation (based on HFO)


TIER III, EGR Example of EGR Installation with CTU (HFO) versus updated RTU (LSF)


New alternative arrangement Including Receiving Tank Unit - RTU

RTU RTU

TIER III, EGR Example of EGR Installation with updated RTU (LSF)



2

TIER III, SCR3


4


TIER III, EGR

SOx Rules, Status 6

7 Conclusions



Capital cost: EGR – SCRRough estimate

Comparison SCR versus EGRCapital cost


EGR

SCR

Ship 182.000 DWT Bulkcarrier

Engine 6G70ME-C9.5

Power 16,4 MW

NECA time 600 h/year

NECA Fuel 0.1% S

Tank margin 33%

Urea bunker 2 times/year

NaOH bunker 2 times/year

Sludge discharge 12 times/year

NaOH tank Sludge tank

Urea tank

EGR/SCR tank installation

Assumptions

Comparison SCR versus EGRTank size for Urea and NaOH


Operational cost: EGR – SCRExample 60.5 MW, 4800 h/year (TII) + 1200 h/year (TIII)

Comparison SCR versus EGROperational Cost


EGR

On-Engine

SCR

HP or LP

Deciding factors:

Yard preferences • First cost (CAPEX)

• Space requirements

• Installation flexibility

Owner preferences • Operation cost (OPEX)

• Operation simplicity

• Reliability

• Maintenance cost

• Waste disposal cost

Comparison SCR versus EGRDeciding factors for selection of Technology


MAN B&W is Leading Tier III Technologist

SCR and EGR proven in service.

Developed for different scenarios:

Primarily for max. 0.1 % sulphur in fuel

For heavy fuel for Tier III compliance and later for

Tier II compliance with fuel saving potential

OG-LS 3339448.2014.05.07

30 bore -

46 bore

SCR preferred solution

EGR alternative solution

50 bore - 70

boreBoth solutions recommended

80 bore - 95

bore

EGR preferred solution

SCR alternative solution

HP SCR difficult for more than eight cyl.

Both methods are

commercially

available now.

General Recommendation for Tier III SCR and EGR

54< >MAN Diesel & Turbo Author Current topic 00.00.2012RASA/ Dept LSP

NOx Tier III reference listEGR & SCR

16.09.2015

No. of

ships

No. of

enginesCyl St Bore Type Mk Gas Technology Vessel Type Cap. Unit Shipowner

Shipowner

CountryShipyard

Shipyard

country

Engine

Builder

Del

Year

1 1 6 S 46 MC-C 8.1HP SCR

From Hitachi

Bulker Open

Hatch38206 dwt Nissho Shipping Japan Naikai Shipbuilding Japan HZC 2011

3 3 6 S 50 ME-C 8.2HP SCR

From HHILPG tanker 20600 dwt YARA Norway HMD Korea HHI 2015

6 6 6 G 60 ME-C 9.5LP SCR

From DoosanEthane Carrier 82000 dwt Reliance industries India Samsung Heavy Ind. Korea Doosan 2015

1 1 6 S 60 ME-C 8.2 EGR Bulker 81600 dwt NYK Line Japan Tsuneishi Japan MES 2014

2 2 6 G 70 ME-C 9.2 EGR Crude Oil Tanker 158000 dwt Chevron USA Samsung Heavy Ind. Korea Doosan 2013

1 1 6 S 80 ME-C 9.2 EGR Container 4496 teu A.P. Moeller-Maersk Denmark HHI-SBD Korea HHI 2012

6 12 5 G 70 ME-C 9.5 GI EGRLNGC

Tanker174000 CBM BP Shipping UK DSME Korea Doosan 2017

5 5 6 G 60 ME-C 9.5 GI/E EGREthane Gas

Carrier

Total SCR engine 10 engines

Total EGR engine 21 engines



2

TIER III, SCR3


4

Comparison SCR versusd EGR 5

TIER III, EGR

SOx Rules, Status 6

7 Conclusions



SOx rules, StatusCompliance options Globally and within ECA in 2015

3336719.2010.04.27 (NK/LDF)

ME-GI / ME-LGI engine

Dual Fuel:

LNG/Ethan and MGO

LPG / MeOH

MC/ME/-C engine

Single Fuel:

MGO or ULSF

MC/ME/-C engine

Diesel fuels:

HFO/MDO + Scrubber

Three basic options available for different levels of fuel flexibility

Link


SOx rules, StatusCompliance with DFDS Seaways, Thor Ficaria and 5 other ferries


MAN B&W 9L60MC-C

Operator / Vessel DFDS Seaways / Tor Ficaria

Engine 1 x MAN B&W 9L60 MC-C

MCR kW 20.070

Ship type & capacity Ro/Ro Cargo, 11600 Dwt, 32389 GT

Builder

Yard Flensburger Schiffbau Gesellschaft

Hull no. 726

Shop test 2006

IMO no. 9320568

TechnologyAlpha Laval, wet scubber, open/closed loop First field test, 0.1 % Sulphur compliant for year 2015 in ECA.

Other scrubber references in service:

SOx rules, StatusCompliance with DFDS Seaways, Thor Ficaria and 5 other ferries


Detailed information on scrubber

types and capacities is described in

the EGCSA 2012 handbook

available at EGCSA’s homepage. Link

EGCSA 2010 handbook Link

DFDS Ficaria Seaways movie on Youtube.

List of Scrubbers

SOx rules, StatusExhaust Gas Cleaning Systems Association (EGCSA)

http://www.egcsa.com/index.php

2010 EGCSA Scrubber handbook.pdf

http://www.youtube.com/watch?v=dYfpXDLHT0g

Scrubber Plants 2014-03-17.pdf



2

TIER III, SCR3


4

Comparison SCR and EGR 5

TIER III, EGR

SOx Rules, Status 6

7 Conclusions



Conclusions

• Efficiency optimisation will continue in the quest for saving fuel and reducing

CO2, IMO has recently announced a minimum required vessel power for safe

operation. The existing EEDI requirement will not be changed.

• SCR and EGR are proven in service.

Development will continue with different scenarios:

Primarily for max. 0.1 % sulphur in fuel

Heavy fuel for Tier III compliance and later for Tier II compliance with fuel

saving potential

Both scenarios are available.

• SOx Scrubbers are big and expensive, and if low sulphur fuels in the future

will be cheap, additional equipment and installation cost will be avoided.


< 62

Thank You for Your Attention – Questions?

All data provided in this document is non-binding.

This data serves informational purposes only and is

especially not guaranteed in any way. Depending on the

subsequent specific individual projects, the relevant data may be subject to

changes and will be assessed and determined individually for each

project. This will depend on the particular characteristics of each individual

project, especially specific site and operational conditions.

emission rules nox, sox & co · man diesel & turbo author current topic 00.00.2012 < 2...

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