energy-savings basics for the maritime industry - engines, machinery, alternative fuels

8/13/2019 Energy-Savings Basics For The Maritime Industry - Engines, Machinery, Alternative Fuels

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Dr.GeorgeGougoulidis


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Improve

Technology

ExteriorofshipHull

SuperstructurePropulsioncomponents

Interiorofship

Mainengines

Machinery

Operations

Fuels


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Variable

exhaust

valve

timing Tuning

Derating

Permanentcylinder

cut

out

improved

engine

efficiencyforslowspeedoperation1014%


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Retrofitsolutionforlowloadoptimization Suitableforslowsteamingoperations Adjusts

the

exhaust

valve

timing

between

10

60%

of

load 2 5g/kWfuelsaving IncreasedPmax cylinderpressure


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Optimizes

cylinder

pressure

distribution

1

2% Deltatuning(Wrtsil)forreducedfuel

consumptionintheloadrangethatismost

commonlyused

Tunedforlowerconsumptionatpartload

Wrtsil IntelligentCombustionControl

ensuresoptimal

firing

pressures

fuel

reduction2.5g/kwh


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Longerstrokeengines(MAN

G

type)

low

rpm largepropeller highefficiency

S80engine

78

rpm

G80engine68rpm Potentialsavings47% MANreportshaving

almost200

G

type

enginesonorder(spring2013)


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Cutoutofa

turbochargerforimprovedengine

efficiencyatpart&low

loads

Potentialsavings24%


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Consistsofahigh

pressurefuel

rail

feeding

individual

solenoid/piezoelectric

valves

CommonRailcontrols

combustionsoitcanbe

optimized

at

every

load


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Nosacvolume

LowerHC,

NOx,

particulateandsmoke

emissions

Improvedlow

load

performance

Bettercombustionprocess

Reducedfoulingofgasways,exhaustgas boiler,pistontopland

Nodrips,nooilwaste

Canbe

retrofitted


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Recoversenergyfrom

exhaustgas Convertsthermal

energytoelectricityfor

reducedgenset

consumption

Savingsupto12%


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Addingcertainsubstancestoheavyfueloilcanreduceclumping,modifyviscosity,andmakethefuelmorehomogenous,resultinginimproved

combustionandallowingformoreenergytobe

extracted

Wateremulsionisbasedoninjectingwaterintothefuelortheengine.Emulsifiedfuelsleadtoamore

effectiveatomization

and

abetter

distribution

of

thefuelinthecombustionchamber


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Waterlowerscombustiontemperature LowerNOx

Waterincreasesfluegasmass Increasedpoweroutputofmassflowdevicessuchas

gasturbines

Ashortcombustiontime Lowerexcessoxygenneeded

99%carbon

burnout

Lowparticulateemissions

Minimizespistonfouling


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Multiphase

Superfine

Atomized

Residue

SyntheticFuelOil

Madebycombiningaliquidhydrocarbonwith

waterand

proprietary

additives

Ahighlystablefuelemulsionconsistingof70

80%hydrocarboninwater

Anyliquid

hydrocarbon

can

be

used

Canemulsifyveryheavylowcostresidues


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ENRJ HROHomogenisation System

Neftech Pte LtdProprietaryCavitation

Technology

Nonox Ltd EmulsionCombustionUnit


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76%

of

the

marine

fuel

used

is

Heavy

Fuel

Oil

(HFO)whichhashighsulphur content

TheoptionstocomplywiththeSOx

regulationsare:

Operateonlowsulphur fueloil(MDO,MGO,ULSD)

OperateonHFOwithanexhaustgastreatment

system Operateonalternativefuels:LNG Biodiesel


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LloydsRegister


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Composed

mainly

of

methane,

containing

smallquantitiesofethane,propaneandbutane

Tomaximize

storage

capacities,

natural

gas

is

usuallyrefrigeratedtochangeitsstatetoa

liquid(LiquefiedNaturalGas LNG)


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EliminationofSOx Low

NOx and

particulate

emissions

SavingsfromnothavingtoseparateandheatHFO

LNGcanbeusedtocooltheshipsHVACtosaveAC

compressor

power

Lackofinfrastructureandsupplychainnetwork Gasprovidersandbunkersuppliersunwillingto

invest

in

infrastructure

until

there

is

sufficient

demand thereisnodemandsincethereisnoinfrastructure


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Extremely

low

temperatures

hazards

of

coldburnsoncrewandbrittlenessonstructures

BLEVE

due

to

high

expansion

ratio

~600:1

(a

smallvolumeofliquidcanyieldalarge

amountofgas)

Highflammability


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Wrtsil

34DF

50DF

MANDiesel

&

Turbo

32/40DF(400kW/cylinder)

51/60DF(975kW/cylinder)


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Ottocycleengines

MANDiesel

&

Turbo

51/60G

Wrtsil 34SG&50SG


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TheworldsfirstnewLNG

fuelledtanker

classed

by

LR

6,100dwt dualfuelled

chemicaltanker

L=110

m

Dualfuelsystemdesigned

toburnan80/20mixtureofnaturalgasanddiesel

LNGstored

in

atransport

tanklocatedondeck

DualfuelCaterpillarDF3512

1,115

kW

each


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Thefirstcruiseferrypoweredexclusivelybynaturalgas

In

service

in

the

Norwegian

fjords 4xRolls

Royce

Bergen

B35:40V12PGas

gas

engines,5.400kWeach


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AlternativetoLNG Global

consumption

~45vs ~90millionton

production Advantages

Lowcost:

in

Europe

~$350

/tn

Noneedforcryogenicpressuretanks

Canbeproducedfromnaturalgas,orforestrybiomass

Sustainable,madefromcellulose,doesnotcompetewithfoodsources


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Conversionofmethanetoliquidfuelsismoreexpensive

than

LNG

production

TheGasToLiquids(GTL)process consumesabout30%oftheenergyinthegasvs 10%forthe

LNG

process

Theamountofenergy/ton=2timeslowerthan

thatofHFO

Moretoxic

than

other

fuels


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Specialtankandauxiliaryenginesforthe

methanoltrial

Methanolisconvertedintodimethylether

(DME)priortoinjectionintotheengine


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Anewenginethatenablestheuseofmore

sustainablefuels,

such

as

methanol,

Liquefied

PetroleumGas(LPG) dimethylether (DME),and(bio)ethanolaswellasother,lowflashpoint

fuels MANhassignedaLetterofIntentwith

WaterfrontShippingfortheuseof4MANME

LGI

engines

on

its

ships Theengineswillrunonablendof95%methanol

and5%dieselfuel


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Basedonvegetableoils(camelina,cornetc.)

andanimalfat(tallow)

SignificantlyreducedSOx emissions

Lower

particle

emissions NOx emissionsdependonthefueltype

Enginesmayneedmodifications


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Lowerthermalvalue 5%lessoutputfora4

strokeengine

Lowerenergycontentmeanslargerfuel

tanks

Biofuelproductionhasnotmovedtofull

scale

Moreexpensive

Current

refers

to

2012


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Conflictbetweenthebiofuelandthefood

industry

Thechallengeistofindfeedstocks whichare

sustainable

and

available

at

a

reasonable

cost Additionallandtogrowcropsforbiofuelsis

needed


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TheconsequenceofEUsulphur directivesonthe

supplychain

has

been

that

marine

diesel

oil

will

becontaminatedwithFattyAcidMethylEsters(FAME~biodiesel)

Alreadyusedintheautomotiveindustry Biofuel

trial

on

the

container

vessel

Maersk

Kalmarinoneauxiliaryengine FAMEblendedwithdieselata5%95%ratio(B5)

Results

showed

that

the

biodiesel

for

automotiveapplications

may

not

be

optimal

for

theuseonships


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Builtin2006

Sunkin

2010

Partoftheprojectwasto

breaktheworldrecord

forcircumnavigating

the

globeusingonly

renewablefuels

Theboat's

engines

were

poweredcompletelybybiodiesel


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"FarmtoFleet"collaborationbetweenthe

USNavy and

the US

Department

of

Agriculture(USDA)

The

goal

is

to

be

independent

of

foreign

resources

Advanceddropinbiofuelsblended1050%

withconventional

fuels

Projectedcostby2016


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Notfoundinnatureinitspureform

Producedby

electrolyzing

water,

or

by

reforminghydrocarbonfuels

Production

requires

energy

consumption Ifenergycomesfromrenewablesources,

hydrogenisa100%renewablezerocarbon

fuel Untilrecentlyusedonlyinfuelcellsubmarine

systems


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Theworld'sfirst

hydrogen

powered

ship Launchedin2009 Hydrogenfuelcells

thatgenerate

100

kW

Capacityof100passengers

Operatesoninner

citywaterways

in

Hamburg


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AjointindustryR&D

projectbetween

DNV

andEidesvik Offshore

Offshoresupplyship

VikingLady Thefirsthybrid

propulsionplanttouse

fuelcells

Installedin2009 Fuelcelloutput:330kW


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Itwilltaketimebeforefuelcellsbecomea

competitivealternative

Restrictedbycost Storageofhydrogenonboard Duetothesmallsizeofhydrogenmolecules

therecan

be

leakages

requiresventilationinordertostoptheunavoidableleakagefrombecomingdangerous

Pure

hydrogen

corrodes

metals

maintenance

concerns Lackofinfrastructure


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Intheshort term,LNGisrelativelyeasyto

adoptthanks

to

standards

and

technical

knowledge,despitethechallengesofbuildingLNGinfrastructure

Windand

solar

energy

are

appropriate

auxiliarypowersources Inthemediumandlongterm,biofuelsand

syntheticfuels

have

promise

Intheevenlonger term,hydrogenisseenasanoption


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GreatGreenFleetprojectedfor2016

Demonstrationtook

place in

July 2012

Shipswerepoweredby,eithernuclearorbiofuelblends

Thebiofuelblendswere5050mixturesofbiofuel(made

from

used

cooking

oil

and

algae)

and

petroleumbasedmarinedieseloraviationfuel Thegoalsoftheprogramare:

Reduce

the

dependence

on

oil

based

fuels

by

50%

by

2020 Reducetheconsumptionofenergy

Decreasethedependenceonforeignsourcesofoil


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USSNIMITZ(CVN68)andCarrierAirWing

ELEVEN

USSCHAFEE(DDG90)

USS

CHUNG

HOON

(DDG

93) USSPRINCETON(CG59)

USNSHENRYJKAISER(TAO187)


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Shaftgeneratorsdrivenbythemainengines

Reducetheneedtorunauxiliarygensets

Electricalsystem

requires

fixed

voltage

&

frequency

meaningthatenginespeedhastobeconstant


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Twosolutions:

Powertakeoff(PTO) systemwithfrequencycontrolensuringconstantfrequency

Hybrid systemconditioningthepowerfromshaft

generatorsothatthesupplytotheswitchboardremainsconstantatanyenginespeed

Shaftgeneratormaybeusedasamotor

providingpowertothepropeller


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Benefitfromefficientelectricdriveforcruise

speeds&

cost

effective

mechanical

drive

for

higherspeeds TheelectricdriveallowstheMainDiesel

Generators(MDG)toprovidepowerforthe

shipselectrical

load

and

the

propulsion

motors

ThesemotorsoperateasalternatorswhenrunningontheMainDieselEngines(MDE)athigherspeeds

Theresult

is

fewer

prime

movers,

fewer

engine

runninghoursandalsofueleconomy


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2CPPpropellers

Foreach

shaftline,

1Wrtsil

maindieselengine(ME)and

oneelectricmotor(PTI)are

connectedtoagearbox The

propeller

can

be

driven

bythedieselengine,the

electricmotor,orbyboththe

dieselengineandtheelectricmotor

Themainengineshavea

powertakeoffinthefront

end,

driving

a

shaft

generator

ME GEN

PTI

GEAR

AUX

AUXGEN


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Themainenginecanbeusedasthepropulsionengineatvariablespeed,thepropulsionengineatconstantgeneratorspeed,orasageneratormotordisconnectedfromthepropeller

Thevariable

speed

electric

motors

have

two

nominal

ratings

and

speeds(operatinginparallelwiththedieselengineandoperatingastheonlypropulsionmotor)


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energy-savings basics for the maritime industry - engines, machinery, alternative fuels

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