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PureSOxExhaust gas cleaning

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• Shortpaybacktime(1to2years).

• Sulphurremovalrate>98%(exceedingIMOrequirements).

• Cost-savingsolution(abletooperateonHFOinsteadofexpensivelow-sulphurMGO).

IntroductionTheuniquehybriddesignofAlfaLaval’sPureSOxgivesbothenvironmentalandeconomicaladvantages.

Shipownerscancontinueoperatingonheavyfueloilinsteadofmoreexpensivemarinegasoil,whilestillmeetingthestrictInternationalMaritimeOrganization(IMO)regulationsregardingsulphuroxideemissions.

LegislationInOctober2008theMarineEnviron-mentProtectionCommittee(MEPC)oftheIMOagreedontheprogressivereductionofthemaximumsulphurcontentinfuelsusedonboardships.TherevisedMarpolAnnexVIregula-tionsreducetheglobalsulphurcapto0.5%,effectivefrom1January2020.ThelimitapplicableinEmissionControlAreas(ECA)willbereducedto0.1%,effectivefrom1January2015.ExhaustgascleaningsystemsthatreducetheemissionofsulphuroxidestothesameextentareapprovedbyIMO.

ExperienceAlfaLavalhasmorethan40yearsofexperiencesupplyingscrubbersasanintegratedpartofinertgassystemsonboardships.During2008,ourexperi-encesfromthesesystemswereusedtodesignandtestanexhaustgascleaningsystemattheMANDiesel(1MWengine)testfacilitiesinDenmark.

Installation on large Ro-Ro vesselTheknowledgeandexperiencefromthesetestswassuccesfullyusedtodesignanentirePureSOxsystemonboardtheDFDSRo-Rovessel“FicariaSeaways”.

Amodularandflexibleexhaustgasscrubberdesignwaschosenwithahighdegreeofoperationalflexibility,andfuturepossibilitiesforupgradingtheequipment.

Installedafterthe21MWMANengine,itisbyfartheworld’slargestexhaustgascleaningsystemonboardaship.Thedesignworkwascarriedoutincloseco-operationwiththemarineengineersfromDFDSandMANDiesel.

Acomprehensivetestschemewasper-formedforarangeofoperatingcondi-tionstosecurefullcompliancewiththe2015MarpolAnnexVIlegislation.

MANDieselhasparticipatedintensivelyinthedesignworktoensureasmoothandsafeinterfacewiththemainengine.

Exhaust gas cleaningAlfaLaval’sPureSOxremovessulphuroxidesfromtheship’sexhaustgasbyscrubbingitwithseawaterorfreshwater.

Concern. Commitment. Contribution.Pure Thinking from Alfa Laval Longserviceatseahasgivenusadeepunderstandingofthemarineenvironmentandthedemandsonindustry.

Wearecommittedtoefficientsolutionsthatsaveenergyandsupportyouinmeetingenvironmentalregulations.

Meetingthesedemandsrequiresacommitmentthatcannotbeunder-estimated.

ForAlfaLaval’spart,theevidenceofthatcommitmentcanbeseeninouractionsandinthestrengthofourongoingcontribution.

Legislation

ECAGlobalEU portsCaliforniaUSA 200 NM

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5

2005 2010 2115 2020 2025

Sulphur in fuel, %


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Seawater circuit

Freshwater circuit

Exhaust gas

Bypass damper

Pump

Pump

Pump

Cooler

Circulating tank

Water cleaning

Sludge tank

Freshwater

NaOH

Scrubber

Gas/water

monitoring

Seawater SeawaterSeawater

The Ro-Ro vessel “Ficaria Seaways” with PureSOx installed. 1) Jet scrubber2) Absorber3) Circulation tank4) Circulation pump

5) Plate heat exchanger6) Caustic soda tank7) Water cleaning8) Sludge tank

Schematic overview of the PureSOx hybrid system.

Hybrid systemAlfaLavaldesignedthehybridsystemformaximumflexibility,combiningaseawaterandafreshwatersystem.

Inopensea,PureSOxoperatesonseawater,providingsavingsoncausticsodaandfreshwater.Whileinlowalka-linitywaters,harboursandestuaries,thesystemcanoperateonfreshwaterinaclosedloop.Infreshwatermodeonlysmallquantiesofsludgearegener-ated,whichcanbehandledasnormalenginesludge.

Switchingbetweenseawaterandfresh-watermodecanbedonemanuallyorautomatically,basedontheship’sGPSpositioning.

Tominimizeenergyconsumption,waterflowisautomaticallyadjustedtoenginepower.Thesystemisalsodesignedtovarywaterflowaccordingtothesulphurcontentofthefuel.

PureSOxhasbeendevelopedwithdesignupgradesinmind,toensurecompliancewithfuturelegislation.

Advantages of the hybrid system:• Runsonseawaterinopensea

wheneverpossible,forlowestcostandeaseofoperation.

• Zerodischargewhenrequired,insomeports,estuariesorsensitiveareas.

• Abletocopewithlow-alkalinitywaters(Baltic,estuariesandrivers).

• NoswitchingbetweenMGO/HFO,formaximumfuelsavings.

• Maximumflexibility.

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Retrofit of the Ficaria SeawaysIn2009,AlfaLavalinstalledtheworld’slargestscrubberonboardtheFicariaSeaways.Thevesselispropelledbya21MWMANB&Wtwo-strokemainenginethatemits200,000kilogramsofexhaustgasperhour.ThefuelburnedbytheFicariaSeawaysisheavyfueloilwithasulphurcontentof2.2%.TheexhaustgasiswashedinthescrubbertoreducetheSOxcontenttothe0.1%levelrequiredbyIMOregulationsthatcomeintoforcein2015.

• Cost-savingsolution(abletooperateonHFOinsteadofexpensivelow-sulphurMGO).

• ComplieswithMARPOLAnnexVI–MEPC59.

• Sulphurremovalrate>98%(exceedingIMOrequirements).

• PureSOxisavailableasaSeawater,FreshwateroraHybridsystem.

• Trapsupto80%ofparticulatematter.

• Proventechnology,currentlythelargestscrubberinstalledonavesselaftera21MWmainengine.

• Abletooperateinlowalkalinitywaters.

• Powerconsumptioninoperation:approximately1.5%ofenginepower.

PureSOx facts:

How does PureSOx work?


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Heigh

t

Length

Diameter

AlfaLavalhasdevelopedPureSOxsystemswithmultipleinletsinordertolimitthenumberofscrubbersonboardthevessel.Mainandauxiliaryenginescanbecombinedinonesystem.TheenergyneededtodrivethePureSOxpumpsisautomaticallyadjustedtotheengine.

Dimensions and weightThedimensionsandweightofthePureSOxsystemaredependentonfactorssuchasthepercentageof

Engine

MW

Diameter

m

Length

m

Height

m

Dry weight

tonnes

Operational weight

tonnes

4 2.0 3.5 5.6 11 13

8 2.9 4.9 7.2 15 18

12 3.5 5.8 8.1 18 22

16 4.0 6.7 9.0 22 29

20 4.6 7.8 10.0 25 35

24 4.9 8.3 10.4 28 41

32 5.9 10.6 11.6 38 52

55 7.7 13.9 14.4 62 86

Multiple-inlet PureSOx system for main engines and auxiliary engines.

The table provides indicative information on sizes and dimensions per engine size (based on a single-inlet PureSOx system).

Benefitsofthemultipleinletsysteminclude:

• Lower investment costs.Bycombiningmultipleenginessignificantsavingsareachievedonequipmentandinstallationcost.

• Smallest footprint.Asspaceislimitedonexistingvessels,onemultipleinletsystemcanbethesolutionwheresingleinletsystemswillnotfit.

• Reduced weight.Amultipleinletsystemsavesonweight,preventingpossiblestabilityissues.

sulphurinHFO,thealkalinityofthesea-water,andtheamountofexhaustgasthatneedstobecleaned.

Multiple-inlet systemsMainandauxiliaryenginescanbecombinedintoonesystem.


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Water cleaningTheAlfaLavalcleaningsystemsecurescompliancewithIMOMarpolAnnexVIwashwatercriteria.

AlfaLavalhigh-speedseparationtech-nologyisusedtocleantheeffluent,ensuringcompliancewithIMOwashwatercriteriaaccordingtoMarpolAnnexVI.Thistechnologyiswellproven,andthefootprintissmallerthanmanyotherwatercleaningsolutions.Theunitmeasures,controlsandlogsthewashwatercontent.

• Simple process.Noadditionalprocessstepsneeded,suchasgenerationofair,ozoneorothermedia.

• Minimized sludge generation.Thehigh-speedseparationtechnologyiswithoutdoubtthesolutionthatgeneratesthedriestsludgeinthelowestquantities,withthepossibilitytocleanthewashwaterbeyondtheIMOcriteriashouldstricterregula-tionscomeintoforceinthefuture.

• Instant bleed-off.Excesscleanedscrubberwatercanbedischargedoverboardinstantly.Nosettlingtime,filteringofeffluentorfloatationwithflocculantsandskimmingneeded.

• Effective removal of particles hazardous to health.Dangerousparticulatematterforhumansandanimalsiseffectivelytrappedinthewashwaterandcleanedoutinasimpleone-stepsystemsolution.

• Flexible and space saving design.Thedesignspansthefullenginepowerrange.Withitsmodulardesignandsmallfootprint,thesystemfitsequallywellintoexistingshipsandnewbuilds.

Engine power (MW) Footprint (m) Electrical power (kW, nominal)

0-8 2.5 2.5 15

9-27 2.5 2.5 35

28-47 2.5 2.5 45

48-56 5.0 3.0 70

The picture shows an example of the water cleaning module.

The table provides indicative information on dimensions and electrical power consumption per engine size. Note that the power consumption in normal operation is normally 80-85% of nominal power.


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Basedoneachship’senginesandoperationalprofile,aPureSOxsystemwasselected.Detailedstudieswerecarriedouttoascertainthebestwaytofitthesystemintothevessel.Returnoninvestmentcalculationswerealsocarriedoutfordifferentscenarios.

AlfaLavalhastoolsthathelpshipownersdeterminethefeasibilityofaPureSOxsystemonboardtheirvessels.Size,weight,requiredutilities,retrofittime,investmentcost,operat-ingprofileandmanyotherparametersareconsideredagainstthesavinginfuelcosts(operatingonHFOinsteadofMGO).Wecanassistyouinmakingsuchevaluations.

Case 1: Container feederThecontainershippingsectorintheBalticandNorthSeaishighlycompetitiveandfragmented.Bothcharterersandshipownersbenefitfromtheinstallationofascrubber,whichlowerstheoperatingcostoftheirvessels.

Installing PureSOx on board the Ficaria Seaways.

Location of the scrubber as viewed from the stern.

Summary

• Singleinletforthemainengine.

• Hybridsystem.

• Sailing100%inECA.

• Paybacktimeof1.9years.

Ship’s data

DWT 9,300

TEU 800

Length (m) 140

Depth (m) 10

Breadth (m) 22

Number of main engines 1

Main engine power per engine (MW) 8

Main consumption (tonnes/year) 5,800

PureSOx data

Type Hybrid,singleinlet

Exhaust gas mass (tonnes/hour) 60

Width (m) 2.7

Height (m) 8.2

Weight (tonne) 9

Sludge production (tonnes/year) 1

Caustic soda consumption (tonnes/year) 31

Freshwater consumption (tonnes/year) 88

Economics

Operational profile

Operation area Baltic/Northsea

Hours at open sea per year 5,000

Hours in port per year 3,760

Costs based on HFO with PureSOx per year

Fuel (HFO) €3,110,000

Operational costs PureSOx €109,000

Total cost of HFO operation €3,219,000

Costs based on MGO per year

Fuel (MGO) €4,490,000

Savings per year

€1,271,000

Case studiesAlfaLavalhasinitiatedcasestudieswithseveralshipownersondifferentvesseltypestodeterminetheimpactofPureSOxonboardtheirvessels.


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Case 2: Aframax tankerInthiscaseweevaluatedtheimpactofascrubberonboardanaframaxtanker.Asthisstudyshowsevenwhenoperatingonly60%ofthetimeinECA,ascrubberisstillanattractivesolution.

Case 3: Ro-Ro ferryRo-Rovesselshavepowerfulengines,astimeiscrucialinthismarket.Thepaybacktimeforthistypeofvesselisconsequentlyveryshort.

Extending the funnel backwards facilitates placement of theScrubber.

The footprint of PureSOx is minimized by extending the funnelsideways.

Summary

• Multipleinletformainengineandauxiliaryengines.

• Hybridsystem.


• Paybacktimeof3years.Summary

• Multipleinletformainenginesandauxiliaryengines.

• Hybridsystem.


• Paybacktimeof1.2years.

Ship’s data

DWT 115,000

Tank Capacity (m3) 130,000

Length (m) 250

Depth (m) 21

Breadth (m) 44


Main engine power per engine (MW) 13.74

Main consumption (tonnes/year) 5,925

Number of auxiliary engines 3

Auxiliary power per engine (MW) 0.85

Aux. consumption (tonnes/year) 876

Ship’s data

DWT 14,210

Gross tonnage 28,744

Length (m) 213

Breadth (m) 26.5


Main engine power per engine (MW) 6.2

Main Consumption (tonnes/year) 17,534

Number of auxiliary engines 2

Aux. power (MW) 1.4

Aux. consumption (tonnes/year) 712

PureSOx data

Type Hybrid,multipleinlet


Width (m) 4.3

Height (m) 8.9

Weight (tonne) 24



Freshwater consumption (tonnes/year) 453

PureSOx data

Type Hybrid,multipleinlet


Width (m) 4.5

Height (m) 9.5

Weight (tonne) 24



Freshwater consumption (tonnes/year) 1.492

Economics

Operational profile





Fuel (HFO) €4,225,000




Fuel (MGO) €6,105,000

Savings per year

€1,590,000

Economics

Operational profile





Fuel (HFO) €9,732,000




Fuel (MGO) €14,062,000

Savings per year

€3,994,000


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Return on investmentThetablesshowtypicalpaybacktimesforPureSOx.

14

44 MW engine

1,500

Hours in ECA

RO

I [ye

ars]

3,000 4,500 6,000

4

3

2

1

0

22 MW engine

1,500

Hours in ECA

RO

I [ye

ars]

3,000 4,500 6,000

5

4

3

2

1

0

10 MW engine

1,500

Hours in ECA

RO

I [ye

ars]

3,000 4,500 6,000

7

6

5

3

4

2

1

0

4 MW engine

1,500

Hours in ECA

RO

I [ye

ars]

3,000 4,500 6,000

16

14

10

8

12

6

4

2

0

Retrofit

Newbuild


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Alfa Laval in brief

AlfaLavalisaleadingglobalproviderofspecializedproductsandengineeredsolutions.Ourequipment,systemsandservicesarededicatedtohelpingcus-tomerstooptimizetheperformanceoftheirprocesses.Timeandtimeagain.Wehelpourcustomerstoheat,cool,separateandtransportproductssuchasoil,water,chemicals,beverages,foodstuffs,starchandpharmaceuticals.Ourworldwideorganizationworkscloselywithcustomersinalmost100countriestohelpthemstayahead.

How to contact Alfa Laval

Contactdetailsforallcountriesarecontinuallyupdatedonourwebsite.Pleasevisitwww.alfalaval.comorwww.aalborg-industries.comtoaccesstheinformation.

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