4 Green Ship of the Future - GSF Coordinator

Green Ship of the Future - www.greenship.org

Presentation of ‘Green Ship of the Future’

by

Christian Schack, Coordinator, Green Ship of The Future

Presentation at Green Ship of the Future Conference, Asia Pacific Maritime, Singapore, March 2010


’Green Ship of the Future’ is a Danish joint industry project for innovation and demonstration of technologies and methods that makes shipping more environmental friendly.

With respect to airborne emission the aim of the project is to provide the necessary technologies and operational means to reduce emissions as follows for newbuildings:

- 30 % reduction of CO2 emissions- 90 % reduction of NOx emissions- 90 % reduction of SOx emissions

Have we reached these goals - or will they be reached?

Green Ship of the Future


’Green Ship Project Partners


Network Partners

Green Ship of the Future has established a network partnership agreement with the following Danish maritime organisations:

• Danish Maritime Authority

• Danish Shipowners' Association

• Danish Maritime

• Danish Marine Group

• Transport Innovation Network

• Danish Ministry of the Enviroment

The role of the network partners is to provide a network and to communicate events and project results to their respective members.


To meet the reduction targets, the following four main areas are considered:

• Machinery WHR, scrubbers, EGR, etc.

• Propulsion Propellers, rudders, trim optimization, etc.

• Operations Route planning, performance monitoring, etc.

• Logistics Better interaction between transport forms, development/modification of existing ship types etc.



Development of scrubber systems for removal of SOx and particles

Investigate and utilise exhaust gas scrubber technology to clean the exhaust gas.

Full design, development, and installation of the scrubber.

Removal of SOX and particulate matter

The scrubber was installed onboard DFDS Tor Ficaria in June 2009, and commissioning is scheduled to take place in March 2010.

Potential 98% SOX reduction and at least 50% reduction in particulate matter

Scrubber Systems

Partners:

The expected reduction in SOx is approx. 98% and CO2 is approx. 3 %

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard


EGR Systems

Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Development of an Exhaust Gas Recirculation (EGR) system

A retrofit EGR system has been specified and designed for Installation on board Alexander Maersk.

Major installation work took Place in July 2009 and will be completed in March 2010.

Software tests completed in Copenhagen test facility in January 2010, paving the way for a fully automated EGR System.

Final testing & commissioning on board the Alexander Maersk to take place in March 2010The expected reduction in

NOX is approx. 50 %


Machinery for high-speed LNG-ferries

Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Evaluation of efficiency and emissions of LNG-powered high-speed ferries

In this project Mols-Linien and DTU Mechanical Engineering co-operate on studying the machinery for future gas-powered, high-speed ferries.

Based on an outline specification of an INCAT design of a 112 m fast ferry, an alternative arrangement will be made with LNG powering. Different solutions in terms of propulsion will be evaluated, and for the final proposal detailed calculations will be made of the total efficiencies.

The first preliminary results suggest that if a recuperated gas turbine is combined with an Organic Rankine Cycle, an efficiency of about 48% would be achievable, which is about 30-35% higher than existing machinery.

As a spin off, Mols-Linien is currently evaluating the implementation of LNG to power two gas turbine-powered high-speed ferries.

The expected reduction in CO2 is approx. 48% and NOx is approx. 55%


Pump and Cooling Water Systems

Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Partners: Optimization of pump and cooling water systems on a 35,000 DWT Bulk Carrier:

Overall vessel CO2 emission reduction of 1.5%.

Corresponding to 20% of the daily auxiliary generated power.

Reduced wear on diesel generators/reduced maintenance.

The expected reduction in fuel consumption is minimum 1.5 %


MAN B&W ME-B with VTA

Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Optimisation of CO2 emissionand fuel efficiency of a MAN B&W 6S50ME-B8 main engine with a MAN Diesel TCA66 (w/VTA) Turbocharger

Shop test completed in July 2009. Sea trial to be completed in April 2010 on Torm Alice.

Application of the 6S50ME-B8 with a VTA turbocharger gives an annual saving of 90 – 135 tonnes HFO, dependent on sailing profile, when compared to a conventional camshaft controlled engine with a non variable turbocharger

A technical summary of the system will be written on completion of the sea trial

Partners:

The expected reduction in fuel consumption is approx. 2%


CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

System Integration and Waste Heat

Use of pre-insulated pipe systems on a tanker vessel

The purpose of this project is to reduce the overall fuel consumption onboard a 74999 DTW oil tanker owned by MARINVEST.

In the project, the cooling water and boiler system will be analysed to cover how the heat can be utilized.

The HT water from the ME is to be used for cargo heating, transfer pipe heating and heating of the charge/discharge equipment. Because of the pipe insulation, it is possible to transfer relatively large amounts of energy from the ME with relatively small losses.

Partners:

The expected reduction in fuel consumption is approx. 20% for a tanker


Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

SCR System with Digital Airless Multipoint®

Urea Injection for NOx-reduction

During the past 2 years DANSK TEKNOLOGI has developed a unique SCR system for NOx-reductionon marine engines. The system is based on DigitalAirless Multipoint® injection of urea.

The Digital Airless Multipoint® technology gives a high NOx-reduction with long term stability, no needfor compressed air (giving low auxiliary powerrequirements compared to conventional SCRsystems), no need for a mixer and a very compactsize. This again means that the complete SCRsystem takes up the same space as the traditionalsilencer which it substitutes.

The developed SCR system is based on a modular concept and can be adapted to any engine running on marine diesel.

The vessel is fulfilling the IMO requirements of 2016 and onwards.

SCR System for NOx-reduction

The expected reduction in NOx is approx. 90%


Dual / Multi MCR Certification

Partners:

The expected reduction in fuel consumption is approx. 1 to 3 %

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Development of main engines with dual or multi certification for easy change of MCR rating for any trade route or speedOptimal running conditions for different ship speeds e.g. Turbocharger cut-out, Variable Turbine Area, fuel system equipment, engine settings etc.

Procedure for certification of a T/C cut-out retro-fit is complete for K98 type engines

Practical experience gained from installation on Maersk Salalah

Common documentation approved by Class GL and Class BV, as long as a technical file already exists


Automated Engine Monitoring

Partners:

The expected reduction in CO2 is approx. 0 to 5 %

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Optimisation of engine performance by automated tuning to best adjustments

Introduce an automated control system that monitors engine operating parameters and adjusts engine settings for optimal fuel consumption.

Electronically controlled engines (ME):Auto-tuning algorithms has been successfully verified at various full scale field tests. Auto-tuning system is since January 2010 being offered as an (ME) upgrade option.

Mechanically controlled engine (MC):Full scale “proof of concept” test on Maersk 7K90MC-C initiated December 2009. Closed loop VIT controllability has been successfully verified (March 2010).Next step to develop a prototype / commercially suitable solution.


Turbo Charging & Variable Nozzle Ring

Partners:


CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Turbo charging with variable nozzle rings results in high efficiency in a wider load range compared to traditionalturbo chargers, especially at low engine loads, i.e. low speeds.

Together with Maersk ABB has installed the new A100 VTG turbo charger with variable nozzle onboard Alexander Maersk. The system are currently undergoing tests but initial conclusionsare very positive.

Next stage for turbocharging is with two-stage turbo charging, which is currently being developed by ABB.

Variable nozzle rings


Waste Heat Recovery Systems

Partners:

The reduction in CO2 is approx. 7 to 15 % depending on ship load

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Further development of Waste Heat Recovery (WHR) systems

Optimisation of WHR system in close cooperation with partners.

Determination of vessel operation profile and optimisation of engine for improved exhaust gas data.

Installation of new exhaust gas fired boiler, turbo generator (steam/gas turbine and generator).

Optimisation of WHR system given the available space constraints.

Maersk is currently installing WHR on a wide range of vessels based upon the GSF project.


Pump & Auxiliary Systems

Partners:

The expected reduction in CO2 is approx. 1 to 2 % on a large container vsl.

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Optimisation of pump and auxiliary systems

Re-design pump & auxiliary systems with a focus on power consumption.

Introduce automated systems that continuously control the power demand.


Optimised Control for Ship Cooling

Partners:

The expected reduction is still being evaluated

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Optimised Control for Energy Optimisation of Ship Cooling Systems

In two projects, optimised control algorithms for Reefer systems (joint project with Lodam A/S) and for general High Temperature (HT) and low temperature (LT) onboard refrigeration systems are being developed by Aalborg University.

The latter system is designed for a Maersk newbuilding, and the effect is documented by means of advanced simulations.

Potential: The project is still at an early stage, but preliminary results indicate significant energy savings, possibly as much as 45% (rough estimate)


Fact Box

‘GreenSteam’ Trim Optimisation

Dynamic trim optimisation with GreenSteam

GreenSteam is a new energy saving system for ships, providing reduction in energy consumption by adjusting ship trim and power.

Based on readings from multiple sensors over a period of time, the relations between the dynamically changing conditions and the energy requirements are mapped and analysed into a mathematical model. This model is used for onboard guidance to the crew as regards optimum trim and power.

Fuel savings of at least 2.5% have been demonstrated onboard a product tanker owned by DS NORDEN A/S. The system will be installed on 4 or more new NORDEN vessels during 2010.

The expected reduction in fuel consumption is approx. 3%

CO2 NOX SOX

Newbuilding

Retrofit

Design Test Onboard

Partners:


Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Air Resistance of Ships

Air Resistance of Ships

The air resistance of a Bulk Carrier is approxi-mately 5-8 percent of the total resistance. By advanced wind tunnel studies and optimization of the superstructure the air resistance will be lowered to a minimum.

The following steps is included in the project:• Wind Tunnel test of existing design.• Superstructure optimization (eg.

Crane, forecastle, accommodation –Rounded shapes, elimination of recirculation zones etc.)

• The future bulk carrier where all traditions are reconsidered…

Based upon the results investigations might continue on other vessel types.

Initial tests are being performed March 2010The expected reduction in Fuel consumption is approx 2 to 3 %


Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Trim Optimisation & Performance Monitoring

Trim optimisation & Performance monitoring

SeaTrim is a trim optimisation application based on model test results of a large matrix of different combinations of draught, trim and speed. SeaTrend is a system for performance monitoring, using operational data from the ship.

With SeaTrim & SeaTrend installed onboard the six L-Class chemical tankers owned operated by Nordic tankers, it is the aim of the project to demonstrate the effect of the tools in terms of

• Ability to determine hull and propeller fouling and trends

• Ability to guide the crew as regards to optimum trim

The expected reduction in Fuel consumption is approx. 1 to 3%


CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

New high efficient nozzle

Partners: New high efficient nozzle from MAN Diesel.

MAN Diesel’s propulsion division in Frederikshavn has developed a new nozzle, which can enhance the performance for many types of vessels.

Where existing nozzles designs have primarily been applied to ships that requires high thrust at low ship speeds, the new product is intended for vessels with a higher service speed i.e. tankers, bulkers, PSVs etc.

The new nozzle will be tested in model scale on a tanker that is operated by Nordic Tankers. The test will be carried out in the towing tank at FORCE Technology.

The expected reduction in CO2 is approx 5 to 10 %


CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

Effect of Silicone paint

Partners:

The expected reduction in fuel consumption is approx 2 to 5 %

Documentation of effect of silicone paints

HEMPEL and FORCE Technology has made an official agreement to monitor all new applications of HEMPASIL X3 with the SeaTrend performance monitoring software.

Currently a number of vessels have been applied with both X3 paint and SeaTrend software.

Based on the experience from the project the effect of the newest generation of silicone paints will be documented in real service


Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

SeaPlanner – Fuel saver

SeaPlanner on the DFDS fleet

The advanced version is specially suited for Short Sea Shipping and will allow the officers to plan their route taking into account ETA, weather (wind, waves and current), and shallow waters.

With highly detailed weather prognoses of the North Sea and Baltic Sea (supplied by DMI) and with a GPS link, SeaPlanner continuously monitors and guides the Master on the optimum speed and heading.

With this project DFDS and FORCE Technology will show the potential of the SeaPlanner based upon the experience gained through the initial operation.

The system is currently installed on 7 vessels and will be installed on additional 15 vessels in spring 2010.

Partners:

The expected reduction in Fuel consumption is approx. 1 to 3%


‘Lab on a ship’

RealTime analysis of bunker quality and emissions with LOAS

‘Lab on a ship’ (LOAS) is a new and innovative product by NanoNord. During bunkering LOAS provides online measurements of the elements of the bunker oil, lube oil, cylinder oil etc. In addition the system offers online measurements of exhaust gas emissions of NOx and SOx.

With the LOAS system, the sulphur content of both the bunker oil and the exhaust emissions are measured and documented which is important for the verification of the MARPOL Annex IV regulations.

LOAS is installed onboard two Bulk Carriers owned by Lauritzen Bulkers, and the project aims at demonstrating the applicability of the system.

Partners:


CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard


SIMAC GSF Student Forum

Partners:

CO2 NOX SOX

Newbuilding

Retrofit

Fact Box

Design Test Onboard

SIMAC will establish a Student Forum with focus on Green Ship technologies

The forum will consist of a number of SIMAC students writing their final project. The students will study different topics related to on-board applications, problems or procedures of green ship technologies.

DCMT will arrange contact between the students and relevant partners in the GSF if needed.

A list on projects has been established and this will be used to encourage students to study topics related to Green shipping.


‘Low emission concept ships’

The challenge was to take an existing modern design and evaluate the technologies suitable and to generate a picture of the improved performance of the vessel.

We have evaluated two different vessel types.

We have not changed the hull form, the DWT or other main parameters


‘Low emission concept ships’

A-Class 8500 TEU Container ShipBy Odense Lindoe Shipyard

SEAHORSE 3535.000 DWT Bulk CarrierBy Grontmij Carl Bro


Conclusion from Study

Goals Results-30 % reduction of CO2 emissions - Achieved 7 %-90 % reduction of NOx emissions - Achieved 90 %-90 % reduction of SOx emissions - Achieved 79 %

SEAHORSE 35 Bulk carrier, optimised with:

• Speed nozzle/optimized propeller• Twisted spade rudder with Costa bulb• Water in fuel (WIF)• Exhaust gas recirculation (EGR)• Waste Heat Recovery system (WHR)• Exhaust Gas Scrubber• Ducted/direct air intake for main engine • Optimised coolers and cooling pumps• Auxiliary engine operation on marine diesel oil (MDO)• High capacity fresh water generator

Extra costs 5 mill USD (Corresponds to approx 20% of newbuilding costs)


Conclusion from Study

8500 TEU container vessel, optimised with:

• Water in Fuel technology (WIF)• Exhaust gas recycling (EGR)• Waste heat recovery exhaust boilers• Power and Steam turbine technology• Exhaust gas Scrubber

Extra costs 10 mill Euro (Corresponds to approx 10% of newbuilding costs)

Goals Results-30 % reduction of CO2 emissions - Achieved 11 -14 %-90 % reduction of NOx emissions - Achieved 80 %-90 % reduction of SOx emissions - Achieved 90 %


Main Conclusions from Concept Studies

• With respect to NOx and SOx it is possible to reach the goals.• Reducing NOx and SOx will in some cases cost increased CO2 emission.• With respect to CO2 the study shows that we still need to work with

technical solutions and operation to meet goal.• Further reduction in CO2 must be obtained through continued efforts to

reduce vessel resistance, optimised operation (slow steaming), more effective propulsion systems, more fuel efficient engines, alternative fuel (LNG, Biofuel etc.) and addition of alternative green means of propulsion (fuel cells, wind, solar etc.) etc.

• Further reductions in CO2 will also reduce NOx and SOx emissions.• Retrofit challenges.

• The challenge continues!


Status of the Green Ship of the Future project

• Green technologies developed under GSF have now been introduced in more than 40 ships from different Danish Shipowners.

• Some of the ‘Green ship technologies’ have already been implemented as ‘standard products’ especially with respect to machinery equipment and onboard systems.

• An increased awareness for implementation of GSF technologies is now observed amongst partners the maritime business.

• The GSF project has now moved into a more ‘mature’ status, but new projects are still needed to meet our targets.

• More focus in the future on service experience (‘lessons learned’). • Hopefully scientific papers presenting the GSF technologies will be an

outcome in the future.


Green ship of the Future @ Sea

Almost 40 ships @ sea with GSF technologies onboard

……………….….And more to come


Invitation …

All companies, Organisations and Educational institutionsare invited to join ’Green Ship of the Future’

Contacts:

Christian SchackMail: [email protected]; Phone: +45 72 15 78 05

Rasmus CarstensMail: [email protected]; Phone: +45 72 15 77 85

www.greenship.org

4 Green Ship of the Future - GSF Coordinator

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