Emission Rules NOx, SOx & CO · MAN Diesel & Turbo Author Current topic 00.00.2012 < 2 > Agenda...
Transcript of Emission Rules NOx, SOx & CO · MAN Diesel & Turbo Author Current topic 00.00.2012 < 2 > Agenda...
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]
2< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
3< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
4< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
5< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
6< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
7< >MAN Diesel & Turbo Author Current topic 00.00.2012
Emission Rules OverviewExisting and Future ECA Areas
01.10.2014
Source: DNV GLMEPC 66, London, April 2014
8< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
9< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
10< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
11< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
12< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
13< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
15< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
16< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
17< >MAN Diesel & Turbo Author Current topic 00.00.2012
TIER III, MDT StrategyExample of SCR reactor program, High versus Low sulphur fuel
18< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
19< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
20< >MAN Diesel & Turbo Author Current topic 00.00.2012
EGR SCR SCR
On-Engine High-pressure Low-pressure
(HP) (LP)
TIER III, MDT StrategyLow sulphur fuel focus includes low pressure SCR
21< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
22< >MAN Diesel & Turbo Author Current topic 00.00.2012
TIER III, MDT Strategy
Revised Expected Market Penetration
23< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
24< >MAN Diesel & Turbo Author Current topic 00.00.2012
• 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%)
25< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
26< >MAN Diesel & Turbo Author Current topic 00.00.2012
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)
27< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
28< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
29< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
30< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
31< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
32< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
33< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
34< >MAN Diesel & Turbo Author Current topic 00.00.2012
Installation
SCR reactor Vaporizer/mixer
M/V Santa Vista
TIER III, SCR Example of HP SCR installation
35< >MAN Diesel & Turbo Author Current topic 00.00.2012
HP SCR programme example
Hitachi Zosen
36< >MAN Diesel & Turbo Author Current topic 00.00.2012
Bypass of EGE boiler
Engine delivery
TIER III, SCR Example of HP SCR installation
37< >MAN Diesel & Turbo Author Current topic 00.00.2012
SCR Engine room arrangement
182 K Bulk – 6G70ME-C
TIER III, SCR Example of HP SCR Outline
38< >MAN Diesel & Turbo Author Current topic 00.00.2012
LP SCR on 6G60ME-C9.5 engine on test bed
Vaporiser
SCR
reactor
TIER III, SCR Test Installation with LP SCR
39< >MAN Diesel & Turbo Author Current topic 00.00.2012
Low pressure SCR
TIER III, SCR Example of LP SCR Outline
40< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
41< >MAN Diesel & Turbo Author Current topic 00.00.2012
• 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
42< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
43< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
44< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
45< >MAN Diesel & Turbo Author Current topic 00.00.2012
TIER III, EGRExample of EGR installation (based on HFO)
46< >MAN Diesel & Turbo Author Current topic 00.00.2012
TIER III, EGR Example of EGR Installation with CTU (HFO) versus updated RTU (LSF)
47< >MAN Diesel & Turbo Author Current topic 00.00.2012
New alternative arrangement Including Receiving Tank Unit - RTU
RTU RTU
TIER III, EGR Example of EGR Installation with updated RTU (LSF)
48< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
49< >MAN Diesel & Turbo Author Current topic 00.00.2012
Capital cost: EGR – SCRRough estimate
Comparison SCR versus EGRCapital cost
50< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
51< >MAN Diesel & Turbo Author Current topic 00.00.2012
Operational cost: EGR – SCRExample 60.5 MW, 4800 h/year (TII) + 1200 h/year (TIII)
Comparison SCR versus EGROperational Cost
52< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
53< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
55< >MAN Diesel & Turbo Author Current topic 00.00.2012
1 Emission Rules Overview
2
TIER III, SCR3
TIER III, MDT strategy
4
Comparison SCR versusd EGR 5
TIER III, EGR
SOx Rules, Status 6
7 Conclusions
Agenda – Emission RulesUniversity of Piraeus – 25.11.2015
56< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
57< >MAN Diesel & Turbo Author Current topic 00.00.2012
SOx rules, StatusCompliance with DFDS Seaways, Thor Ficaria and 5 other ferries
58< >MAN Diesel & Turbo Author Current topic 00.00.2012
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
59< >MAN Diesel & Turbo Author Current topic 00.00.2012
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)
60< >MAN Diesel & Turbo Author Current topic 00.00.2012
1 Emission Rules Overview
2
TIER III, SCR3
TIER III, MDT strategy
4
Comparison SCR and EGR 5
TIER III, EGR
SOx Rules, Status 6
7 Conclusions
Agenda – Emission RulesUniversity of Piraeus – 25.11.2015
61< >MAN Diesel & Turbo Author Current topic 00.00.2012
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< >MAN Diesel & Turbo Author Current topic 00.00.2012
< 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.