DOK/2431 2004-09-01 1

2004-09-01

Topics1. What are exhaust gas emissions?

2. Emission Control

3. Emission regulations

4. Procedure for IMO NOx certification

5. Summary

Diesel Academy - Emissions

DOK/2431 2004-09-01 2

What are Exhaust Gas Emissions?Heat

Air

Fuel

Lube

Work

Exhaust gas

O2 , N2 , CO2 , H2O

NOx , SOx , CO, HC,Particulate matter (PM)

Flow process

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Effects of Diesel Exhaust

NOx, CO, HC and SOx cause Respiratory health problemsNOx + HC form ground level ozone (toxic)

NOx + SOx contributes to acid rain

Particulate matter (PM):• Probable human carcinogen• Cause respiratory and heart diseases• Cause premature deaths

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Contribution of emissions from marine diesel engines to total deposition of SOx and NOx in selected countries:

Impact of emissions from ships

1613Sweden

1313Netherlands

2015Denmark

3816Malta

Oxides of NitrogenContribution (%)

Oxides of SulphurContribution (%)

Country

Source: Norwegian Metrological Institute

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Emission control

Oxygen and Nitrogen (air)forms NOx at high combustion temperatures

SourcePrimary and secondarymethods

NOxControlPollutant

Fuel sulphur content Low sulphur fuelScrubbers?

SOx

•Slide valves•Reduced lube oil consump.

Unburned fuel and lubeHydrocarbons

• Unburned fuel and lube• Soot • Sulphur from fuel

•Slide valves•ME smokeless operation•Low sulphur fuel•Reduced lube oil consump.

Particulate matter

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NOx Emission Control

• Primary methods (Engine produces less NOx)1) Engine adjustments/Design modifications

2) Engine process modifications• Water-in-fuel emulsion / Water injection• Exhaust Gas Recirculation (EGR)• Scavenge Air Moisturizing (SAM)

• Secondary methods (NOx is removed after the engine)SCR (Selective Catalytic Reactor NOx)

• Low NOx atomizer• Retarded injection timing• ME-engine emission mode

IncreasingNOx

reduction

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The ME engine withfully integrated control of:

• Starting air valves• Start and reversing sequences• Governor function • Auxiliary blowers• Electronically profiled injection control• Exhaust valve actuation• Cylinder oil feed rate

3330172/20030904 (3000/OG)

Electronically Controlled EnginesElectronically Controlled Engines

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Advantages of ME Engines

L/72562-0.0/0302 (2440/PCS)

‘‘low emission modeslow emission modes’’ where NOwhere NOxx is be reduced below the IMO limit is standardis be reduced below the IMO limit is standard

Flexibility regarding exhaust gas emissions:Flexibility regarding exhaust gas emissions:

mode for smokeless slow steaming can be made availablemode for smokeless slow steaming can be made available

adaptation to different fuelsadaptation to different fuels

computer controlled cylinder lubricator with intermittent lubriccomputer controlled cylinder lubricator with intermittent lubrication, enables a ation, enables a reduction in lube oil dosage. We expect some 0.2 reduction in lube oil dosage. We expect some 0.2 g/BHPhg/BHPh reduction (or more) at reduction (or more) at presentpresent

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ME Engine Standard Modes Economy Mode vs. Low NOx Mode

L/74498-4.3/0903 (2430/NK)

SFOC

-100

10

40 50 60 70 80 90 100 110

g/kW

h

Ecomomy mode Low Nox mode

75115155

40 50 60 70 80 90 100 110Bar

(abs

) Pmax Economy modePcomp

Pmax Low Nox modepcomp

Relative NOx emission

100120140

40 50 60 70 80 90 100 110Engine load

%

Economy mode

Pmax and Pcomp

Low Nox mode

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• IMO Annex VI (world-wide)

• EPA (US waters)Limits equal to IMO, only for US flag

• EU (Strategy for marine engines)1.5% sulphur limit in EU waters from 2007

Strategy for emissions from marine engines

• Market based instruments Benefit from reducing emissions

Examples: Sweden and Norway

Emission Regulations

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IMO Regulation (Annex VI to MARPOL 73/78)

Regulation 13: NOx limit (speed dependent)

Regulation 14: Sulphur limit (4.5% general/1.5% special)

Regulation 18: Bunker delivery note

IMO NOx Regulation

Entry into force: 19 May 2005 (retro-active from jan-2000).

Discussion of new (tighter) limits to start alreadylate 2004

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IMO regulation applies to:• engines (>130 kW) build on or after 2000-01-01• or all engines, which goes through a major

conversion after 2000-01-01

Applicable engines

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NOx emission for MAN B&W engines

0

5

10

15

20

25

50 100 150 200Engine - r/min

NO

x g

/kW

h, E

2/E3

cyc

le

Before 2000

After 2000

IMO Limit

All MAN B&W engines comply with IMO NOx limit

IMO NOx Limit

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Engine Certification

Tools: Technical File and Surveys

IMO Certification ensures compliance:

• at delivery (on test bed)

• when taken into service (sea trial)

• in service

Classification societies handle the certification on behalf of the Flag States

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The engine builder is responsible for test bed survey and issuance of the Technical File

Test bed survey

Approved Technical File => EIAPP certificateEIAPP: Engine International Air Pollution Prevention

Demonstration of compliance on test bed:• NOx emission are measured on one engine of series of identical

engines

• Remaining engines are approved by inspection of components and evaluation of performance (parameter check method)

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• To specify the engine

• To present the NOx level for the engine

• To provide a NOx verification method (survey method) for the engine in service

Purpose of the Technical File

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MAN B&W standard Technical File:

• is accepted by all major classification societies

• ensures identical Technical Files independent of engine manufacturer

• allows adjustments and modifications of engines in service

Unified Technical File

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Initial and periodical surveys in service• ‘parameter check method’ (inspection of

components and evaluation of performance) OR• ‘simplified measurement method’ OR• ‘continuous NOx monitoring method’ (for periodical

surveys only)

Passed survey => Issuance of IAPP certificateIAPP: International Air Pollution Prevention

The yard (with the manufacturer) is responsible for the IAPPbut the ship owner for continuing compliance

On-board survey methods

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Emission measurement

”Transportable” equipment Test bed equipment

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MAN B&W Parameter Check Method

If two engines have:• similar design features (i.e. same design spec.)• same ”NOx components”• same performance values (within given tolerances)they will have the same NOx emission

Reference values and maximum allowed tolerancesfor the critical performance parameters are given in theTechnical File

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NOx Influencing Components• Cylinder liner• Piston crown• Cylinder cover• Fuel pump plunger and barrel (MC)• Pressure booster top cover and pressure booster

housing (ME)• Fuel nozzle• Fuel and exhaust cams (MC)• ELFI valve and ECS units (ECU & CCU’s) (ME)• Software version / mode selection (ME)

Turbocharger, scavenge-air cooler, aux. blower and governor and for ME engines ELFI and ECS units to be verified through their name plates.

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• The Technical File must be available

• The engine must be adjusted according to the Technical File

• Standard performance data must be recent i.e. within 30 days from a scheduled survey

• A record book describing changes in NOx components and settings must be kept

• Only NOx components with proper marking are allowed

Requirements for On-Board Surveys

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MAN B&W On-BoardNOx Verification Procedure

1. Inspect Technical File and Record Book2. Perform standard MAN B&W Performance

Check (must be taken within last 30 days)3. Verify compliance using the Survey Code 4. Check fuel nozzle and ECS version *)5. Add output from survey code to record book

*) Check other NOx components and settings (incl. IMO check sums) as considered necessary

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Record book of engine parameters

Contents:Description of any changes affecting engine parameters that may influence NOx emissions (as described in the Technical File):

• Adjustments• Part replacements• Modifications of engine parts

Shall be recorded chronologically and kept with the Technical File

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Change in design for NOx components(Equal to introduction of new ME engine mode):

New component => NOx lower or unchanged:MBD will issue amendments to the existingTechnical File

New component => Higher NOx:New Technical File to be issued

New NOx components

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Maintaining certificates (drawing revisions) • without ID change ⇒ forward new drawing• with ID change ⇒ amendment

New components• without NOx influence ⇒ amendment • with possible influence ⇒ amendment *)

(but application supported by in-house tests)

*) if NOx increase ⇒ new TF (parent or member)

Amendment Procedures

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Defined as:• replacement engine• maximum rating increase > 10% • or any substantial modification

A substantial modification is defined as,for engines build:• after 2000 – NOx possibly exceed IMO limit *)• before 2000 – increase existing NOx beyond

tolerances (meas. w. simplified meas. method) **)

*) may require a new parent engine**) complete compliance with Annex VI

Major Conversion

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• MAN B&W has prepared a unified TF for all licencees for the benefit of the customer

• The TF defines the future on-board surveymethod

• MAN B&W are prepared for future tougheremission regulations

• MAN B&W participate in the different regulationdiscussions

• Service letter concerning on-board surveyshave been published and a new being prepared

Summary

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• On-board IAPP surveys from next Year

• Tighter IMO regulations

• Individual State regulations

• Voluntary programs

• More components regulated (HC, PM, CO)

Future Challenges

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Questions?

Diesel Academy - Emissions