Tier III emission technology

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1 Tier III emission technology By Johan Kaltoft, Senior Project Manager, Emission Reduction Technology < 1 >

2 Tier III emission technology Tier III strategy SCR - Selective Catalytic Reduction EGR Exhaust Gas Recirculation ME-GI Tier III SO X scrubbing < 3 >

3 Flexible two-way approach for fulfilling IMO demands < 4 >

4 Requirements for Tier III engine design Tier III from an engine designers point of view: 76% reduction on cycle value (14.4 to 3.4g/kWh) Not To Exceed- mode caps (5.1g/kWh at 25%, 50%, 75% and 100% load) On/off emission control systems Certification of new systems Fuel flexibility/combined with scrubber Tier III technology does not affect EEDI in the present form EEDI is for the ship when operated outside ECA s 5

5 Tier III emission technology Tier III strategy SCR - Selective Catalytic Reduction EGR Exhaust Gas Recirculation ME-GI Tier III SO X scrubbing < 6 >

6 Selective Catalytic Reduction (SCR) Exhaust gas NO 2 NO 40% urea solution CO (NH) (HO) 2 N O NH 3 H N H H N N O N N H H H N N N N 2 HO 2 N H O H O H H N N 4NO + 4NH + O = 4N + 6H NO + 8NH = 7N + 12H O < 7 >

7 The SCR development Two partners MDT Copenhagen Hitachi Zosen Corporation Engine builder Catalyst division MDT provides Dedicated SCR engines < 8 >

8 SCR and two stroke diesel engines The challenge The current lower temperature requirement for operation on HFO is between 300 and 350 C < 9 >

9 The Tier III SCR system Pre-turbine SCR Non ECA operation The exhaust gas goes directly to the turbine < 10

10 The Tier III SCR system Pre-turbine SCR ECA operation The exhaust gas is directed to the SCR reactor < 11

11 Low load method Ensures correct temperature The air-fuel ratio is decreased resulting in higher exhaust gas temperature < 12

12 Engine control system < 13

13 Shop test of 6S46MC-C with SCR SCR reactor Control panel for reductant injection and soot-blow Air compressor & air tanks Tests were carried out from January to April 2011 Urea solution tanks Urea supply unit < 14

14 Tier III achievement Results Tier III is achieved with pre-turbine SCR Sufficient temperature for HFO operation Also, at low load with Cylinder & SCR Bypass Valve support The not to exceed (NTE) limit is also fulfilled 6S46MC-C 25 % load 50 % load 75 % load 100 %load Cycle Tier I (17 g/kwh) Tier III (3.4g/kWh) < 15 >

15 Tier III SCR service test MDT and Hitachi Zosen Corporation Service test on bulk carrier installed with 6S46MC-C engine applied with pre-turbine SCR catalyst. Objectives of the test is to obtain: No clogging by sulphates Engine control system maintains engine performance Urea dosing system is reliable Bypass valves work satisfactory < 16 >

16 The SCR service test installation < 17 >

17 SCR prelimenary service test experience - conclusions Engine control system performed as expected. 80% NO X reduction measured at % engine load. 13 test on MDO completed. < 18 >

18 The SCR system - first Tier III compliant engine < 19

19 Tier III emission technology Tier III strategy SCR - Selective Catalytic Reduction EGR Exhaust Gas Recirculation ME-GI Tier III SO X scrubbing < 20 >

20 Basic EGR principle O 2 in the scavenge air is replaced with CO 2. CO 2 has a higher heat capacity thus reducing the peak temperatures. Exhaust gas loop Reduced O 2 content in the scavenge air reduce the combustion speed thus reducing the peak temperatures. Decreased peak temperatures reduces the formation of NO x

21 EGR principal system layout < 22 >

22 EGR principal system layout < 23 >

23 EGR principal system layout < 24 >

24 EGR principal system layout < 25 >

25 EGR system layout with 2 turbo charges < 26 >

26 EGR key components EGR cooler Scrubber Blower EGR sensor WMC s Water Treatment system Drainere Valves < 27

27 EGR investigation and service test EGR investigation on 4T50ME-X: 7 MW diesel engine and >40% EGR EGR service test on Alexander Maersk: 10 MW diesel engine and 20% EGR < 28 >

28 EGR investigation on 4T50ME-X IMO Tier III NO X cycle value is verified on test engine. More than 85% reduction of NO X is obtained. Running with EGR alone < 29

29 EGR investigation on 4T50ME-X 4T50ME-X test engine, 7 MW (Power for EGR blower is not included) < 30

30 EGR investigation on 4T50ME-X EGR scrubber performance: Engine load [%] PM reduction [%] ISO 8178 SO 2 reduction [%] FTIR < 31 >

31 EGR Service Test - installation in July 2009 at Lisnave Shipyard EGR components on the deck of Alexander Maersk < 32 >

32 Arrangement of EGR system in engine room on Alexander Maersk Shut down valve Scrubber Blower EGR Cooler Change over valve Water cleaning Buffer tank Drainers Scrubber pump EGR cooler pump < 33 >

33 EGR Service Test on Alexander Maersk with 3% sulphur HFO Currently more than 600 running hours with EGR in operation is achieved and the crew onboard is operating the EGR system. < 34 >

34 EGR Service Test - challenges Corrosion on EGR components 9 First type of coating New improved coating First type of EGR blower wheel New stainless steel EGR blower wheel 9 < 35

35 EGR Service Test challenges Corrosion of EGR cooler Before After Countermeasures: Exchange cupper cooler element with stainless steel element. < 36

36 EGR Service Test challenges Deposits of sodium- and iron sulfate on M/E cooler top Before Countermeasures: After Reduce scrubber water carry over from EGR WMC. Adjust scrubber water quality. < 37

37 EGR Service Test challenges Deposits of sodium sulphate in the scrubber Countermeasures: Ensure necessary dilution of scrubber water. Correct balance of scrubber water split between pre-scrubber and scrubber. < 38

38 EGR Service Test - results Cylinder condition Before test After test < 39

39 EGR Service Test results Deposits on M/E cooler and EGR blower M/E cooler top after approx. 500 hours of running. Not cleaned for 200 hours. EGR blower after approx. 400 running hours June < 40

40 EGR Service Test results Condition of EGR unit and water mist catcher EGR unit after scrubber after 500 hours EGR water mist catcher after 600 hours < 41

41 EGR Service Test - results Scrubber Water Cleaning Scrubber discharge water is in compliance with IMO: Scrubber system is kept in clean condition. ph = 8 ph Turbidity < 25 FNU PAH < 200 µg/l (1 m 3 /MWh) < 42

42 2 nd EGR service test Project 6S80ME-C rpm Shop trial at HHI-EMD APMM derated to 73.9rpm 43

43 EGR unit integrated on engine Turbine cut-out valve Smaller TC EGR inlet pipe & prescrubber EGR shut down valve Compressor cut-out valve Distribution chamber Dual Cooler Larger TC Cylinder bypass EGR Scrubber EGR blower Blower cut off valve EGR mixing chamber EGR change over valve EGR return pipe 44

44 Installation PI diagram < 45 >

45 EGR water treatment system WTS example for an 6S80ME-C9 engine Capacity: 70m 3 /h. 4x5 m footprint and 2.2m high. Fully automated. NaOH dosing included. Discharge is in compliance with IMO criterias. 46

46 EGR installation example < 47 >

47 MDT Low Speed NO X Tier III compliance plan Low speed Path 1.a: EGR on 4T50ME-X test engine Pre-study & 1 st EGR test Extreme EGR Control HP Boiler CGR Path 1.b: EGR 1 st Service test Path 2.a: SCR on Hitachi test engine & rig Pre-study & concept Fundamental test Control test Final design Integrated design Modulation Apply to all engine types EGR 2 nd Service tests Apply to all engine types by specifications Path 2.b: SCR Service test Eksternt støttede projekter:

48 Tier III emission technology Tier III strategy SCR - Selective Catalytic Reduction EGR Exhaust Gas Recirculation ME-GI Tier III SO X scrubbing < 49 >

49 ME-GI - fuel flexibility Fuel flexibility - operation on LNG, HFO or MGO Lowest possible fuel cost Low GHG emission and no gas slip No knocking protects the engine < 50 >

50 ME-GI Emissions Reduction with ME-GI* CO 2 23% NO x 13% SO x 92% To ensure Tier III ECA operation application of EGR or SCR is nessecary *assuming operation in gas fuel mode, and HFO pilot fuel oil < 51 >

51 ME-GI Tier III solutions 2016 ME-GI solely for non ECA operation on LNG, HFO and MGO ECA operation on LNG and MGO 0,1% sulfur content Full fuel flexibility incl. ECA operation on HFO with high sulfur content + EGR SO X scrubber ME-GI or + + SCR < 52 >

52 ME-GI Status December 2010 Development Plan Year / Quarter Task & Schedule ME-GI Development Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 ME-GI concept Test rig development Test rig TS50ME-GI Test Rig Start Test & Optimization Cont. 4T50ME-GI Research Engine Conversion 4T50ME-GI Tier II Test Cont. Tier III Test Decision full Scale Test Agreement DSME Engine Start Tier II verifikation Cont. Tier III verifikation Agreement HHIEMD Customer Demonstration Development of Gas Injection ECS Gas Injection & Engine Control System; GI-ECS Start integration test 4T50ME-GI Helios Project EU FP7 Preparation Evaluation Execution Application Full grant obtained 7S60ME-GI8 Design Order (DSO) ME-GI Order QG Letter of intent First Order ME-GI QG Order Yes / No ME-GI retrofit (46x 2x6/7S70ME-GI)

53 Tier III emission technology Tier III strategy SCR - Selective Catalytic Reduction EGR Exhaust Gas Recirculation ME-GI Tier III SO X scrubbing < 54 >

54 SO X scrubbing Cooperation with Alfa Laval Aalborg on development and test of SO X scrubber < 55 >

55 Tier III emission technology Thank you for your attention! By Johan Kaltoft, Senior Project Manager, Emission Reduction Technology < 56 >

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