Large Marine Diesels in Challenging Times

CIMAC Circle , Marintec 2009

Kjeld Aabo
Director Two-stroke Promotion

© MAN Diesel
What goes in must come out
Heat

Exhaust gas
Air 13.0% O2
8.5 kg/kWh 75.8% N2
21% O2 5.2% CO2
79% N2 5.35% H2O

1500 vppm NOx

Fuel 600 vppm SOx
175 g/kWh 60 ppm CO
97% HC 180 ppm HC
3% S 120 mg/Nm3 part.

Lube
1 g/kWh
97% HC
2.5% CA
0.5% S

Work

© MAN Diesel <2>

 History and Future for
SFOC and NOx

SFOC
g/kWh 2007
250

200
SFOC
Full-rated
De-rated
150 Ideal Carnot cycle

NOx
NOx g/kWh
100 20

50 10
GB/GBE
K98FF GFCA 3.4
84VT2BF180 KGF MC/MC-C ME/ME-C/ME-B
0
1940 1960 1980 2000 2020 Year

3334808.2009.01.29 (LSP/LB) © MAN Diesel 5

IMO NOx Limit Curves Tier I, II & III

1990-1999
engines
Tier I
- 15 %

- 20 % Tier I: (global)
Tier II: 2011
- 80 % (global)

Tier III: 2016

(ECA’s)

© MAN Diesel 4
Tier III Candidate Technology

Tier III candidate technology:

ƒ WFE (Water/Fuel Emulsion)
ƒ SAM (Scavenge Air Moisturization)
ƒ EGR (Exhaust Gas Recirculation) Turbocharger
compressor outlet

ƒ SCR (Selective Catalytic Reduction)

Seawater
injectors

Freshwater
injectors

Flow change
cyclone water
separator
WMC
Sea water drain
Fresh water drain

5 © MAN Diesel
 SCR or EGR for Tier III Compliance

Possibilities EGR, EGR+WIF or SCR

•Decisive factors:
•Applicable for ME and MC
•Sailing time and pattern in ECA’s
•Fuel types and prices
•Discharge of wash water
•NaOH/Urea logistic
MAN Diesel will go both ways

3330171/20030429 (3001/UM) © MAN Diesel 6

SCR System

1 SCR reactor 1
2 Turbocharger bypass
3 Temperature sensor after SCR
4 Large motors for
auxiliary blowers
5 Urea injector 2 5
3
6 SCR bypass 6
7 Temperature sensor 8
7
before SCR
8 Additional flange in exhaust Deck
gas receiver 4

6S35MC

L/71835-9.0/0801 (2160/PZS) © MAN Diesel <7>

Principal Sketch of the EGR
Prototype System

3335433.2008.04.09 (NK/LDA) © MAN Diesel 8

 MAN Diesel EGR Unit for 7S50MC

….to reality:
EGR gas pipes
- scrubber to cooler

EGR shutdown
EGR scrubber valve

EGR cooler EGR gas pipe/s

& WMC - exhaust receiver to
Cooling water pipes scrubber

© MAN Diesel <9>

IMO & CARB Fuel-Sulphur Content Limits

© MAN Diesel
 Emission Trend
Emission restricted areas by IMO – ECAs in 07/2009

Top Container Ports :

1. Singapore
2. China, Shanghai
3. China, Hong Kong
4. China, Shenzhen
5. South Korea, Busan
6. Netherl., Rotterdam
Most used trading routes
7. UAE, Dubai
8. Taiwan, Kaohsiung existing ECAs: Baltic Sea, North Sea

9. Germany, Hamburg planned ECAs: Coasts of USA, Hawaii and Canada

10. China, Qingdao discussed ECAs: Coasts of Mexico, Coasts of Alaska and Great Lakes, Singapore, Hong Kong, Korea, Australia, Black
Sea, Mediterranean Sea (2014), Tokyo Bay (in 2015)

© MAN Diesel 11
 Aalborg Industries & DFDS
Exhaust gas scrubber retrofit project

•20MW MAN B&W two-stroke engine

•Operating in SECA on MDO
•Exhaust gas scrubber permits HFO operation
•Expected payback time less than two years

RO RO vessel M/V Tor Ficaria

JPA / LEO © MAN Diesel 12

 MAN Diesel’s Investigation in
Scrubber Technology

Participants Scrubber principle Ship test

Clean Marine & MAN Diesel Cyclone scrubber

Aalborg Industries, Alfa Laval, Absorption scrubber

known from
DFDS and MAN Diesel
inert gas units

APMM and MAN Diesel “bubble” bath scrubber

© MAN Diesel 13
ME-GI: Gas and Pilot Oil Injection

14 © MAN Diesel
 Alternative Fuel for Container Ships
ME-GI Engine for LNG

LNG fuel supply system

?

LNG tank
ME-GI main engine
Reduction with Reduction with
Reduction with ME-GI ME-GI + WHR ME-GI + WHR+EGR
CO2 (gram per tonne mile) 23% 35% 33%

NOx (gram per tonne mile) 13% 13% 80%

SOx (gram per tonne mile) 92% 92% 94%

Engergy (gram per kWh) 0% 12% 10%

Particulate matter (mg per m3) 37% 37% 48%

3336366.2009.07.31 (LS/OG) © MAN Diesel 15

 Green Ship of the Future
Targets

Provide technology to obtain:

30% reduction af CO2
90% reduction af SOx
90% reduction af Nox

All aspects of ship transportation must be taken into

account (engine, hull, painting, service, harbour,
logistics….)!

(LEE/CSU) © MAN Diesel

Exhaust Gas
Waste Heat Recovery System

Reduction gear
Reduction with overspeed
gearbox clutch
Emergency
Generator, Steam generator
AC alternator turbine
Exh. gas boiler

HP
LP LP Exh. gas
turbine
Steam for Superheated
steam Switchboard
heating
services HP

Diesel generators

Turbo-
chargers

Exhaust gas receiver

Shaft motor/
generator
Main engine

3332588.2009.05.06 (LEE4/BGJ) © MAN Diesel 23

Low sulphur fuel

ƒ Use of low-sulphur crude oil, but limited availability

ƒ Blending of fuels is a possibility, and is done today
ƒ Desulphurisation of HFO

According to the major fuel companies :

Much better investment to build high-efficient
refineries that can produce more valuable
products such as gasoline, diesel and LPG
than to build desulphurisation plants for HFO.

© MAN Diesel
 Low-sulphur Fuel Operation
Fuel change-over unit
High S% Low S%

BN
Oil 10-40-70!
Compatibility
of mixed fuels!

Engine
Viscosity!
Tank system
considerations!

© MAN Diesel
Mixing Two Different Fuels
Case story

Before Bunker
separator sample
Density @ 15C
928.0 932.4

Viscosity @
19.5 22.1
50°C
Water 0.2 <0.10
MCR 9 10
Sulphur 1.24 1.54
TSP 0.34 0.01
Total sediment ~ A fuels stabillity reserve
U/F 0.60
accelerated
Vanadium 92 100 Source: DNVPS

MAN Diesel / Charlotte Røjgaard 2008-11-06 © MAN Diesel 20

 Low-sulphur Fuel Operation
Fuel change-over unit!
High S% Low S%

BN
Oil 10-40-70!
Compatibility
of mixed fuels!

Engine
Viscosity!
Tank system
considerations!

© MAN Diesel
 Low-sulphur Fuel Operation
Fuel change-over unit!
High S% Low S%

BN
Oil 10-40-70!
Compatibility
of mixed fuels!

Engine
Viscosity!
Tank system
considerations!

© MAN Diesel
 Low-sulphur Fuel Operation
Fuel change-over unit!
High S% Low S%

BN
Oil 10-40-70!
Compatibility
of mixed fuels!

Engine
Viscosity!
Tank system
considerations!

© MAN Diesel
 Different individual factors on engines and ex. Fuel
system, have an influence on capability to operate on low
viscosity fuels.

ƒ Fuel pump high pressure leakage mainly generated at cut off holes
Design of fuel pumps

Wear of Plunger and Barrel

Fuel Volume of the ex. fuel system

Isolation of the fuel system

Design of external fuel pumps

Conclusion ;

Each ship needs to test sensitivity

to fuel viscosity above the min. 2
cSt.

Install a cooler or Chiller if

necessary.
2009.02.25 (LD/MZP) © MAN Diesel
 Slow Steaming
T/C Cut-out Concept

T/C cut-out
Exhaust gas receiver
1 of 3 T/C, 66% power
1 of 4 T/C, 75% power
Cut-out at stopped or dead slow engine condition

Development on ME engines
Stage 1: Manual adjustment of ME engine
control
Stage 2: Fully integrated system
with interlock to ME ECS
Cooler Cooler Cooler
Scavenging air receiver

3336373.2009.08.06 (LD/MZP) © MAN Diesel 25

Let Nature Prevail.
Sea Transport with
MAN B&W
MC and ME

© MAN Diesel < 26