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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 - www.greenship.org

Green Ship of the Future


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 - www.greenship.org

Green Ship Project Partners

Green Ship of the Future - www.greenship.org

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.

Green Ship of the Future - www.greenship.org

Green Ship of the Future


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

Green Ship of the Future - www.greenship.org

Better interaction between transport


forms, development/modification of
existing ship types etc.

Scrubber Systems
Partners:

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

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit

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

The expected reduction in


SOx is approx. 98% and
CO2 is approx. 3 %
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

EGR Systems
Partners:

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.

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit
The expected reduction in
NOX is approx. 50 %

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 2010

Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Machinery for high-speed LNG-ferries


Partners:

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.

Fact Box
CO2

NOX

SOX

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.

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

As a spin off, Mols-Linien is currently evaluating the implementation of LNG


to power two gas turbine-powered high-speed ferries.

Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Pump and Cooling Water Systems


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.

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit
The expected reduction in
fuel consumption is
minimum 1.5 %
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

MAN B&W ME-B with VTA


Partners:

Optimisation of CO2 emission


and 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.

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit

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

The expected reduction in


fuel consumption is
approx. 2%
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

System Integration and Waste Heat


Partners:

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.

Fact Box
CO2

NOX

SOX

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.

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

Green Ship of the Future - www.greenship.org

Test

Onboard

SCR System for NOx-reduction


Partners:

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-reduction
on marine engines. The system is based on Digital
Airless Multipoint injection of urea.

Fact Box
CO2

NOX

SOX

Newbuilding

The Digital Airless Multipoint technology gives a


high NOx-reduction with long term stability, no need
for compressed air (giving low auxiliary power
requirements compared to conventional SCR
systems), no need for a mixer and a very compact
size. This again means that the complete SCR
system takes up the same space as the traditional
silencer which it substitutes.

Retrofit

The developed SCR system is based on a modular concept and can be


adapted to any engine running on marine diesel.

The expected reduction in


NOx is approx. 90%

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


Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Dual / Multi MCR Certification


Partners:

Development of main engines


with dual or multi certification
for easy change of MCR rating
for any trade route or speed
Optimal 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

Fact Box
CO2

NOX

SOX

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

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

Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Automated Engine Monitoring


Partners:

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.

Fact Box
CO2

NOX

SOX

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

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.
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Turbo Charging & Variable Nozzle Ring


Partners:

Variable nozzle rings


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

Fact Box
CO2

NOX

SOX

Newbuilding

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

Retrofit
The expected reduction in
CO2 is approx. 1 to 3 %
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Waste Heat Recovery Systems


Partners:

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).

Fact Box
CO2

NOX

SOX

Newbuilding

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.

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

Green Ship of the Future - www.greenship.org

Test

Onboard

Pump & Auxiliary Systems


Partners:

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.

Fact Box
CO2

NOX

SOX

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

Green Ship of the Future - www.greenship.org

Test

Onboard

Optimised Control for Ship Cooling


Partners:

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.

Fact Box
CO2

NOX

SOX

Newbuilding

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)

Retrofit
The expected reduction is
still being evaluated
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Green Ship of the Future


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

Green Ship of the Future - www.greenship.org

Better interaction between transport


forms, development/modification of
existing ship types etc.

GreenSteam Trim Optimisation


Partners:

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.

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit
The expected reduction in
fuel consumption is
approx. 3%

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.
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Air Resistance of Ships


Partners:

Air Resistance of Ships


The air resistance of a Bulk Carrier is approximately 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.

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit
The expected reduction in
Fuel consumption is
approx 2 to 3 %

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 2010
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Trim Optimisation & Performance Monitoring


Partners:

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

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit

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%
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

New high efficient nozzle


Partners:

New high efficient nozzle from


MAN Diesel.
MAN Diesels 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.

Fact Box
CO2

NOX

SOX

Newbuilding
Retrofit

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 %
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Effect of Silicone paint


Partners:

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.

Fact Box
CO2

NOX

SOX

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

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

Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Green Ship of the Future


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

Green Ship of the Future - www.greenship.org

Better interaction between transport


forms, development/modification of
existing ship types etc.

SeaPlanner Fuel saver


Partners:

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.

Fact Box
CO2

NOX

SOX

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

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.
Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Lab on a ship
Partners:

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.

Fact Box
CO2

NOX

SOX

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

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.

Design

Green Ship of the Future - www.greenship.org

Test

Onboard

SIMAC GSF Student Forum


Partners:

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.

Fact Box
CO2

NOX

Newbuilding
Retrofit

SOX

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.

Design

Green Ship of the Future - www.greenship.org

Test

Onboard

Green Ship of the Future


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

Green Ship of the Future - www.greenship.org

Better interaction between transport


forms, development/modification of
existing ship types etc.

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

Green Ship of the Future - www.greenship.org

Low emission concept ships

SEAHORSE 35
35.000 DWT Bulk Carrier
By Grontmij Carl Bro

Green Ship of the Future - www.greenship.org

A-Class
8500 TEU Container Ship
By Odense Lindoe Shipyard

Conclusion from Study


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)

Goals
-30 % reduction of CO2 emissions
-90 % reduction of NOx emissions
-90 % reduction of SOx emissions
Green Ship of the Future - www.greenship.org

Results
- Achieved 7 %
- Achieved 90 %
- Achieved 79 %

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
-30 % reduction of CO2 emissions
-90 % reduction of NOx emissions
-90 % reduction of SOx emissions
Green Ship of the Future - www.greenship.org

Results
- Achieved 11 -14 %
- Achieved 80 %
- 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!

Green Ship of the Future - www.greenship.org

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 - www.greenship.org

Green ship of the Future @ Sea

Almost 40 ships @ sea with GSF


technologies onboard
..And more to come

Green Ship of the Future - www.greenship.org

Invitation

All companies, Organisations and Educational institutions


are invited to join Green Ship of the Future
Contacts:
Christian Schack

Mail: crs@force.dk; Phone: +45 72 15 78 05

Rasmus Carstens

Mail: rac@force.dk; Phone: +45 72 15 77 85

www.greenship.org

Green Ship of the Future - www.greenship.org