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Thermel Efficiency PDF
Thermel Efficiency PDF
Contents:
Introduction ........................................................................... 3
Summary................................................................................ 13
References ............................................................................ 13
Introduction Efficiency System is that the reliability 25% of the total fuel energy. In the
and safety of the main engine/ship op- standard high-efficiency engine version,
Following the trend of required higher eration must not be jeopardised. the exhaust gas temperature after the
overall ship efficiency since the first oil turbocharger is relatively low, and just
crisis in 1973, the efficiency of the main As an example, the heat balance diagram high enough for production of the ne-
engines has increased and, today, the for the nominally rated 12K98ME/MC cessary steam for a ship’s heating pur-
fuel energy efficiency is about 50%. engine (18.2 bar) of the standard high- poses by means of the exhaust gas
This high efficiency has, among others, efficiency version is shown in Fig. 1a. fired boiler.
led to a correspondingly lower exhaust Fig. 1b shows an example based on
gas temperature after the turbochargers. the Thermo Efficiency System, valid for However, a main engine with changed
a single-pressure steam system, to- timing and exhaust gas bypass – which
Even though a main engine fuel energy gether with the corresponding figures redistributes the exhaust gas heat from
efficiency of 50% is relatively high, the for a dual-pressure steam system high amount/low temperature to low
primary objective for the shipowner is shown in parenthesis. amount/high temperature – increases
still to lower the total fuel consumption the effect of utilising the exhaust gas
of the ship and, thereby, to reduce the The primary source of waste heat of a heat, but at the same time may slightly
CO2 emission of his ship. main engine is the exhaust gas heat reduce the efficiency of the main engine
dissipation, which accounts for about itself. Such a system is called a Thermo
Today an even lower CO2 emission can half of the total waste heat, i.e. about Efficiency System (TES).
be achieved by installing a Thermo
Efficiency System. However, the main 12K98ME/MC with TES
demand for installation of a Thermo SMCR : 68,640 kW at 94.0 r/min
ISO ambient reference conditions
TES : Single pressure (Dual pressure)
Shaft power 12K98ME/MC Standard engine version
output 49.3% Total power output 54.2% (54.8%)
SMCR : 68,640 kW at 94.0 r/min
Shaft power El. power production of
ISO ambient reference conditions output 49.3% TES 4.9% (5.5%)
Lubricating oil
cooler 2.9%
Lubricating oil
cooler 2.9%
Jacket water
cooler 5.2%
Jacket water
cooler 5.2%
Exhaust gas
25.5% Exhaust gas and
condenser
22.9% (22.3%)
Air cooler
16.5% Air cooler
14.2%
Heat radiation Heat radiation
0.6% Fuel 100% 0.6%
Fuel 100%
(171 g/kWh)
(171 g/kWh)
Fig. 1a: Heat balance diagram of the nominally rated 12K98ME/MC Fig. 1b: Heat balance diagram of the nominally rated 12K98ME/MC
engine of the standard engine version operating at ISO ambient engine in Thermo Efficiency System (TES) version operating at
reference conditions and at 100% SMCR ISO ambient reference conditions and at 100% SMCR
3
Description of the Thermo gas turbine produces extra output is needed in order to protect the exhaust
power for electric power production, gas turbine from overspeeding in case
Efficiency System which depends on the bypassed ex- the generator drops out.
haust gas flow amount.
Power concept and The total electric power output of the TES
arrangement When a part of the exhaust gas flow is – which reduces the ship’s fuel costs
bypassed the turbocharger, the total – is only a gain provided that it can re-
The Thermo Efficiency System (TES) amount of air and gas will be reduced, place the power output of other electric
consists of an exhaust gas fired boiler and the exhaust gas temperature after power producers on board the ship.
system, a steam turbine (often called a the turbocharger and bypass will increase. Otherwise, a shaft power motor con-
turbo generator), an exhaust gas tur- This will increase the obtainable steam nected to the main engine shaft could
bine (often called a power turbine) and production from the exhaust gas fired be an option, as also shown in Fig. 2a,
a common generator for electric power boiler. but this extra system is rather expensive.
production. The turbines and the gen-
erator are placed on a common bed- The exhaust gas bypass valve will be In general (without a shaft power motor
plate. The system is shown schemati- closed for engine loads lower than about installed), when producing too much
cally in Fig. 2a, and the arrangement of 50% SMCR, which means that the ex- electric power, the (high pressure) su-
the complete turbine generating set as haust gas temperature will be reduced perheated steam to the steam turbine
proposed by Peter Brotherhood is when operating below 50% SMCR. is controlled by a speed control governor
shown in Fig. 2b. through a single throttle valve, which
The power output from the exhaust gas means that the surplus steam is dumped
The exhaust gas turbine is driven by a turbine is transmitted to the steam tur- via a dumping condenser. When the
part of the exhaust gas flow, which by- bine via a reduction gear (see Figs. 2a generator is operating in parallel with
passes the turbochargers. The exhaust and 2b) with an overspeed clutch, which the auxiliary diesel generators, the gov-
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
4
Reduction gear with Steam turbine Reduction Generator, Approx. dimensions
overspeed clutch gearbox AC alternator referring to a
Exh. gas
12K98ME/MC:
turbine Length: 10 metres
Breadth: 3.5 metres
Weight: 58 tons without
condenser
Weight: 75 tons with
condenser
Fig. 2b: Arrangement of the complete turbine generating set as proposed by Peter Brotherhood Ltd
ernor operates in the normal way to The mixed exhaust gas temperature be- ating under higher ambient air tempera-
give correct load sharing. fore the exhaust gas boiler, and valid for tures, the exhaust gas temperature will be
the TES and based on ISO ambient ref- higher (about +1.6°C per +1°C air), and
Main engine performance data erence conditions, is shown as a function vice versa for lower ambient air tempera-
of the engine load in Fig. 3. When oper- tures.
The exhaust gas bypass and turbine
are available with the following approx. Exhaust gas temperature Ambient reference conditions:
effects, compared with a standard after exh. gas bypass Tropical 45° C air / 36° C c.w.
high-efficiency main engine version °C ISO 25° C air / 25° C c.w.
without an exhaust gas bypass: Winter 15° C air / 36° C c.w.
350
Open exhaust gas Tropical
Parameters bypass for exhaust
gas turbine
Power output of 300 ISO
exhaust gas tur-
bine at 100% Winter
SMCR, up to +4.6% SMCR power
Total increase of
mixed exhaust gas 200
temperature after 40 50 60 70 80 90 100 % SMCR
bypass, up to +50°C
Exh. gas bypass Main engine shaft power
Increased fuel
consumption from 0.0% to +1.8% closed open
Fig. 3: Exhaust gas temperature after exhaust gas bypass for a main engine with TES
5
The increased fuel consumption of the
main engine depends on the actual
Exh. gas boiler
sections:
maximum firing pressure (Pmax) used.
The Pmax used for TES will normally be
Preheater Steam increased – compared with a standard
drum engine – and thereby an increase of the
Evaporator
specific fuel oil consumption can be
avoided when using TES.
Superheater Circ. pump
Exhaust gas boiler and steam
systems
200
Steam/water min 20 °C
Saturated Exh. gas
steam 150 7 bar abs/165 °C
100
A B C
50 Feed-
water
Ambient air
0
0 20 40 60 80 100 %
Heat transmission
6
2. Dual-pressure steam system
When using the dual-pressure steam
Alternative WHR
system, it is not possible to install an sources for feedwater
exhaust gas low-pressure preheater preheating
section in the exhaust gas boiler, be-
Exh. gas boiler
cause the exhaust gas boiler outlet sections:
temperature otherwise would be too LP LP-steam drum
low and increase the risk of wet (oily) LP-Evaporator
soot deposits on the boiler tubes. LP-circ. pump
HP-Preheater
The more complex dual-pressure
LP-Superheater
steam system, therefore, needs HP HP-steam drum
supplementary waste heat recovery
HP-Evaporator
(WHR) sources (jacket water and
HP-circ. pump
scavenge air heat) for preheating of HP-Superheater
the feedwater which, of course, will
increase the obtainable steam and HP LP
electric power production of TES. Exhaust
Surplus HP-steam
See the process diagram in Fig. 6 gas Steam
valve for heating
turbine
and the corresponding temperature/ services
heat transmission diagram in Fig. 7.
200
Steam/water min 20 °C
Saturated
HP steam 10 bar abs/180 °C Exh. gas
150 min 15 °C
Feedwater
4 bar abs/144 °C preheated
by alternative
100 WHR sources
A B C D E
50
Ambient air
0
0 20 40 60 80 100 %
Heat transmission
7
Obtainable Electric Power Exhaust gas and steam As an example valid for the nominally
Production of the Thermo turbine generator output rated 12K98ME/MC (18.2 bar) engine
– single pressure operating at ISO ambient reference
Efficiency System conditions, we have calculated the steam
The single-pressure steam system is a production and the electric power pro-
Exhaust gas turbine output system where all heat recovered comes duction of TES, see Figs. 10 and 11.
from the exhaust gas heat only, which
The exhaust gas bypass for the exhaust makes it relatively simple, see Figs. 4 The total electric power production in %
gas turbine has a bypass gas amount and 5. of the main engine shaft power output
of approx. 12% of the total exhaust gas is also shown as a function of the engine
amount at 100% SMCR. This bypass-gas As low gas temperatures (risk of conden- load, see Fig. 9.
amount led through the exhaust gas sed sulphuric acid) and low gas veloci-
turbine will typically produce an available ties (risk of soot deposits) through the The results for operation at 85% SMCR
power output of max. 4.6% of the SMCR exhaust gas boiler may have a deterio- are shown in Fig. 14, together with the
power when running at 100% SMCR. rating effect on the boiler, Ref. [1], we calculated ISO ambient temperature based
The corresponding electric power out- have, in our studies, selected an exhaust results for three other main engine types.
put will be somewhat lower because of gas boiler designed for a single-pressure The corresponding results based on
generator and gear losses. steam system of minimum 7 bar abs tropical ambient temperature conditions
(6 bar g) steam pressure (165°C), and are shown in Fig. 15. However, it should
At part load running of the main engine, be emphasised that it is probably more
minimum 20°C pinch point. The super-
the power output will be reduced by realistic to use the ISO ambient tem-
heated steam temperature is about
approximately the square root of the peratures as the average ambient tem-
270°C. The steam turbine is a multi-
engine load. peratures in worldwide operation. In
stage single-pressure condensing type.
The alternator/generator is driven both Fig. 16, the ISO based total electric
As an example, the maximum available
by the steam turbine and the exhaust power production at 85% SMCR is also
power output of the exhaust gas turbine
gas turbine. shown as a function of the main engine
valid for a nominally rated 12K98ME/MC
size measured in SMCR power.
(18.2 bar) engine is shown in Fig. 8, as
a function of the engine load.
Electric power production of TES
relative to the main engine power output
%
Available power output of exhaust gas turbine 13 Main engine 12K98ME/MC
kW
12 SMCR = 68,640 kW at 94 r/min
3,500
Dual press.
11 ISO amb. cond.
3,000 10 Single press.
9
2,500
8
2,000 7
6 Steam turbine
1,500
5
1,000 4
3
500
2 Exhaust
gas turbine
0 1
30 40 50 60 70 80 90 100 % SMCR 0
Exh. gas bypass Main engine shaft power 50 60 70 80 90 100 % SMCR
closed open Main engine shaft power
Fig. 8: Expected available power output of exhaust gas turbine for a Fig. 9: Expected electric power production in % of the main engine
12K98ME/MC with SMCR = 68,640 kW x 94 r/min shaft power output valid for a 12K98ME/MC with Thermo Efficiency
System (TES) and based on ISO ambient reference conditions
8
Obtainable steam production Electric power production
kg/h kW
8,000
35,000
12K98ME/MC with TES (single press.)
7,000 Total el.
12K98ME/MC with TES (single press.) SMCR = 68,640 kW at 94 r/min
30,000 production
SMCR = 68,640 kW at 94 r/min ISO amb. cond.
Total steam 6,000
ISO amb. cond.
production
25,000
5,000
20,000
4,000 Exhaust
gas turbine
15,000
3,000
Superheated steam
10,000 for steam turbine
2,000
Steam turbine
5,000 1,000
0 0
40 50 60 70 80 90 100 % SMCR 40 50 60 70 80 90 100 % SMCR
Main engine shaft power Exh. gas bypass
Exh. gas bypass Main engine shaft power
closed open closed open
Fig. 10: Expected steam production of an exhaust gas boiler with Fig. 11: Expected electric power production of the Thermo Efficiency
single-pressure steam system valid for main engine 12K98ME/MC System (TES) with a single-pressure steam system valid for main
with TES and based on ISO ambient reference conditions engine 12K98ME/MC and based on ISO ambient reference conditions
Exhaust
20,000 4,000 gas turbine
15,000 3,000
Superheated 2,000
10,000
HPsteam Steam turbine
for steam turbine
5,000 1,000
0 0
40 50 60 70 80 90 100 % SMCR 40 50 60 70 80 90 100 % SMCR
Main engine shaft power Exh. gas bypass Main engine shaft power
Exh. gas bypass
closed open closed open
Fig. 12: Expected steam production of an exhaust gas boiler with a Fig. 13: Expected electric power production of the Thermo Efficiency
dual-pressure steam system valid for main engine 12K98ME/MC System (TES) with a dual-pressure steam system valid for main engine
with TES and based on ISO ambient reference conditions 12K98ME/MC and based on ISO ambient reference conditions
9
Exhaust gas and steam The feedwater, therefore, has to be The results for operation at 85% SMCR
turbine generator output preheated by means of alternative heat are shown in Fig. 14, together with the
– dual pressure sources such as the jacket water and calculated ISO ambient temperature
scavenge air cooler heat. based results for three other main en-
Besides the single-pressure steam system, gine types. The corresponding results
a more complex and more expensive Furthermore, the pinch point should not based on tropical ambient temperature
dual-pressure steam system is also be too low (giving low gas velocities conditions are shown in Fig. 15. How-
available, see Figs. 6 and 7. The high through the boiler) in order to protect ever, it should be emphasised that it is
and low steam pressures used are the exhaust gas boiler against soot probably more realistic to use the ISO
about 10-11 and 4-5 bar abs (9-10 and deposits and fires. ambient temperatures as the average
3-4 bar g), respectively. ambient temperatures in worldwide op-
As an example valid for the nominally eration. In Fig. 16, the ISO based total
The steam turbine is a multi-stage dual- rated 12K98ME/MC (18.2 bar) engine electric power production at 85%
pressure condensing type. The alternator/ operating at ISO ambient reference SMCR is also shown as a function of
generator is driven both by the steam conditions, we have calculated the the main engine size measured in
turbine and the exhaust gas turbine. steam production and the electric SMCR power.
power production of the TES, see
Because of the low steam pressure and Figs. 12 and 13. Payback time of the Thermo
corresponding low saturated steam tem- Efficiency System
perature (144°C/4.0 bar abs), there is no The total electric power production in
room for an LP-preheater section in the % of the main engine shaft power out- The payback time of TES depends very
exhaust gas boiler for feedwater preheat- put is also shown as a function of the much on the size of the main engine
ing, because the exhaust gas boiler engine load, see Fig. 9. and the trade pattern (main engine load
outlet temperature has to be higher than and ambient temperatures) of the ship.
about 160-165°C in order to avoid sulphu-
ric acid corrosion of the boiler outlet.
0DLQHQJLQHVRSHUDWLQJDW60&5DQG,62DPELHQWUHIHUHQFHFRQGLWLRQV
Fig. 14: Steam and electric power production and payback time of the Thermo Efficiency System (TES)
when operating at 85% SMCR and ISO ambient reference conditions
10
0DLQHQJLQHVRSHUDWLQJDW60&5DQGWURSLFDODPELHQWFRQGLWLRQV
Fig. 15: Steam and electric power production of the Thermo Efficiency System (TES)
when operating at 85% SMCR and tropical ambient conditions
11
Fuel costs = 280 days/y x 24 h/day
x 0.00017 t/kWh Payback time of TES
x 58,344 kW Year
x 160 USD/t 13
= 10,664,000 USD/year
12 Normal service : 85% SMCR
In service per year : 280 days/year
For the single and dual-pressure sys- 11 Fuel consumption : 0.17 kg/kWh
tems, respectively, the TES gain in
10 Fuel price : 160 USD/t
saved fuel consumptions will then be as
follows:
9 ISO ambient reference conditions
TES1 savings = 0.086 x 10,664,000 8
= 917,000 USD/year
7
TES2 savings = 0.098 x 10,664,000
= 1,045,000 USD/year 6
5
as shown in Fig. 14.
4
The similar fuel cost savings valid for the
3
other three cases with smaller main en-
gines are also stated in Fig. 14, and in 2
curve form in Fig. 16 as a function of
1
the main engine size, SMCR power.
0
Based on the extra investment costs of 20,000 40,000 60,000 80,000 kW
the TES plant (without installation of a Size of main engine, SMCR power
shaft power motor on the main engine
shaft and minus the investment cost of
Fig. 17: Estimated payback time of the Thermo Efficiency System (TES) valid for both
a normal exhaust gas boiler system) for
a single and a dual-pressure steam system
the four main engine cases compared
to a standard main engine installation,
the estimated payback time found is as
stated in Fig. 14, i.e. in principle the
same for the single and dual-pressure
systems. For the 12K98ME/MC engine,
the calculated payback time is about
five years.
12
Summary References
Our calculations indicate that for ISO When selecting the type of Thermo Effi- [1] Soot Deposits and Fires in Exhaust
ambient reference conditions, a reduc- ciency System, the correspondingly in- Gas Boilers, MAN B&W Diesel A/S,
tion of the fuel consumption of 8-10% volved higher risks for soot deposits and Copenhagen, Denmark, p. 280,
for a single-pressure system is possible fires of the exhaust gas boiler has to be March 2004.
in the normal service range of the main considered, see Ref. [1].
engine. The larger the engine load, the
greater the possible reduction. Because of this, but also because of the
more simple single-pressure steam boiler
For the more complex dual-pressure system, MAN B&W Diesel recommends
system, the corresponding reduction is using the single-pressure steam system,
about 9-11%. when installing TES.
All calculations presume unchanged Of course, the more complex and more
MTBOs (maintenance time between expensive dual-pressure steam system,
overhauls) compared to today’s expec- which gives a somewhat higher electric
tations. power output, may also be used in
connection with MAN B&W Diesel’s
However, if the ship sails frequently in two-stroke main engine types.
cold weather conditions, the electric
power production of the steam turbine The TES is rather expensive, and relatively
will be reduced, and the above-stated more expensive the smaller the main
reduction of fuel consumption and cor- engine and the TES are, giving a rela-
responding reduction of CO2 emission tively higher payback time. Therefore,
might not be met. the installation of the TES is normally
only relevant for the large merchant ships,
The extra investment costs of the Thermo such as the large container vessels.
Efficiency System and the payback of
the investment can be obtained by The TES may be delivered as a package
means of lower fuel/lube oil costs and, by Peter Brotherhood (turbines) in co-
not to forget, the possibility of obtaining operation with Aalborg Industries (boiler)
additional freight charters and higher and Siemens (generator) or by other
freight rates, thanks to the ‘green ship’ makers.
image!
13