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The scope of the guideline is to provide an overview of the most relevant fuel saving
measures that are available for bulk carriers to be built in China.
Appendices:
1. Methodology ................................................................................................................ 77
1.1 Objective ............................................................................................................... 77
1.2 Assumptions .......................................................................................................... 77
1.3 Model .................................................................................................................... 77
1.3.1 Fuel saving measure & estimated costs ......................................................... 78
1.3.2 Operating profile & fuel consumption........................................................... 78
1.3.3 Financial scenario & fuel price development ................................................ 78
1.3.4 Fuel savings and cost-benefit of fuel saving measure ................................... 78
1.3.5 Sensitivity ...................................................................................................... 79
Most energy saving devices works by changing the flow before or after the propeller.
Some devices aim at improving the propeller working conditions, while others seek to
regain parts of one or more of the energy loss types caused by the basic principle of
propulsion by a propeller. Typically they aim at affecting either one or more of the
following:
• Axial wake
• Tangential wake
• Rotational losses
• Vortices
• Tip vortex
• Hub vortex
One of the most difficult aspects when addressing energy efficiency measures is that most
measures usually affect more than one parameter. E.g. making the aft body fuller may
increase the form factor and the thrust deduction, and decrease the open water efficiency,
all of which are negative effects. On the other hand, it may increase the wake fraction,
which is a favourable effect. Hence, the net effect is difficult to assess without an analysis
of the whole vessel. To complicate matters further, changes in propeller operating
conditions may also affect the efficiency of the main engine.
For all energy efficiency devices the aim will be to increase the total efficiency of the
propulsion. This is also what the reported improvement values will relate to.
Further information may be found in e.g. /21/.
In the following discussion of the different fuel saving measures, most documentation of
fuel savings for bulk carriers are scarce. Therefore also tanker specific results are presented
especially since tankers and bulk carriers traditionally have a similar hull form.
Further comparisons should be carried out between different design options. The
optimization on bow shape and aft body may be performed with the help of CFD analyses.
The wave making resistance may be reduced based on potential flow software and the
viscous resistance may be investigated and optimized based on a viscous code (RANS –
Reynolds Averaged Navier Stokes). Self-propulsion tests may also be simulated using
CFD. CAD softwares allow for parametric hull variation generation. Combined with CFD
analyses, a large number of variations can be automatically generated and evaluated to
optimize the solution in regards to a set of constraints (fuel consumption, deadweight,
speed,…) using for example genetic algorithm optimization.
The Mewis Duct (MD) is a new energy saving device invented and designed by Friedrich
Mewis for full-form slower ships. Financing, development and construction was done by
Becker Marine Systems, and this company now promotes and sells the device. The Mewis
duct has been installed, among others, on the Grieg I-class vessels, see /24/ and /25/.
And for the shipyard, it’s their duty to weld the MEWIS Duct onto the hull body and
consider relevant strengthening inside the main hull body which should be approved by
classification society.
The inventor claims power savings in the order of 7-9% for bulk carriers. The IBMV from
Rostock has performed numerical calculations, and model tests have been carried out at
HSVA, SVA and SSPA to validate savings.
A ducted propeller or propeller with nozzle consists of a nozzle and specially designed
propeller. It is important that the clearance between the propeller and nozzle is as small as
practically possible. The duct has an airfoil cross-section or profile.
The efficiency gain is very dependent on the thrust load coefficient. For normal operation
of bulk carriers, only a small increase in power efficiency is expected.
An efficiency improving propeller nozzle changes the flow field in and around the
propeller and divides the thrust force among itself and the propeller.
Bp = N P
Va 2.5 ,
Where N is shaft speed in RPM, P is power in HP and Va is advance speed in knots.
Compatibility
Since the non axis symmetrical nozzle changes the wake field of the propeller, the effect of
combining it with a PSS device is somewhat uncertain. Axis symmetrical nozzles are
expected to have a larger benefit from a PSS than non axis symmetrical nozzles.
Wärtsilä claims that their new HR-nozzle is able to improve the propulsive efficiency with
10% compared to an open propeller when operating at speeds common for bulk ships.
Figure 7 Illustration of possible increase in propulsive efficiency by use of a propeller nozzle. From
/16/.
As an example a HR nozzle from Wärtsila has been quoted at approx.. € 150 000,-
Propeller diameter should in general be as large as possible. However the presence of the
hull above the propeller normally limits the maximum possible propeller diameter. A
certain clearance between the propeller tip and the hull plating should be provided,
depending on the propeller operational conditions and requirements to noise and vibration.
Increasing the distance between the propeller and the hull in general leads to less transfer
of propeller induced noise and vibrations into the hull / ship. On the other hand, a larger
propeller size (but smaller clearance) reduces the specific propeller load, which may
reduce radiated noise and pressure pulses. In general, propeller tip clearances are typically
in the range of 15 to 25% of propeller diameter.
In order to take advantage of a large propeller diameter, it is necessary to run at a
sufficiently low RPM. In many cases, the available RPM range is limited by the engine
selection and /or possibilities for reducing the RPM with a gear system. The propeller pitch
and RPM are selected in combination – a relatively high RPM leads to a low pitch and vice
versa.
Number of blades should in general be chosen as low as possible from an efficiency point
of view. 4 blades is normally a starting point (except for very small propellers, which may
be 3 or even 2 bladed), but a higher No. of blades may be necessary to avoid excitation of
Figure 10. Contra rotating propeller from Mitsubishi Heavy Industries, LTD
Table 10. Reported fuel savings for coaxial contra rotating propeller.
Source Ship type Design draught Ballast draught Comments
Ghassemi /18/ VLCC 7%
Ghassemi /18/ Bulk carrier 2%
ITTC /12/ 7-20%
Min /20/ 8%
Stierman /11/ Tanker 5%
Stierman /11/ All vessel 5-12%
types
Mewis /1/ 7-14%
In recent advertisements MOTech, Mitsui O.S.K Techno-Trade, Ltd., reports more than
1700 installations with average savings of 5% for their patented Propeller Boss Cap Fin,
PBCF.
Table 11. Reported fuel savings for propeller boss cap fins and propeller cap turbines.
Source Ship type Design draught Ballast draught Comments
HSVA /9/ 3%
Mewis and Hollenbach /4/ 3%
Mewis /1/ 2-4%
Gearhart and McBride /5/ 5%
ITTC /7/ 5%
Ship Propulsion Solutions /13/ 2-4%
Svardal and Mewis /23/ 3-4%
Renilson Marine Consulting Pty Ltd reports the following costs for Mitui’s PCBF, see /2/:
Table 13. Reported fuel savings for propeller rudder transition bulb.
Source Ship type Design draught Ballast Comments
draught
HSVA /9/ Up to 6% Efficiency
rudders
HSVA /9/ Up to 3% Costa bulb
Ship Propulsion 2-4% Costa bulb
Solutions /13/
ITTC /7/ 2-4% Costa bulb
Mewis /1/ 0-3% Costa bulb
Fathom /27/ 6-9% (supplier) PROMAS
Fathom 2-9% (supplier) ENERGOPAC
Description/27/
In normal operation thinner rudder profiles have less drag, but are more likely to develop
separated flow and cavitation. During manoeuvring, thinner profiles may stall easier,
leading to reduced manoeuvring performance.
Twisted rudder design will improve the total propulsive efficiency, as the twist should
adapt the rudder to the rotation of the propeller slipstream and reduce the local angle of
attack on the leading edge of the rudder.
Becker Marine Systems holds a patent for a refined rudder profile called the twisted
leading edge rudder, which aims at aligning the rudder with the propeller flow. For a right
turning propeller, the leading edge is moved slightly to port from the centre line above the
boss and slightly to starboard below the boss. The twisted leading edge reduces the risk
against slow separation and cavitation, hence allowing a thinner rudder profile.
Roll’s Royce is also proposing a twisted rudder design.
Compatibility
An optimized rudder profile is in theory compatible with all other flow modifying devices.
The rudder twist should be adapted to the rotation of the propeller slip stream.
From the design point of view, a smaller and thinner rudder will benefit the propulsion
efficiency. Rudders with high lift profiles can lead to substantial power savings. Rudders
with a twisted leading edge can also lead to power gain compared with non twisted
rudders. The power consumption can be reduced by shifting the propeller and rudder
further aft.
Figure 17 Relative fuel consumption in normal service of different derated main engines for a 75,000
dwt Panamax product tanker at 15 knots. From /22/.
Figure 20 Example of benefits of variable turbine (VT) for mechanically controlled engines. From /31/.
Note, however, that the common feature for all above items (Figure 18 to Figure 21) is that
there is an optimal point where the engine is performing most efficiently, and that even
small deviations from this point gives a large penalty in the form of reduced efficiency.
Figure 22 Power concept for a waste heat recovery system. From /32/.
WHR has the largest potential for efficiency improvement for the traditional two-stroke
engines, but there are challenges related to exploiting this potential. Both the complexity of
the system and cost has made these types of systems rare on bulk carriers.
WHR consists of exhaust gas boiler(s), steam turbine generators, turbo generators, gear
and electrical generator. Depending on the size of the engine and complexity of the WHR
system one would either use only a steam turbine or a combination of exhaust turbine and
steam turbine. Combing exhaust turbine and steam turbine will increase the efficiency of
the system, but also contributes to the complexity of the system.
The output from a waste heat recovery system is electrical power, which may be used
onboard the ship. Bulk carriers have modest electrical power consumption when underway
and a WHR may therefore be able to completely replace an auxiliary engine.
If the WHR system produces more electrical power than what is required onboard the ship
there is no fuel saving above this level. An alternative if one has a very efficient WHR
system is to install a power intake on the main shaft.
Table 15. Estimated fuel savings for different fuel saving measures on bulk carriers.
Fuel saving Savings Cost in kUSD Comment Means of
measure in % validation
power
Mewis duct 5-8 170 -290 dep. on ship size Design cost of Model tests
210 Panamax USD 140 000 / and CFD.
290 Capesize series Full-scale
trials
Propeller 2-4 67 – 170 dep. on ship size Design cost of Model tests
boss cap fin 67 Handysize USD 72 000 / and CFD
179 for 205K DWT series
Pre swirl 3-5 50-85 dep. on ship size Design cost of Model tests
stator 50 Handysize USD 85 000 / and CFD
85 for 205K DWT series
Propeller 0-7 Highly variable
nozzle
Contra 2-14 Very high cost Complex
rotating system,
propeller requires
different
machinery
setup
Propeller 2-4 160 for Costa bulb
rudder combined with twisted
transition spade rudder
bulb
Rudder 1-3 No additional price unless
Table 16. Matrix showing compatibility between different fuel saving devices.
Compatibility
Propeller nozzle
Pre swirl stator
Rudder profile
Mewis duct
Mewis duct P N N N P C
Propeller boss cap fin P P C N N C
Pre swirl stator N P P N P C
Propeller nozzle N C P N C C
Contra rotating propeller N N N N N C
Propeller rudder transition P N P C N C
bulb
Rudder profile C C C C C C
/31/ MAN Diesel Turbo (2010), SFOC optimization Methods, For MAN B&W Two-stroke
IMO Tier II Engines, http://mandieselturbo.com/files/news/filesof15180/5510-0099-
00ppr_low.pdf
/32/ MAN Diesel Turbo (2010), TCS-PTG, Savings with extra power,
http://www.mandieselturbo.net/tcbrochures/data/TCS-
PTG%20Savings%20with%20Extra%20Power.pdf
8. Disclaimer
"The Guideline for the Fuel Saving Devices and the Return of Investment Calculator (the
"SDARI and DNV Products")are developed by SDARI and DNV and provided to our
clients free of charge. We have taken all reasonable care in the development of the SDARI
and DNV Products, but SDARI / DNV cannot guarantee that the SDARI and DNV
Products will function error free or that estimated fuel savings will be met. Therefore,
SDARI and DNV disclaim any responsibility, liability and consequences in relation to the
use of the SDARI and DNV Products."
1.2 Content
The ROI tool consists of several worksheets with different tab colours:
- Orange colour indicates sheets which require inputs
- Green coloured sheets are calculating and showing the financial results
- Blue coloured sheets contain useful bulk carrier information
- White coloured sheets contains information about the tool
Editable input cells do either have white or lightblue background colour. Values entered
into the white coloured cells are used in calculations while lightblue cells are only for
informational purposes.
1.2.3 Print
In addition to the common Excel printing features it is possible to print out a complete
report by pushing the “Print Report” button that is found on the top of the “Project data”
worksheet. All sheets will then be adjusted to be print friendly. If some charts or content
for some reason are not printed as wanted, it is possible to adjust printer settings through
the usual Excel print features.
All notes, tips, and buttons are removed in printouts.
The “Project data” sheet contains optional inputs which are for pure informational
purposes. The values do not have any effect on any of the calculations, but some inputs are
useful when deciding other inputs which have an effect on the investment analysis.
In this sheet the main input fields are found. Fuel saving measure is selected at the top and
the corresponding costs are stated. Investment cost is a required input while maintenance
cost and re-sale impact are optional. See the Guideline document section 5 for relevant
input data. The selection of fuel saving measure at the top does not effect any calculations,
but are used in titles in charts throughout the tool.
The investment scenario is defined through the investment period, discount rate and a fuel
price. Select a predefined heavy fuel oil (HFO) price development scenario or enter a fixed
fuel price to use in the calculations. To edit the fuel price scenarios go to the sheet named
"Fuel price scenario". The selected investment period also changes the scale of the x-axis’
in most of the charts.
The two charts in this worksheet are also found in the “Cost Benefit” sheet, thus they will
not appear in printouts.
Bulker size and speed are only for informational purposes and does not have any effect on
calculations. The operating profile could contain maximum 5 operating states, e.g. sailing
laden, cargo handling. It is however not necessary to fill out all operating states, but at least
one is required. The operating states are defined by a name, a speed, number of days and
the excepted fuel reduction for this state. The speed and name of the states are optional and
do not need to be selected/given.
There are two ways of calculating the fuel consumption. It could be calculated based on
installed engine power, specific fuel consumption (SFOC) and average engine load
(%MCR) or it could be entered directly as ton/day without any calculations. Some
common fuel consumption data is found in the sheet named "Vessel data" for guidance.
Only the selected fuel consumption alternative is used in the calculations.
If total days are below 365 days, the fuel consumption is assumed to be zero in the
remaining days, and if the total days are more than 365 a red background colour will
appear. Note that the average fuel consumption numbers stated to the right in the figure do
not include the fuel reductions due to the applied fuel saving device.
The “Fuel price scenario” sheet contains the three fuel price development scenarios and
one custom scenario. These scenarios’ may be edited. In order to evaluate fuel price
sensitivity or use a fuel price development in the calculations it is necessary to fill out these
fields.
Sensitivity to fuel price and sensitivity of changes in initial investment cost could be
evaluated in this sheet. Use the scrollbar to change initial investment and to evaluate the
implications on the cash flow. Changes only apply to the two charts at the bottom.
If the investment period is quite long (typically above 10 years) it could be useful to resize
the charts by pushing the “Resize charts” button at the top of the sheet.
In this sheet it is possible to estimate the reductions in CO2, SOx, NOx and particle matters
(PM) due to the fuel saving device. The emissions factors used to calculate the reductions
could be changed, and some guidance values are found in the “Vessel data” sheet
1.1 Objective
The objective is to describe an approach to evaluate the cost-effectiveness of different fuel
saving measures/devices.
1.2 Assumptions
When evaluating a fuel saving measure all the costs and benefits should be considered.
However, this method focuses primarily on covering the most important economical
changes due to the fuel saving devices, which is considered to be the following:
Costs Benefits
- Initial investment - Fuel savings
- Annual maintenance cost - Increased resale value
- Reductions in CO2, NOx, and SOx
emissions
1.3 Model
The proposed methodology to evaluate cost-effectiveness is presented in the figure below.
The starting point is that a user (ship owner) wants to analyse the cost-benefit of a fuel
saving device listed in the introduction (e.g. pre-swirl stator) applied to a particular bulk
carrier design.
The normal fuel consumption without the fuel saving device applied is either specified for
each operating state directly in tonnes per day, or it could be calculated based on detailed
engine data. For the latter approach the following data must be defined:
and the amount of installed engine power must also be given. The daily fuel consumption
for each operating state is then calculated as follows:
Tonnes per day = Average engine load [kW] x Average sfoc [g/kWh] x 24 hours x
1.000.000
Based on the fuel savings reductions in air emissions (CO2, NOx, SOx, PM) due to the
fuel savings may also be estimated.
All of these are covered in the ROI tool, and in the following sections the different
financial metrics are briefly explained.
The term Return on Investment (ROI) is commonly used in different ways and what that is
included in such a calculation varies. Business literature commonly rather recommends
focusing on financial metrics such as net cash flow, discounted cash flow (net present
value), IRR, and payback period instead of calculating the “simple” resulting amount
divided by initial amount without considering the time value of money.
The ROI measure could be based on the net cash flow without considering the time value
of money (most common!) or based on the discounted cash flow. Both are calculated in the
tool.
• Accept if ROI > minimum acceptable rate of return (also known as hurdle rate)
The present value of an investment's future net cash flows minus the initial investment:
NPV = PVfuture cash flows - inital cost at t = 0
Decision criteria
• Independent project:
Accept if NPV ≥ 0
• Mutually exclusive projects:
Accept project with highest NPV ≥ 0
Instead of proposing of discount rate and finding the NPV, it is possible to find the
discount rate that produces a NPV = 0. This discount rate is what is known as the internal
rate of return (IRR).
Decision criteria
In general, the higher the IRR, the better the returns relative to cost are, and the lower the
risk is.
• Independent projects:
Accept if IRR > OCC (opportunity cost of capital)
• Mutually exclusive projects:
Accept project with highest IRR > OCC (if the projects are the same size)
Payback period is the time required for an investment to recover its cost. The annual cash
flows are used to determine the payback period. It could be based on the net cash flow or
discounted cash flow (not mixed), and both are calculated in the ROI tool.
Decision criteria
• Independent projects:
Accept if payback > ROI threshold
• Mutually exclusive projects:
Accept project with shortest payback > threshold
(As described previously a discounted ROI is calculated quite similarly, except that the
initial investment is subtracted in the numerator)
Decision criteria
• Independent projects:
Accept if PI ≥ 1
• Mutually exclusive projects:
Accept project with highest PI ≥ 1
- o0o -
DNV
Please contact your local customer service manager or unit for Ship Hydrodynamics
NTANO362@dnv.com