Emission

Seminar
“Teams” on-line tips and functions

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June 30, 2020 2

Agenda

1. Regulations.

2. SOx scrubber.

3. EGR.

4. SCR.

June 30, 2020 3

Air Polluting Emissions from Engine Exhaust Gas

 Oxides of Nitrogen (NOx)

 Oxides of Sulphur (SOx)
 Particulate Matter (PM): Many types but typically
grouped by particle size (PM2.5 and PM10).
 Other types of pollution: Other pollutants include
carbon monoxide (CO), volatile organic
compounds (VOC), black carbon (BC) and ozone
(O3).
“Global NOx and SOx emissions from all shipping
represent about 15% and 13% of global NOx and SOx
from anthropogenic sources.” (IMO)

June 30, 2020 4

Engine Type Designations

MAN B&W Low Speed Propulsion Engines

June 30, 2020 5

MARPOL Annex VI NOx Limits

Two-stroke diesel
engines

June 30, 2020 6

Emission regulations for shipping

Global: Max. 3.5% S 2015: max. 0.1%S within SECA Baltics, North Sea SECA + NECA:

2020: Max. 0.5% S Vessels with keel laid as of 1st January 2021

2021 NOx ECA, agreed at MEPC70 October 2016

US NECA:
Vessels with keel laid as of
1st January 2016
2016: 0.5%S SECA

Waters within 200 nautical parts of Chinese waters

miles from the coast of

USA, and Canada.

ECA´s: Emission Controlled Areas:

NOx Emission Control Areas (NECA) – applies depending vessel keel laying date
Sulphur Emission Control Areas (SECA) – applies to ALL ships

June 30, 2020 7

Sulphur limits

June 30, 2020 8

 SOx and NOx compliance combination

Fuel to use 0-3.50% S

globally 0-0.50% S
+ Scrubber

Fuel to use in 0-3.50% S

0-0.10% S 0-0.10% S
ECA area + Scrubber

Tier III
technology

HS EGR HS HPSCR LS EGR LS HPSCR LPSCR

June 30, 2020 9

Tier III orders - Status May 2020
• 2011 - Shoptest of first HP-SCR

• 2012 - Shoptest of first EGR

• 2014 – Shoptest of first LP-SCR

• 2016 – US NECA introduced

• 2017 – Baltic and North sea NECA adopted for 2021

June 30, 2020 10

Environmental Impact

June 30, 2020 11

Scrubber

− 1. Why Scrubbers
−2 Market & Considerations
− 3. Types and principles

June 30, 2020 12

Sulphur scrubber
What is a scrubber ?

Scrubber is a popular name for EGCS – Exhaust Gas Cleaning Systems.

EGCS is a system designed to clean exhaust gases from primarily Sulphur Oxides (SOx)
and Particulate Matter (PM).
Wet scrubbers work by showering exhaust gas with water – by far most common in marine.
Dry scrubbers work by leading exhaust gases through an alkaline granulate – mainly for
shore applications and not covered in this presentation.
Can work in open or closed systems. Closed systems require additional Water Treatment
Systems (WTS). Closed loop systems are NOT equal to zero water outlet. Zero water
outlet requires additional holding tanks.

June 30, 2020 13

Why Sulphur scrubbers ?
Engine maker view.

• Scrubbers can be applied to almost all

our two- and four stroke engines
• New engines can be purpose built
for scrubber operation
• Retrofit possible most engines

• Allows full fuel flexibility =

free choice for owners
(World wide bunkering)

• Eliminates concerns of new

blended fuel qualities and
compatibilty issues.

June 30, 2020 14

 Fuel options
Fuels options in shipping (Source DNV)

− Number of ships alone is not truly indicative of fuel shares used – ship type and fuel consumption must be considered for
real image. Vessels above 8500 kW accounts for 20% of the fleet but 67% of consumption.

June 30, 2020 16

Back pressure
MAN-ES scrubber requirements
Back Pressure concerns – SL2018-665

Different back pressure limitations for standard and specially tuned engines

June 30, 2020 18

Owner considerations

Scrubber challenges:

Not all vessels suitable for scrubbers (size, asset value, owner
finances, operational patterns etc)

Wash water outlet restrictions: Local requirements may apply

in addition to international regulations

Sludge:
Ports required to receive waste
Ship owners to facilitate agreement with ports.
Scrubber sludge considered hazardous material.

Scrubber – absorber type single inlet 40 MW

Approx 14 x 6 m, 64 ton operational weight

June 30, 2020 20

Other considerations
Wash water outlet restrictions

June 30, 2020 21

Sulphur scrubber overview
Sox scrubbers, common types;

I - type U - type

Packing material sample

June 30, 2020 22

Sulphur scrubber overview
Sox scrubbers, common types, single or multi inlet;

Multi-inlet scrubber plants;

1 x 15 MW 1 inlet scrubber for main engine 1 x 25 MW 3 inlet scrubber for main engine and aux.
1 x 4MW 3 inlet scrubber for auxiliaries 1 x 6MW 1 inlet scrubber for auxiliaries in port
Open loop system Hybrid system

June 30, 2020 23

Sulphur scrubber overview
Sox scrubbers, common types

 In-Line Open Tower scrubbers – common layouts

are;
 Open loop
 Closed loop
 Hybrid

Pro’s and Con’s

• Slim design requiring less installation space

• Some designs can replace silencer
• Sea or Fresh water media – single inlet
• Less effective for PM uptake
• Relatively low back pressure increase

June 30, 2020 24

Sulphur scrubber overview
Sox scrubbers, common types

 Packed Bed Absorber type scrubbers – common layouts are;

 Open loop
 Closed loop
 Hybrid

Pro’s and Con’s

 Very efficient for both SOx and PM removal

 Large physical proportions making retrofit
installation challenging
 Sea or Fresh water media – single or multi inlet
 Higher back pressure increase due to absorber
layer (static & dynamic pressure) Sample of
packing material

June 30, 2020 25

Sulphur scrubber overview
Sox scrubbers, common types

 Cyclonic / Vortex type – common layouts are;

 Open loop
 Closed loop
 Hybrid

Pro’s and Con’s

 Built-in suction blowers negate impact on engine

performance
 Sea or Fresh water media – single or multi inlet
 Higher energy demands for blower power

June 30, 2020 26

Sulphur scrubber overview
Working principle; Open loop
Please note:
• No alkali needed Not all systems
• High water volume incorporate bypass
• No WTS
• Lowest CAPEX

June 30, 2020 27

Sulphur scrubber overview
Working principle; Closed loop

• No discharge
• Alkali dosing
needed
• WTS needed

June 30, 2020 28

Sulphur scrubber overview
Working principle; Hybrid system

• Max flexibility
• Future proof
• Highest CAPEX

June 30, 2020 29

Introduction of EGR

June 30, 2020 30

EGR
Basic EGR principle

Basic principle
Exhaust Gas Recirculation

Exhaust gas is recirculated to the scavenge air receiver.

• O2 in the scavenge air is replaced with CO2
• CO2 has a higher heat capacity thus reducing the peak
temperatures
 Reduced O2 content in the scavenge air reduce the
combustion speed thus reducing the peak temperatures.

 Decreased peak temperatures reduces the formation of NOx

The recirculation ratio is controlled based on measured O2
content in the scavenge air.

June 30, 2020 31

EGR

EGR efficienctly reduces thermal NOx by reducing the

combustion temperature. Exhaust
gas
loop

Comparison factor No EGR EGR

Oxygen content of scavenge air ~20.5 mole % ~17 mole %

Average molar mass of scav gas 29.0 g/mole ~29.3 g/mole *

Air mass required to burn 1 kg of fuel 14.7 kg ~17.9 kg (+22%)

Heat from combustion of 1 kg of fuel 42.7 MJ 42.7 MJ

Fuel heat added per mass unit of burned 2.55 MJ/kg 2.14 MJ/kg ( -16%)
fuel+air

* Molar mass of exhaust is close to unchanged compared to air due to equal formation of CO2 that is heavy
and and H2O that is light. Most H2O in the EGR gas however removed in the EGR cooler, and hence the
molar mass increases slightly.

June 30, 2020 32

EGR
EGR unit
Function:
Cleans & cools recirculated
exhaust gas
Principle:
- Pre spray
- EGR cooler Spray
- Water mist catcher
- EGR blower
Implementation:
Integrated on the Engine
Made in stainless steel
- freshwater cooling for the
EGR cooler

June 30, 2020 33

EGR water injection

Water from
RTU Pre spray injection of
scrubber water

Rough distribution of
Cooler spray water water over cooler face

June 30, 2020 34

EGR cooler unit
Components:
• Gas distribution chamber
• Cooler spray cleaning
• Cooler
• Reversing chamber
• Water mist catcher
• EGR shut down cleaning spray
Description
• Wet gas is distributed to the face of
the stainless steel cooler
• Scrubber water is sprayed over full
face of cooler in order to keep clean.
• The wet gas is cooled to 30-40degC
and vapor condensates
• The water is separated from the gas
by the WMC and drained to RTU

June 30, 2020 35

EGR blower and EGR gas pipe
Components:
• EGR blower
• Piping
• Blower cut-out valve
• Sludge trap for removal
of sludge
• Alignment
compensators
Description:
• High efficiency blower
increase pressure of
EGR gas to scavenge
air pressure
• Blower cut-out valve
Sludge trap
controls EGR start-up Blower cut out EGR blower
procedure valve

June 30, 2020 36

EGR RTU system

EGR Drain pipes

Tank

Circulating pump

Pump protection
RTU shut off valve screen

Transmitters for pH
pH sensors
sensor

June 30, 2020 37

EGR Components

June 30, 2020 38

Picture from HHI
7G80 ME-C

June 30, 2020 39

EGR Gas valves - SOV, BTV, CBV

 SOV – shut off valve – On/off valve seals the EGR when stopped

 BTV – Blower throttle Valve – variable valve. Adjust EGR rate

when blowers reach minimum RPM

 CBV – cylinder bypass valve – Variable valve. Transport warm

compressor air to turbine inlet.
Gives extra energy to TC-turbine and reduces the needed EGR
flow.

SOV and BTV are double acting valves. Tier3 air controls the
valve position and Control air is used for failsafe.

(all valves in the EGR system are fail safe closed.)

June 30, 2020 40

EGR Blower
Howden EGR-10
• VFD-driven
VFD sends ready and trip signal to ERCS.
VFD monitors Oil Temp, oil pressure and
differential pressure and sealing air.

• More or less maintenance free.

Howden recommend maintenance
after 16000 hours (2 years of running)

• Several new EGR-blower makers in pipeline:

• MDT-Augsburg
• SamJeong (Korea)
• Sung Il (Korea)
• Osaka (Japan)

June 30, 2020 41

EGR blower
MAN ETB blower

VFD-driven

A major overhaul of the blower must be

carried out at the latest after :

12,000 - 20,000 operating hours

A major overhaul includes the disassembly of the complete blower for

inspection of the actual condition, thorough cleaning and a check of all parts/
components.

June 30, 2020 42

Blower
Instalation and VFD cabinet

June 30, 2020 43

Oxygen measurement of scavenging air
New Oxygen measuring setup in the pipe-line
SUC – Sensor Unit Cabinet
Features
• 3 sensors
• Single point calibration - from MOP
• Two point calibration – from sensor
OSU – Oxygen Sensor Unit
• Based on 4 pcs. NOx-Sensors
• No calibration (Manuel check by compressed air – replacement
if needed)
• Easy access to sensors and filter
• Junction box now placed
on the same plate for
easier access
• 2 redundant setups
• One block for sensors
and pressure sensors

June 30, 2020 44

OSU – Placement near Scavenging Air Receiver

Example for Small bore engine Example for large bore engine

June 30, 2020 45

High Sulfur – EGR unit

What is added on HS compared to LS-solution:

• 2 Precatcher plates (remove dirty water with low
pH)

• Post spray
(for adding neutralized water into EGR-gas-
stream)

• Additional cleaning spray nozzles

(for better cleaning of EGR unit before Tier 2
running).

June 30, 2020 46

EGR – Water Handling System • WHS = Water Handling System (all)
WHS 2
• WTS = Water Treatment System (water cleaning)

LS-WHS 2 HS-WHS 2

June 30, 2020 47

EGR – Water Treatment System
WTS & Supply Unit

June 30, 2020 48

WTS –Water Treatment System - Alfa Laval

WTS has 2 main task:

• Clean EGR-water
• Clean and check bleed-off-water going
overboard.

In case overboard criteria cannot be meet - > bleed-

off-water will be send to EGR-drain-tank.

WTS - secondary task:

• Reduce water content of EGR-drain-tank (Waste
Reduction)
Allowed turbidity:
• Cleaning of EGR-water – no limit (normally 50-500)
• Sending water overboard – max. 25 FNU

June 30, 2020 49

 EGR as today
Gas Flows Matching modes

TC cut out EGR Bypass EGR

80-95 bore (2+ turbines) 35-70 bore

A Small Turbine is matched to equal EGR flow The Turbine is matched to run in Tier II and Tier III
The Small Turbine is “cut-out” and replaced by EGR in Tier III operation EGB is used in Tier II to reduce flow to turbine during
Tier III high load

June 30, 2020 50

ECS Control System

June 30, 2020 51

ERCS – Emission Reduction Control System
ERCS 1811 have 4 EGR-screens.

Main EGR EGR Gas system:

• General overview • O2-sensors
• EGR blowers
• EGR valves

EGR Water is
split into 2 screens:
Water Auxiliaries
Water Recirculation
• Buffer-tank
• Pump + valves
• pH
on the engine
• WTS
• pH
(depends on
setup).

June 30, 2020 52

EcoEGR

June 30,
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2020
EcoEGR - Continuously EGR operation
EcoEGR is a new engine tuning for EGR engines:

Tier III operation: Tier II operation:

NOx < 3.4 g/kWh NOx < 14.4 g/kWh

June 30, 2020 54

EcoEGR
SFOC optimization in Tier II mode

SFOC is optimized in Tier II and NOx is reduced by Eco-EGR by:

− Fuel injection optimization
− Compression volume optimization
− Pcomp, Pmax optimization
− Only approx. 10-15% EGR will be needed to meet the Tier II limit

SFOC savings:

June 30, 2020 55

EcoEGR Conclusions

Benefits with Eco EGR:

 Improved heat load
 Improved soot emission during Tier III operation
 Reduced SFOC during both Tier II and Tier III operation (confirmed for G60, G70 and G80 engine type)

Disadvantages:
• SFOC penalty in Fallback mode ranging from 1-3 g/kWh
• The EGR system need to operate continuously
• Additional costs for NaOH, sludge handling etc.
• Increased mechanical load on the engine

Overall savings:
• NaOH consumption depend on the Sulphur contend in the fuel oil
• LS fuel (< 0.5%): Considerable overall savings
• HS fuel (3.5%): No overall savings with present setup

June 30, 2020 56

7G80ME-C9.5 EGRTC
EcoEGR Service test

• Tier II EcoEGR mode • Tier II fall back mode – High • Tier II fall back mode – Low
load (2 TC) load (1 TC)
• Tier III mode

• The small turbine is matched • The small turbine is cut out.

• The small turbine is ”cut-out”
to equal the EGR flow.
and replaced by EGR in EcoEGR
Tier II and EGR Tier III modes.

June 30, 2020 57

SCR
SCR Intro

June 30, 2020 58

Tier III - SCR Status March 2020

2011
• Shoptest of first
HP-SCR

2014
• Shoptest of first LP-
SCR

− Built and In service

June 30, 2020 59

Agenda

SCR Principle

June 30, 2020 60

SCR - Basic SCR principle
SCR: Selective Catalytic Reduction

What does it do? By means of after treatment of the exhaust gases the NOX is removed.

How does it work? NOx is removed over an SCR catalyst when a reducing agent
(ammonia NH3) is added. The result is harmless nitrogen and water.
Added amount of reducing agent has to be controlled.

flow

SCR reaction:
NOx + NH3 + 0.5 O2 → N2 + 1.5 H2O

June 30,
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2020
Reducing Agents for SCR

• Ammonia is the reducing agent that participates in the SCR reaction.

• But: Ammonia is a toxic compound.

•Typically SCR installations therefore use an aqeuous solution of Urea

instead of ammonia. Urea is a non-toxic, non-flammable, bulk chemical.

•Urea is converted to ammonia inside the exhaust gas and on the catalyst:

CO(NH2)2+ Heat --> HNCO + NH3

HNCO + H2O --> CO2 + NH3
Total: CO(NH2)2+ H2O --> CO2 + 2NH3

June 30,
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2020
ABS considerations
• ABS=AmmoniumBiSulphate: undesired ”sticky” product
It’s formed at low temperatures: NH3 + SO3 + H2O <=> NH4HSO4 (s)

•ABS can in principle be regenerated if the temperature is high enough

Two problem areas:

1) Inlet of the SCR reactor: High amounts of NH3 and sulfur present.
Solution: HP SCR: Temperature > ABS formation temperature (300-350 °C)
LP SCR: Limit sulfur content and regenerate

2) After SCR reactor (especially EGE < 180°C): NH3 slip and cold surface
Solution: Limit NH3 slip

 Dosing amount must be controlled!

June 30,
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SCR - Basic SCR principle

To make it work we must ensure:

• Correct inlet conditions

-Mainly Temperature

• Correct amount of reducing agent

-Dependent on exhaust flow and
NOx

• Controlled impact on engine performance

-Least possible impact to SFOC

June 30,
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2020
Basic principles of SCR

Engine NH3 dosed

NOx NOx
SCR reactor
1000 ppm 1000 ppm
”14.4 g/kWh” ”14.4 g/kWh”

NOx NH3 Nox out NH3 slip

June 30,
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2020
Basic principles of SCR

Engine NH3 dosed

NOx NOx
SCR reactor
1000 ppm 200 ppm
”14.4 g/kWh” ”3.4 g/kWh”

NOx NH3 Nox out NH3 slip

June 30,
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2020
Basic principles of SCR

Engine NH3 dosed

NOx NOx
SCR reactor
1000 ppm 50 ppm
”14.4 g/kWh”

NOx NH3 Nox out NH3 slip

June 30,
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2020
Basic principles of SCR
Uncertainties in the system

Engine NH3 dosed

SCR out emissions
NOx
SCR reactor

NOx NH3 NOx out NH3 slip

Actual engine operation Dosing system accuracy Bad flow distribution

Actual fuel quality Reducing agent quality Bad ammonia/flow distribution
Ambient conditions Leaks Aged catalyst
Aging Mechanical damage to the catalyst
Transients
Valves

June 30,
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2020
SCR operating temperatures

Condensation of ABS
Oxidation of Ammonia
(reaction of ammonia with sulfur)
Oxidation of SO2
Formation
Hydrolysis of urea not
of Ammonium
possible < 180-200 °C Catalyst degradation
Temperature
Nitrate < 140 °Climit dependant on fuel S
content
Typically > 500-550°C
Typically 300-350°C for marine HFO
TSCR,limit

 Temperature must be controlled!

June 30, 2020 69

Agenda

1 Tier III Introduction

2 SCR Principle
3 Introduction HP-SCR vs. LP-SCR
4 HP-SCR
5 LP-SCR
6 Commissioning
7 Service experience

June 30, 2020 70

Two SCR layouts
High Pressure and Low Pressure SCR

HSF and
LSF: max.:
LSF: 0-
0.1%S
3.5%S
(Low temp.)
(High temp.)

June 30,
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2020
Schematic layout HP-SCR and LP-SCR
HP SCR LP SCR

LP SCR

•Typical temperature 200*-280 °C

•Pressure ~1 bara

• Typical temperature 250- 500 °C •Typical temperature 200- 280 °C

• Pressure 1-4.5 bara •Pressure ~1 bara
June 30,
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2020
How SCR affects the engine
HP SCR LP SCR

• Increased pressure drop between • Increased backpressure

cylinder and T/C
• Increased heat load in cylinder due
• Increased heat capacity/thermal
to low load method, EGB
mass betweeen cylinder and T/C
• Increased heat load in cylinder
due to low load method, CBV

June 30,
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2020
Engine and SCR control
HP SCR LP SCR

• Valve control • Temperature control

• Temperature control
• Dosing control
• Dosing control

June 30,
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2020
Agenda

HP-SCR

June 30, 2020 75

Tier III HP-SCR System

Tier II operation
The exhaust gas goes
directly to the turbine

June 30, 2020 77

Tier III HP-SCR System
Tier III operation
The exhaust gas is
directed to the SCR
reactor

June 30, 2020 78

SCR control Reducing agent
Air
Dosing unit

Vaporizer/mixer
Compensator

T-reactor in Venting air inlet

RSV
T-SCR in
Heat
tracing
SCR
Reactor dT ref Exhaust gas receiver
incl.
Soot Heating/
Blower air Venting Tturb_in
RBV
dp-SCR

T-SCR out
RTV EGB
T/C

Compensator Tamb
dp-RTV Rhamb
Pamb
C/A cooler NOx Conc.
CBV
WMC
T-scav

Scavenge air
receiver
June 30,
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2020
HP-SCR temperature requirement

June 30, 2020 80

CBV function

Turbine

Exhaust gas
Reactor
Receiver

CBV

Scavenge air
Receiver

Compressor

June 30, 2020 81

Temperature Control Stages

June 30, 2020 82

HP- SCR MOP screen

June 30, 2020 83

LP SCR – Items controlled by ERCS

Main items:
Treac_in

• Dosing amount controlled via open loop and

adjusted with NOx measurements

Furthermore:

• Temperatures increased via EGB valve Tscr_out

(currently ME-ECS). But in general
accepted that ABS formation limit NOx
temperature cannot always be reached!
Tscr_in

• Interface to regeneration system

• SCR valves controlled externally Tamb

Rhamb
Pamb
Tscav

June 30,
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2020
LP- SCR MOP screen

June 30, 2020 85

Thank you
very much!
PrimeServ Academy Copenhagen