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Thermo Efficiency System PDF
Thermo Efficiency System PDF
Technology
Contents
Introduction.................................................................................................. 5
Tier III Technologies................................................................................. 5
SCR Application for Tier III............................................................................. 6
Fuels for Tier III engines .......................................................................... 6
Selective catalytic reduction..................................................................... 6
SCR system for MAN B&W engines......................................................... 7
SCR control system............................................................................... 10
Results and discussion.......................................................................... 11
SCR and HFO operation.............................................................................. 15
SCR service experience.............................................................................. 15
Future development aspects.................................................................. 15
Conclusion.................................................................................................. 17
EGR Application for Tier III........................................................................... 18
EGR investigation on 4T50ME-X............................................................ 18
EGR Tier III confirmation test.................................................................. 19
EGR scrubber performance................................................................... 19
EGR service test.................................................................................... 21
Preparation of service test on newbuilding with 6S80ME-C9.2................ 23
Water treatment system (WTS)............................................................... 25
EGR high-speed blower......................................................................... 27
Conclusion.................................................................................................. 29
Introduction
requirements:
As
both
EGR
and
after-treatment
Tier III applies when operating the engine in a NOx emission control area.
Furthermore, details on the SCR development, not only for the catalyst appli-
will be outlined.
Fig. 1.
catalysts.
emission
control
areas
(ECA). The 2015 0.1% fuel sulphur content limitation and the 2016 80% NOx
reduction limits are the targets.
Exhaust gas
NO2
NO
N
O
NH3
H
H
N N O
SCR
Reactor
N N
N N N
N2
H2O
4NO + 4NH3 + O2 = 4N2 + 6H20
6NO2 + 8NH3 = 7N2 + 12H20
Tamb=10C
25% load
50% load
75% load
100% load
T in turb. [C]
299
308
337
395
245
217
207
221
Tgain [C]
54
92
130
174
tems.
Table 1
MDTs focus has been on the development of a dedicated SCR engine that
Fig. 2.
diesel engines.
SCR reactor
SCR
reactor
Cylinder &
SCR bypass (CBV)
bed operation.
Item Function
unaffected.
T1
SCR
reactor
T4
T2
Controllable
valve (V2)
Cylinder &
SCR bypass (CBV)
Fig. 4.
Table 2.
system
temperature Tmin.
formance.
10
1 SCR reactor
2 Vaporiser & mixer unit
3 Control panel for reductant injection and soot
blow
4 Air compressor & air
tanks
5 Urea solution tanks
6 Urea supply unit
Cylinders 6
Bore
460 mm
Stroke
1,932 mm
Output
MEP
19 bar
Before turbine
Fuel
Reducing agent
15,000 kg
1,900 kg
Type of catalyst
Table 3.
Manufacturer of catalyst
Table 3
11
90
80
To commission ECS
50
3
40
30
2
SFOC
+2.4 g/kWh
20
0
0
50
10
100
150
200
components temperatures
60
T(X/V spindle)
+24C
70
Temperature increase X/V spindle dg. C
Plot 1: Influence of increased T1 on X/V spindle (full line) and SFOC (dashed line). T1 is increased by
opening CBV
120
CBV Feedback
V2 Feedback
V1 Feedback
100
12
Temperature in dg. C
80
60
40
20
0
0
200
400
600
Time
800
Time in sec.
Plot 2: Loading from 20% to 100% of the engine to maintain SCR operation
1000
1200
500
T1 (SCR in)
Temperature in dg. C
350
300
250
SCR
Requirement
400
T2 (T/C in)
450
200
400
600
800
Time in sec.
1000
1200
Plot 3: Loading of the engine to maintain SCR operation (valve position: 0 = closed, 90 = open)
13
Time
Tier III
urea injection.
Table 4
14
Naikai Zosen
Vessel type
droplets impinging on walls may deposit and form solid structures, which
may eventually clog the system. While
this has to be avoided, the SCR unit
IMO number
9527946
Hull number
744
Vessel Owner
Operator
Nissho Shipping
Co., Ltd.
nadium in HFO makes the SO2 oxidation more pronounced over time. It
sive.
Table 5
gained up to now.
in Table 5.
Fig. 8: The worlds first Tier III compliant ship the Santa Vista
15
Fig. 9: Proposed design of a urea mixer. Flow enters tangentially into the mixing chamber from the cylinders via separate runners (a). While swirling, the flow moves upwards, but loses its swirl as it passes
through the vanes at (b). Due to the loss of swirl, static pressure is recovered leading to higher pressure
at (c) than in the centre of the bottom of the mixing chamber. This causes reversed flow in the centrally
mounted pipe. Urea is injected at (d) and evaporates in the non-swirling flow in the central pipe. The urea
seeded flow leaves the pipe in the bottom of the chamber and mixes with the newly injected exhaust gas
Fig. 10: A snapshot from a large eddy CFD simulation of the mixing of a scalar, representing urea. The
scalar is injected in the central pipe and mixes with exhaust gas during its way to the outlet
16
Conclusion
the SCR offers a degree of NOx reduction that ensures IMO Tier III operation.
Proper installation.
17
Effects on CO:
positive effect on CO
itive effect on CO
positive effect on CO
EGR.
Effects on SFOC
scav ratio
has a posi-
Effects on NOX
18
Increased Pcomp
tion.
Test results from engine parameter variations at 75% engine load (auxiliary power
for EGR lower, separator and pumps are not included in dSFOC)
NOx
(g/kWh)
dSFOC
(g/kWh)
CO
(g/kWh)
Pmax
(bara)
EGR
rate(%)
O2
(vol. %)
No EGR
17.8
0.65
152
Max. EGR
2.3
+4.9
4.17
151
39
16.0
EGR ref.
3.7
+3.0
2.57
151
36
16.8
Incr. Pcomp/Pscav
4.0
+2.5
2.18
156
36
16.8
Incr. Phyd
4.2
+2.8
1.83
151
37
16.6
Incr. Pscav
3.6
+1.9
2.12
156
37
16.6
Incr. Tscav
3.9
+3.6
2.82
156
34
16.8
3.4
+0.6
1.34
157
41
16.2
Table 6
5.5
CV08CT70CA60
CV06CT40CA40
0.07
5.0
0.06
HHR (1/deg)
4.5
Pressure Ratio
4.0
3.5
3.0
0.04
0.03
2.0
0.02
1.0
0.05
2.5
1.5
0.00
0 4 8 12 16 20 24
Mass flow [kg/s]
Fig. 11: Turbocharger compressor maps running the engine with and without
EGR
24.0
22.0
100% load
75% load
20.0
0 10 20 30 40 50 60
70
Crank angle
18.0
16.0
50% load
25% load
14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
Fig. 13: NOx emission at different engine loads as a function of oxygen content in the scavenge air
19
0%
The parameters varied and were as fol-
-10%
lows:
-20%
pH variations
-30%
-40%
-50%
-60%
in the scrubber.
-70%
-80%
-90%
-100%
Up to 98% SO2
removal typical
value: 90%
Chemical composition of PM
120.00
100.00
PM mg/Nm3
is between 60 and 95% which is better than what is normally seen in after-
80.00
ash calc
remaining
SO4+Water
EC
OM
60.00
40.00
20.00
0.00
Before scrubber
After scrubber
After T/C
Fig. 15: Chemical composition before scrubber, after scrubber and after turbine
20
test is as follows:
amount
tent of sulphur
ponents
fulfilled
completed
ware internals
the
expected
performance.
NOx (ppm)
1000
900
800
NO-EGR
700
600
60 % NOx reduction
500
400
EGR
300
200
100
0
Fig. 16: Measurements of NOx reduction on board Alexander Maersk during a performance test
21
Fig. 17: Piston rings before and after approx. 900 running hours in EGR operation on HFO
22
Fig. 18: Left deposits of sodium sulphate, iron sulphate and soot on main engine cooler top, caused by
water carry-over from the scrubber system. Right almost no deposits when water carry-over from EGR
scrubber system is avoided
Exhaust receiver
T/C
cut out
Shut-down
valve
Small T/C
Large T/C
T/C
cut out
Mix Cooler
Cooler
Scrubber
WMC
WMC
EGR blower
Fig. 19: EGR system diagram for a 6S80ME-C9 with two turbochargers
Monitoring
combustion
chamber
gramme.
ing of HFO
lowing modes:
down potentials.
23
pre-scrubber
and
scrubber
MW.
into force.
Sequential turbocharging
Electrical installation
tion procedure.
pacity
functionality
ing
ME heat capacities.
and galleries
The main engine outline is only modi-
changed
type project.
would not sail in ECAs, it will be operated in ECA mode for 20% of the time.
For the remaining time, it is agreed to
24
discharge control.
25
In order to make installation highly flexible, the WTS module is divided into two
units:
WTS1 module, see Fig. 22, comprises the separators, scrubber pumps,
NaOH dosing, etc., to be placed wherever there is space in the ship
26
1,30
cases.
9000
1,25
- solids fraction
1,20
7000
1,15
6000
1,10
1,00
- salt concentration
=78
8000
5000
4000
3000
2000 87
1,05
- pH value
=80
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
Draining capacity.
Fig. 24: Requirement for EGR high-speed blower.
blower are:
Compact design
Flange mounting
condition.
27
Fig. 25 shows the EGR blower produced for testing on the 4T50ME-X
test engine. Specifications of the EGR
blower are as follows:
Power: 200 kW
Thermodynamic efficiency: 0%
Weight: 600 kg
28
Conclusion
As can be seen from the above, the
EGR application on two-stroke MAN
B&W engines has, over the last decade,
developed from a basic idea on how to
reduce NOx emissions to a dedicated
design, suitable for application on the
engine in standard configuration.
The development process has ensured
dedicated development of:
This makes MAN Diesel & Turbo confident that the EGR system application
will be available in due time before 2016
for the complete engine range.
29
30
31
32
33
34
All data provided in this document is non-binding. This data serves informational
purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to
changes and will be assessed and determined individually for each project. This
will depend on the particular characteristics of each individual project, especially
specific site and operational conditions. CopyrightMAN Diesel & Turbo.
5510-0125-00ppr Aug 2012 Printed in Denmark