4.3.b - Scr-System-Imo-Tier-Iii

MDT Four-stroke SCR system kit to
fulfill IMO Tier III
MAN Seminar
Dr. Daniel Struckmeier

Head of EEBAE - Emission 2016
Advanced Engineering & Exhaust Aftertreatment
25. - 26.02.2015
MAN Diesel & Turbo Dr. Daniel Struckmeier MDT-SCR System for Medium Speed Engine Portfolio  25.02.2015 < 1 >
Agenda
1 Overview & Technology
2 MDT-SCR System - Development Methods & Field Experience
3 Tier III Certification Procedure & NOx Technical File
4 MDT as First Choice - Customer Benefits of MDT-SCR System
Outcome of MEPC 66
IMO Tier III regulation
All diesel fuelled ships with keel laying 2016 entering North American NECAs
(200nm coastline) will need either SCR or EGR technology
Tier III decision - MEPC 66 on 04.04.2014

• from 01.01.2016 for ships operating in North
American and U.S. Caribbean Sea ECA
• further NECAs are to be introduced by submission
from neighbouring countries
 Adoption process about 2 years
discussed ECAs: Coasts of Mexico, Coasts of Alaska and Great Lakes, Singapore, Hong Kong, Korea, Australia, Black Sea, Mediterranean Sea , Tokyo Bay
NOx-Reduction Technologies 4-Stroke
Comparison of Reduction Potentials
SCR set as standard technology for 4-stroke diesel engines to fulfill IMO Tier III
already attained
potential
SCR Catalyst
Recirc. (EGR)
Exhaust Gas
Motor (HAM)
(Gas Mode)
Fuel Water
Measures
Humid Air
Dual Fuel
Emulsion
Internal
DF (Gas
Internal EGR FWE HAM SCR mode)
0%
10%
20% IMO Tier II
global
NOx Reduction
30%
40%
50%
60%
70%
IMO Tier III
80% ECA
90%
Modular SCR System Concept
for entire four-stroke engine portfolio
• SCR-system entirely developed and validated by MAN Diesel &

Turbo in Augsburg, Germany
• Fully modular component kit for minimum component variety
(family concept)
• Standardized module/component portfolio for min. cost, max.
flexibility and fast order management
Marine
Stationary
430 kW MDT 4-stroke engine portfolio max 3,5% sulfur 21.600 kW
MDT-SCR System
SCR component kit
Modular design of SCR components to cover entire medium

speed engine portfolio with minimum variety
Agenda
MDT-SCR development
three steps of development
System readiness proven after successful completion of all development steps => Market Release
1st step 2nd step 3rd step
Synthetic gas test bed Full scale engine SCR test bed Field Test on Petunia Seaways
etic gas test bed SCR model Engine test bed full scale On board installation
(CentAur)
Database for SCR design
ated NOx efficiency pre-certification results on-board confirmation

CentAur
full scale engine test bed at MDT > 12.000 hours stable and reliable
headquarters in Augsburg, Germany operation under Tier III
conditions
Development methods I
chemical kinetics, CFD calculation, component design
Formation of Ammonia (NH3) Design drawing
1. Evaporation
2. Thermolysis: (NH2)2CO  HNCO + NH3
3. Hydrolysis: HNCO + H2O  NH3 + CO2
CFD calculations
Calculations on
• Atomisation of liquid urea solution
• Flow distribution with different mixing devices
to enable
• High uniformity of the reactant at reactor inlet
• low pressure drop
• Minimum mixing length / installation space
• Robustness against deposits and fouling
Engine test bed
NOx conversion
Verification under real exhaust gas conditions
Interaction with SCR performance
Definition of design guidelines for standard kit uniformity
Development methods II
SCR catalysts and reactor design
100 100,00
Synthetic gas test bed 90
SV = 29,0 k/h
SV = 22.6 k/h 90,00
NOxNOxconversion
80 SV = 15.7 k/h 80,00
SV = 14,9 k/h
• Screening of catalyst technologies under defined

70 70,00
NH3 slip
SV = 11,5 k/h
Umsatz [%]
60 SV = 9.6 k/h 60,00
50 SV = 8,2 k/h 50,00
exhaust gas conditions flow distribution with 40
SV = 5,2 k/h
ideal
40,00
different mixing devices 30

20
30,00
20,00
• Quality control/assurance of catalyst suppliers

10 10,00
0 0,00
0,00 0,20 0,40 0,60 0,80 1,00 1,20
exhaust gas paramter
• Investigations on aging mechanism
alpha [-]
Design drawing
Engine test bed Reactor
Performance under real exhaust gas cond. with different fuels

• SCR conversion
• SO2 oxidation
• backpressure performance (e.g. plugging, fouling)
• transient behaviour (e.g. warm-up)
• endurance tests of components
• validation/release procedure for SCR honeycombs
Catalyst
> 1000 hrs. operation
Ensure reliable & safe operation
Development methods III
Intelligent SaCoS SCR control
Control tasks
Calculation of urea mass flow depending on engine operation
• Reduction of NOx-emisson according to IMO Tier III

• Minimization of ammonia slip
• Control options: feedback or feed forward
• Simple on board verification procedure
Safe and reliable operation of SCR System
• Status of operating process parameters [kg/h]
• System status of sensor / actor

• Status information to Ship Alarm System
• Monitoring of SCR System (also online service)
Engine parameter [-]
In-house test rig Visualisation

SCR Control System Diagnose  Ship Alarm System
• Screening and validation of sensors/electrical parts Operating Values System Status Info
• Process optimization of the SCR control system Alarme
Optimization of entire package: Engine + SCR

for best overall setup and performance
MDT-SCR System released
Field Test on Petunia Seaways
System performance proven: reliable & robust
Over 12.000 operating hours on HFO

Reactor housing:
- Overall good condition
- possible improvenement reg.
fixation and tightness of
honeycombs in reactor
SCR Reactor incl.
honeycombs  Already implemented in
new reactor design
Compr. air
module
Honeycombs:
- No clogging
- thin layer of dry grey soot
Mixing unit +
urea inj. lance Dosing
Soot blowers:
unit - No defects
Pump
module
Pump Module:
- Clogged filter (dirt from ship tank)
Control system - since overhaul no issues reported
SaCoS - Optimized design installed on field test
Agenda
IMO Certification Procedure
The role of the applicant
One party, the applicant, is responsible for compliance of

engine + SCR
MDT offers support to prepare & realize IMO Tier III

certification together with classification societies:
 The applicant must discuss all documents and design

parameters with classification society incl. verification
 The applicant must prepare the technical file covering
drawings, specifications, P&IDs, functional descriptions,
quality and compliance to realize successful IMO-Tier-
III-certification
Status Quo
Fleet Leader - M/V Petunia Seaways
First IMO Tier III certification acc. to Scheme B

EIAPP Certificate and NOx Technical File approved by class (DNV-GL)
Field Test: M/V Petunia Seaways
Status 11/2014
 Issuance of 1st TIER III EIAPP Certificate by class
 Operating hours: ~12000 hrs IMO Tier III
 System performance under permanent online service monitoring
 Constant Reduction rate for IMO Tier III conformity
IMO Tier III Certification Procedure
Scheme A vs. Scheme B
Scheme A Scheme B – MDT standard solution

• Certification of complete system on test bed • Testing of Tier II engine on test-bed as usual
(engine + SCR + original piping) • Application of MDT-SCR Modelling Tool for SCR system
configuration/layout
• On-board-confirmation test during engine commissioning
That means: for each parent engine only
- Installation of aftertreatment test-bed
That means:
- High invest cost
- high skilled personnel + engine certification = business as usual
- system optimization limited + no invest cost for engine test-bed
- Non-reasonable logistic effort of SCR + high accuracy in system optimization for minimum fuel
components oil and urea consumption
- Reduction in test capacity at engine + SCR-layout specified by approved MDT modelling tool
manufacturer, if existing test-bed is used + Guaranteed Tier III system compliance  test on-board
+ Test effort only necessary for parent engine
 no test for following identical Tier III systems
IMO Tier III Certification
Certification Surveys
(1) Pre Certification Survey

 EIAPP Certificate (by class)
• Technical File (Engine + SCR)

@ MDT
• SCR Modeling Tool (Scheme B)

• Parent Pre Certification (Tier II engine)
(3) Annual, renewal Certification
Measurement acc. Chapter 5 NOx Technical Code
• Simplified Measurement
or
on board • Parameter Check Method
(2) Initial Certification Survey according to Technical File
 IAPP Certificate for Vessel

by class
on board
• Check of EIAPP certificates by

class
• On-board Confirmation Test
(Scheme B for parent)
Initial Certification Survey
Parameter Check Method

according to Techn. File
MDT support to receive EIAPP Certificate based on MDT-SCR Modeling Tool & NOx-Technical File
Onboard Verification Process
Optimization for reduced downtimes
IMO-1234
 Authentication of parts due to serialisation Unique Part Number
1
 Less need for physical inspection due to
enhanced documentation
Original Engine Manufacturer (OEM) Certificate
(e.g. SCR-reactor sealed by MDT => verification
Flexible Verification
over OEM certificates)
2
 Reliable easy and quick checks possible
 Time-saving verification process

Inquiry Certificate/Component
3
Additional Customer benefits
DATA-
reduced downtimes Base
simplified inspection
Verification of Certificate Number
From System Layout to Certification
Scheme B Certification Process
Tier II Parent test at MDT testbed Technical File for Check EIAPP
Tier III System Certificates
e.g. 12V32/44CR
Parameter Check
Method acc. TF
MDT SCR-Modeling Tool

for SCR layout
(for entire MDT 4-stroke portfolio)
EIAPP Certificate confirmation test
Easy & problem-free way to a certified system by Class
On-board
with MDT-SCR System & Modelling Tool for parent engine only
Agenda
Strengths of the Integrated Solution
Our core competence in engines and SCR
Engine and SCR set as a core competence
 Up to 2.5g/kWh of fuel oil consumption savings during SCR operation by integrated and
optimized control strategies (compared to third party SCR supplier)
 Intelligent exhaust gas temperature control to optimize system efficiency
 Closed Loop Control to minimize urea consumption
 Modular kit of SCR components to achieve minimum variety and cost
 MDT-SCR Modelling Tool as guarantee to obtain Tier III certification
Optimized TIER III Package

robust, efficient & effective
to satisfy your needs
Profound SCR – Experience in the Field
We know what we are doing!
MAN Truck & Bus – over 220.000 units and over 50 Billion km SCR experience on-raod
MDT- SCR System
MAN Diesel & Turbo – over 850 MW and over 200.000 oh SCR experience on land & at sea
100% HFO operation

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MDT Four-stroke SCR system kit to

fulfill IMO Tier III

Dr. Daniel Struckmeier

1 Overview & Technology

2 MDT-SCR System - Development Methods & Field Experience

3 Tier III Certification Procedure & NOx Technical File

4 MDT as First Choice - Customer Benefits of MDT-SCR System

Tier III decision - MEPC 66 on 04.04.2014

• SCR-system entirely developed and validated by MAN Diesel &

430 kW MDT 4-stroke engine portfolio max 3,5% sulfur 21.600 kW

Modular design of SCR components to cover entire medium

1 Overview & Technology

2 MDT-SCR System - Development Methods & Field Experience

3 Tier III Certification Procedure & NOx Technical File

4 MDT as First Choice - Customer Benefits of MDT-SCR System

1st step 2nd step 3rd step

Database for SCR design

ated NOx efficiency pre-certification results on-board confirmation

Formation of Ammonia (NH3) Design drawing

Engine test bed

Definition of design guidelines for standard kit uniformity

• Screening of catalyst technologies under defined

different mixing devices 30

• Quality control/assurance of catalyst suppliers

Performance under real exhaust gas cond. with different fuels

> 1000 hrs. operation

Ensure reliable & safe operation

• Reduction of NOx-emisson according to IMO Tier III

Safe and reliable operation of SCR System

• Status of operating process parameters [kg/h]

• System status of sensor / actor

In-house test rig Visualisation

• Process optimization of the SCR control system Alarme

Optimization of entire package: Engine + SCR

System performance proven: reliable & robust

Over 12.000 operating hours on HFO

1 Overview & Technology

2 MDT-SCR System - Development Methods & Field Experience

3 Tier III Certification Procedure & NOx Technical File

4 MDT as First Choice - Customer Benefits of MDT-SCR System

One party, the applicant, is responsible for compliance of

MDT offers support to prepare & realize IMO Tier III

 The applicant must discuss all documents and design

First IMO Tier III certification acc. to Scheme B

Field Test: M/V Petunia Seaways

 Operating hours: ~12000 hrs IMO Tier III

 System performance under permanent online service monitoring

 Constant Reduction rate for IMO Tier III conformity

Scheme A Scheme B – MDT standard solution

- system optimization limited + no invest cost for engine test-bed

(1) Pre Certification Survey

• Technical File (Engine + SCR)

• SCR Modeling Tool (Scheme B)

 IAPP Certificate for Vessel

• Check of EIAPP certificates by

Parameter Check Method

 Time-saving verification process

MDT SCR-Modeling Tool

1 Overview & Technology

2 MDT-SCR System - Development Methods & Field Experience

3 Tier III Certification Procedure & NOx Technical File

4 MDT as First Choice - Customer Benefits of MDT-SCR System