Upload
hoangnhi
View
219
Download
2
Embed Size (px)
Citation preview
© Wärtsilä
METHANOL AS ENGINE FUEL: CHALLENGES AND OPPORTUNITIES
Toni Stojcevski
6/29/2016 Toni Stojcevski / Wärtsilä
© Wärtsilä INTERNAL© Wärtsilä
REGULATION DRIVERS - IMPACT ON THE ENVIRONMENT
2
LOCAL
GLOBAL
LOCAL
LOCAL
Acid rains
Tier II (2011)
Tier III (2016)NOx
Greenhouse effect
Under evaluation by IMO
EEDI / SEEMPCO2
Acid rains
Sulphur content in fuel
SECA (2015) – Global 2020/2025SOx
Direct impact on humans
Locally regulated
Particulatematter
Particulates <10μ
3,7 mil / year premature deaths worldwide[1]
Sources: [1] WHO, 2014, Fact sheet No 313; 2 NOAA; 3IIASA ; 4 IPCC
NOx
$562 bil / year
Global health related costs [3]
SOx
Responsible for 50%
of particulates in the air [2]
CO2
$1tr - $3tr “Coping cost”
(1-5% of GDP in 2014) [4]
© Wärtsilä INTERNAL3
ENVIRONMENTAL LEGISLATION CONTINUES
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2025
SOx legislation:• Sulphur free fuels
– LNG
– Methanol, LPG, bio-fuels
– Distillates
• Scrubbers in combination with HFO
NOx legislation:Tier II
• Engine internal methods
Tier III
• Secondary methods (SCR)
• LNG/NG with lean burning process (dual-fuel
engines)
Ballast Water Treaty:• UV ballast water treatment system
• EC ballast water treatment system
• Minimised amount of ballast water through
Ship Design
Global cap 0.5% SOx
Global Ballast Water Management Treaty
NOx Tier III in NECA(North America)
NOx Tier II(Global)
Global 0.5% SOx
limit reviewed
All ECA 0.1% SOx
North Europe ECA 1% SOx
0.1% SOx
in EU ports Global cap 3.5% SOx
US Ballast Water Management Treaty
North America ECA 1% SOx
© Wärtsilä INTERNALINTERNAL5 ©
Wärtsilä
0 5 10 15
50DF
20DF
46DF
0.6 -1.8 MW
3,0 – 10,0 MW
6.2 -18.3 MW
5.8- 17.5 MW
20
34DF
• LNG Carriers
• Cruise ships
• RO-RO/PAX
• Ferries
• Large Offshore Units
• Small LNG / CNG
vessel
• Small cargo vessels
• Supply vessel
• Offshore application &
Production
• Aux. engines with
W50DF
• LNG Feeder
• Jack-up
• Tugs
• Small cargo vessels
• Barges
• Small ferries
• Aux. engines with
W34DF & W50DF
• LNG Carriers
• Cruise ships
• RO-RO/PAX
• Ferries
• Large Offshore Units
31
4,2 – 8,8 MW
DUAL FUEL (GAS/FUEL OIL) ENGINE PORTFOLIO & APPLICATION TYPES
Which engine platforms to be developed for Methanol use
will be defined based on market demand.
© Wärtsilä INTERNALINTERNAL
Wärtsilä dual-fuel references>1,500 engines > 16 million running hours
6
DUAL-FUEL EXPERTISE
MERCHANT
881 ENGINES
204 LNG carriers
14 Tankers
11 LPG carriers
4 Containers
3 Bulk carriers
2 Car carriers
SPECIALS
46 ENGINES
16 IWW vessels
6 Tugs
1 Navy vessel
1 Icebreaker
1 Hopper Dredger
1 Guide ship
1 Cable Layer vessel
DUAL-FUEL
CONVERSION
36 ENGINES
4 FPSO vessels
3 Ferries
2 RORO vessels
1 IWW vessel
1 Chemical tanker
2 STROKE
DUAL-FUEL
35 ENGINES
10 Large LNG
carriers, 2 engines
each
6 Container Feeder
vessels
4 Chemical tankers
4 Asphalt Carriers
1 Small LNG carrier
OFFSHORE
132 ENGINES
24 Offshore supply
vessels
6 FPSO vessels
2 FSO vessels
1 Jack-Up rig
DUAL-FUEL
POWER PLANTS
376 ENGINES
82 plants
Output 5,031 MW
Online since 1997
CRUISE & FERRY
66 ENGINES
12 Ferries
3 ROPAX vessels
1 Cruise and ferry
© Wärtsilä INTERNAL© Wärtsilä
ALTERNATIVE CLEAN FUELS (BESIDES LNG)
In Service
First installation
in service since
Q1 2015
Promising pilot
results
Full engines test
on ZA40 have
taken place
during 2014
Methanol
• Sulfur free
• Low Nox
• Ultra low
particulates
Bio-fuels
• Sulpfur free
• Fuel
specification and
availability is a
question mark
VOC
• Mix of different
HC's and inert
gas
• VOC from a
shuttle tanker can
cover 20% of
energy demand
LPG
• Sulfur free
• Heavier than air
• 2% of global
energy market
In Service
In service since
2012
Operating on
Bio-Fuel or MDO
Several land
based power
plants in
operation
Tested in the
90`s
Challenge with
injection
pressure with
the diesel
principle
Smoke problem
In service today
for 34SG
In Service
Several VOC
recovery
installations in
use
GasReformer
delivered 2013
DF engines in
marine service
since 2001
Ethane
• C2H6
• Sulfur free
• Interesting when
available as
cargo
In Service
DF engines
running on
ethane in
service since
2015
Approval in
principle
SECA
NECA
SECA SECA
NECASECA
NECA
SECA
NECA
6
NECA
© Wärtsilä INTERNAL© Wärtsilä
FUEL PROPERTIES
8
Units Methanol LNG Bunker Fuel
Molecular formula CH3OH >90% CH4 CnH1.8n C8-C20
Carbon Content (wt%) 37.49 ~75 ~87
Density kg/l 0.79 0.44 (LNG) 0.85
Water Solubility Complete No No
Boiling point °C 65 -162 150-370
Flash point °C 11 -188 min.60
Auto ignition °C 464 540 240
Viscosity cSt@20°C ~0.6 n.a. ~13.5
Octane RON/MON 109/89 120/120 -
Cetane No. - 5 - 45-55
LHV MJ/kg 20 45 42
Flammability limits Vol% 7-36 5-15 1-6
Flame speed cm/s 52 37 37
Heat of evaporation kJ/kg 1178 n.a. 233
Stoichiometric AF ratio - 6.45 17.2 14.7
Adiabatic flame temp. °C 1910 1950 2100
Bulk modulus MPa 777 848 1350
Sulphur content % 0 0 3.5 max
© Wärtsilä INTERNAL
Nitrogen
Generator
Oil unit
Diesel pump
Water tank for dilution of
fuel return
Methanol tank and
LP feed system
EHSV
SSV
SSV: Shutdown and Safety Valve
EHSV: Electro-Hydraulic Solenoid Valve
* All methanol lines can be flushed with nitrogen.
Nitrogen purge*
Sealing oil
Control oil
Methanol
Methanol pump
TECHNOLOGY – MD SYSTEM LAYOUT
• Pilot-fuel assisted diesel combustion concept
• Methanol is combusted according to the diesel process. Methanol is injected close to TDC
and ignited by a small amount of diesel pilot fuel.
© Wärtsilä INTERNAL© Wärtsilä
METHANOL INJECTOR - THE HEART OF THE METHANOL ADAPTATION
ACCUMULATOR
BLOCKCONTROL
BLOCKTRANSFER
BLOCK
The methanol injector allows the engine to run on
methanol ignited by pilot fuel or on pure diesel.
© Wärtsilä INTERNAL
CONTROL OIL
FROM SOLENOID VALVE
METHANOL
FROM METHANOL HP PUMP
PILOT DIESEL
FROM DIESEL JERK PUMP
FLOW FUSE
ACCUMULATOR
SEALING OIL
AT METHANOL SEALING SURFACES
+ AROUND METHANOL NEEDLES
SEALING
OIL
CONTROL
PISTON
TRIANGULAR
PLATE
DIESEL
NOZZLE
METHANOL INJECTOR WORKING PRINCIPLE
© Wärtsilä INTERNAL© Wärtsilä
PHI T MAPS – NOX & PPM
14
Source: SAE 2016-01-0887 , Svensson et al. , Lund University
PHI T MAPS – NOX & PPM
Zero particulates , much lower NOx
Typical Diesel FuelMethanol Fuel
“soot”
“soot”NOx
NOx
© Wärtsilä INTERNAL© Wärtsilä
INITIAL TEST RESULTS OF WÄRTSILÄ SULZER ZA40S-MD
15
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00
NO
x M
ari
ne
Sp
ecif
ic IS
O 8
17
8 C
orr
[g
/kW
h]
BMEP [bar]
ZA40S_reference
Z40_reference 2014_LFO_CS
Z40_reference 2003_HFO_CS
Z40_load swing_450bar pinj
Z40_load swing_600bar pinj
200
250
300
350
400
450
500
550
600
650
0 5 10 15 20 25 30
t5 T
em
p b
Tu
rbin
e [°
C]
BMEP [bar]
ZA40S_reference
Z40_reference 2003_HFO_CS_norm
Z40_reference 2014_LFO_CS_norm
Z40_load swing_450bar pinj_norm
Z40_load swing_600bar pinj_norm
150
200
250
300
350
400
0 5 10 15 20 25 30
t6 T
em
p E
xh P
ipe
[°C
]
BMEP [bar]
ZA40S_reference
Z40_reference 2003_HFO_CS_norm
Z40_reference 2014_LFO_CS_norm
Z40_load swing_450bar pinj_norm
Z40_load swing_600bar pinj_norm
160165170175180185190195200205210215220225230235240245
0.00 20.00 40.00 60.00 80.00 100.00 120.00
Tota
l BS
FC
LH
V C
orr
ect
ed
[g
/kW
h]
Engine Power % [%]
Z40_reference
Z40_reference 2014_LFO_CS
Z40_load swing_450bar pinj
Z40_load swing_600bar pinj
Z40_reference_HFO_2003
~2%
* Preliminary tests - Engine consumption
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00
Filt
er S
mo
ke N
um
be
r M
ea
s 1
[F
SN
]
BMEP [bar]
ZA40_reference
Z40_reference 2003_HFO_CS
Z40_reference 2014_LFO_CS
Z40_load swing_450bar pinj
Z40_load swing_600bar pinj
*
© Wärtsilä INTERNAL© Wärtsilä16
• Adaptation of proven engine technology, minor modification to the engine
• No reduction in efficiency or output when running on methanol
• Load response unchanged, full fuel redundancy
• Existing fuel or ballast tanks can be converted into methanol tanks
• Short off-hire time, can be done engine by engine
• Lower thermic load on the engine
• Much lower NOx, SOx, and PM (particulates), good base for future ECA regulations
ENGINE CONVERSION KIT – SUMMARY
© Wärtsilä INTERNALINTERNAL
Natural Gas (CH4)
LNGMeOH
New costly
infrastructure
η=90%η=~70%
Existing
infrastructure
Renewable methanol possible
AVAILIBILITY - MEOH & LNG, TWO OPTIONS TO TRANSPORT NG
6/29/2016 Toni Stojcevski / Wärtsilä
© Wärtsilä 6/29/2016
Case study 3: Pilot methanol vs. Reference shipMonetized annual benefits – central estimate (low & high)
Pilot methanol vs.
Reference ship
Human Health 563 (261-1316) KEUR
Crop damages 0 KEUR
TOTAL 563 (261-1316) KEUR
EMISSIONS & SOCIOECONOMIC BENEFITS – CASE STUDY
Pilot
MethanolReference
ship
SO2 2 29 ton
NOx 56 56 ton
PM2.5 4 32 ton
Fuel use 632 632 TJ
SECA compatible? yes yes
NECA compatible? yes yes
EmissionsMonetized benefits
SO2 28 ton
NOx 0 ton
PM2.5 28 ton
Emission reduction
High benefits, even without NOx reduction effect
Source: ZVT, IVL, Erik
Fridell, Stefan Åström, 2015
“As air quality improves in response to legislation, its public health impact will fall by 2020 across Europe. As
a result, public health costs of air pollution are expected to fall from €803 billion a year in 2000 to €537 billion
in 2020. The number of people dying prematurely from the effects of air pollution is calculated to fall from
around 680,000 people in 2000, to around 450,000 in 2020.” Source: EC – Science for Environmental Policy
Toni Stojcevski / Wärtsilä
© Wärtsilä INTERNAL© Wärtsilä
CHALLENGES
19
Technical
• no issues with corrosion in the combustion chamber due to diesel cycle
‒ fuel combusted directly
• material choice important
‒ special alloys, coatings and sealing materials
• design criteria important
‒ special design for sealing surfaces
Economical
• price disconnection from bunker fuel market
• availability, >60 export/import terminals, how to bunker?
© Wärtsilä INTERNAL© Wärtsilä
FUTURE POSSIBLE DEVELOPMENT - RECOMMENDATIONS
20
• Variable injection timing for both pilot and main fuels
• Separate pilot fuel injector -> minimizing the pilot fuel amount
• Water-blended methanol -> lower NOx
• Pure methanol mode – diesel combustion cycle – hot surface assisted ignition