2004/10/29 < 1>© MAN B&W Diesel

Pacific Ports Air Quality Collaborative Conference Dec. 2006.

How engine manufacturers are meeting the challenge by refining their technologies within Exhaust gas emission

Kjeld Aabo

Director Customer Support

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MAN B&W Diesel

© MAN B&W Diesel

6S35MC and 10K98MC-C on Test bed

L/70479-5.0/0100 (2700/JGJ)

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MAN B&W Diesel

© MAN B&W Diesel

Emission Reduction

AGENDAEmission reduction methodsRetrofit possibilities

IMO meeting statusME-Engine,TES and Alpha lubeSummary

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MAN B&W Diesel

© MAN B&W Diesel

Emission ReductionMethods

Internal measures:Performance and Spray Optimization

Flexibility of Electronic EnginesWater-in-Fuel Emulsion or Direct Injection (FWE, FWI)Saturated Air Moisturising (SAM or HAM)Exhaust Gas Recirculation (EGR)

Aftertreatment:Selectiv Catalytic Reduction (SCR)Particulate Filters (ESP)Scrubbers (wet or dry FGS)

< 5>

MAN B&W Diesel

© MAN B&W Diesel

Heat

Work

Air8.5 kg/kWh

21% O279% N2

Fuel175 g/kWh97% HC

3% S

Lube1 g/kWh97% HC

2.5% CA0.5% S

Exhaust gas13.0% O275.8% N25.2% CO2

5.35% H2O

1500 vppm NOx600 vppm SOx

60 ppm CO180 ppm HC120 mg/Nm3 part.

3331588/20040525 (2160/KEA)

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MAN B&W Diesel

© MAN B&W Diesel 3331589/20040525 (2160/KEA)

Up to 98% reductionNOx

2) Use of water emulsion

From 20-50%NOx reduction

To comply with Tier 1 EPA and IMO NO code

1) Modification of injection equipment

receiver

3) Use of selective catalytic reduction

SCR reactor

Exhaust gas

x

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MAN B&W Diesel

© MAN B&W Diesel

Cross sections of fuel-valve nozzle tips

Valve Designs

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MAN B&W Diesel

© MAN B&W Diesel

0

0.5

1

1.5

2

2.5

0 25 50 75 100

Engine Load - %

Part

icul

ates

- g/

kWh

Std valveMini sacSlide

Particulates

12K90MC Mk VI

Particulate Emission

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MAN B&W Diesel

© MAN B&W Diesel

0

0.5

1

1.5

2

2.5

3

3.5

0 25 50 75 100

Engine Load - %

HC

(as

CH

4) -

g/kW

h

Std valveMini sacSlide

Hydrocarbons

12K90MC Mk VI

Hydrocarbon Emission

< 10>

MAN B&W Diesel

© MAN B&W Diesel

NOx Emission ControlWater Emulsion Fuel

From centrifuge

Aut. deaerating valve

Venting box

Fresh water supply

Supplypumps

Circulatingpumps

Fullflowfilter

Fuel oildrain tank

Heavyfueloil

servicetank

Dieseloil

servicetank

Homo-genizer

Preheater

< 11>

MAN B&W Diesel

© MAN B&W Diesel 3331562/20040525 (2160/KEA)

NOx reduction at 100% Load

20

40

60

80

100

120

0 10 20 30 40

Water content - % mass

Reson HomogenizerHigh pressure mixer10% line

< 12>

MAN B&W Diesel

© MAN B&W Diesel

Alternative SCR configurations

Traditional vertical SCR

Engine integrated SCR

Horizontal SCR

Partial SCR

MAN B&W Diesel patent MAN B&W Diesel patent

< 13>

MAN B&W Diesel

© MAN B&W Diesel

SCR System

L/71835-9.0/0801 (2160/PZS)

32

1

5

6

78

4

Deck

1 SCR reactor

2 Turbocharger bypass

3 Temperature sensor after SCR

4 Large motors forauxiliary blowers

5 Urea injector

6 SCR bypass

7 Temperature sensorbefore SCR

8 Additional flange in exhaustgas receiver

6S35MC

< 14>

MAN B&W Diesel

© MAN B&W Diesel

40 MW KOMIPO Plant at Cheju, Korea 12K80MC-S

3332030/20041123 (3230/JH)

SCR Installation

12700

2425

0

< 15>

MAN B&W Diesel

© MAN B&W Diesel

3332029/20041123 (3230/JH)

40 MW KOMIPO Plant at Cheju, Korea 12K80MC-S

Emission Control Installation

3253

0

112830

Mechanicalannex

9760

Mechanicalannex

Office &HVAC room

Control roomElectrical room

Electricalroom

Engine/generator foundation

Cable room

4 Exhaust gas boiler5 ESP6 Wet FGD

1 12K80MC-S2 Generator3 SCR

< 16>

MAN B&W Diesel

© MAN B&W Diesel

Total Emission Control System 40 MW Power Plant, Buk Cheju, Korea

3334437.2006.09.18 (3230/JH)

MAN B&W two-stroke diesel engine 12K80MC-SEmission limits:

SOx < 50 ppm at 4% O2, dry gas

NOx < 250 ppm at 13% O2, dry gas

PM < 30 mg/Sm3 at 4% O2, dry gas

< 17>

MAN B&W Diesel

© MAN B&W Diesel

APM – CARB (et. al.) demo on SL valves and reduced speed (finished)

APL – CARB (et. al.) demo on SL valves, reduced speed and water emulsion (in progress)

Wallenius, investigation on SAM system (in progress)

Acknowledgements –Demo on Existing Engines

< 18>

MAN B&W Diesel

© MAN B&W Diesel

Scrubber Performance Objectives

•SOx reduction > 95%

•NOx reduction ~10%

•Particulate reduction ~ 80%

•Exhaust noise attenuation

•No measurable impact to sea water condition

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MAN B&W Diesel

© MAN B&W Diesel

Stationary Applications

DeSOx/de-dust testfacility at Ibiza, Spain

3330617.2003.09.07 (3230/JH)

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MAN B&W Diesel

© MAN B&W Diesel

mv Pride of Kent project

First commercial scrubber installation

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MAN B&W Diesel

© MAN B&W Diesel

EGRunit

Schematic Design of EGR system

L/73395-9.0/0902 (2430/NK)

Low O2 in scavenge air gives low combustion temperatures

Re-circulation of exhaust gas lowers O2 in scavenge air

Low combustion temperatures give low NOx

EGR influence on NOx formation

Influence on reliability and safety: Field test

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MAN B&W Diesel

© MAN B&W Diesel

Temperature Distribution

L/74189-3.0/0402 (2430/NK)

Without EGR With 15% EGR

4T50ME-X combustion chamberTemperature distribution in a horizontal incision in line with the atomizer holes

240023802360234023202300228022602240222022002180216021402120210020802060204020202000

Temperatureabsolute kelvin

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MAN B&W Diesel

© MAN B&W Diesel

NOx Formation

L/74188-1.0/0402 (2430/NK)

Without EGR With 15% EGR

4T50ME-X combustion chamber

NOx concentration in a horizontal incision in level with the atomizer holes

0.150E-020.142E-020.135E-020.127E-020.120E-020.112E-020.105E-020.975E-030.900E-030.825E-030.750E-030.675E-030.600E-030.525E-030.450E-030.375E-030.300E-030.225E-030.150E-030.750E-040.000E-00

NOxconcentration

< 24>

MAN B&W Diesel

© MAN B&W Diesel

NOx Emission ControlEGR Emission Parameters

100

100

90

80

100

90

200

100

80

60

150

EGR ratio %

Relative change %

0 105 15 20

NOx

CO

HC

PM

40

100

100

90

80

100

90

200

100

80

60

150

EGR ratio %

Relative change %

0 105 15 20

NOx

CO

HC

PM

40

Emission Parameters at 75% Load at VariousEGR Ratios

< 25>

MAN B&W Diesel

© MAN B&W Diesel

Principle Design of SAM system (Humid Air Motor)

L/73394-7.0/0902 (2430/NK)

SAMunit High heat capacity and low O2

in scavenge air give low combustion temperatures

Humidification of scavenge air increases heat capacity and lower the O2 content

Low combustion temperatures give low NOx

SAM influence on NOx formation

Influence on reliability and safety: Field test

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MAN B&W Diesel

© MAN B&W Diesel

NOx Emission ControlSAM Emission Parameters

Absolute humidity (vol./vol.) of scavenge air (%)

110 100

100

90

300 200 100

%

100 80

60

PM

HC

CO

NOx

zero half full0 3 6 9

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MAN B&W Diesel

© MAN B&W Diesel

NOx Emission Control, SAM Application and Conventional Cooler

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MAN B&W Diesel

© MAN B&W Diesel

SAM Service application

L/74217-0.0/0502 (2430/NK)

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MAN B&W Diesel

© MAN B&W Diesel

L/73847-8.0/0303 (2440/PCS)

7S50ME-C at Alpha Diesel

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MAN B&W Diesel

© MAN B&W Diesel L/74496-0.1/0903 (2430/NK)

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

16:37 16:38 16:39 16:40 16:41 16:42 16:43 16:44 16:45 16:46

NO

x[p

pm]

2003-02-17

140 150 160 170 180 190 200 210 220 2300 0

20 100

40 200

60 300

80 400

100 500

120 600

140 700

160 800

CylinderPump

2003-02-17

140 150 160 170 180 190 200 210 220 2300 0

20 100

40 200

60 300

80 400

100 500

120 600

140 700

160 800

CylinderPump

Economy mode Low NOX mode

Time

NOx and economy mode ME engine

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MAN B&W Diesel

© MAN B&W Diesel

The Alpha Lubricator

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MAN B&W Diesel

© MAN B&W Diesel

Lube oil related HC-Emission

Lub. Oil HC-Emission

0

20

40

60

80

100

0 25 50 75 100Load (%MCR)

Reference

Alpha Lubricator

HC

ppm

< 33>

MAN B&W Diesel

© MAN B&W Diesel

7S60MC Soot-Emission

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

0 25 50 75 100

Load (% - MCR)

Defective injector

Approved injector

Invisibility limit

Bos

chnu

mbe

r(10

str

okes

)

< 34>

MAN B&W Diesel

© MAN B&W Diesel

Green Shipping World, Amsterdam17 & 18 May 2005

0

0.5

1

1.5

2

2.5

3

3.5

0 25 50 75 100

Engine Load - %

HC

(as

CH

4) -

g/kW

h

Std valveMini sacSlide

Hydrocarbons

12K90MC Mk VI

< 35>

MAN B&W Diesel

© MAN B&W Diesel

Low Sulphur Fuel Operation

Two-stroke engine can operate on HFO, GO, DO

Two-stroke engine is less sensitive to fuel quality

Cylinder lube oil base numbers are to be considered

When fuel is mixed to reduce sulphur control fuels, compatibility becomes important

More fuel and cylinder lube oil storage tankers to be implemented on new-buildings

Conclusion: When operating on low sulphur fuels different considerations are to be made

< 36>

MAN B&W Diesel

© MAN B&W Diesel

Pump StationPower concept for a Thermo Efficiency System

Exhaust Gas Heat Recovery(single pressure)

Superheated steam

TG

Generator PTSwitchboard

Diesel generators

Exhaust gas receiver

Main engine

Shaft/motorgenerator

EmergencygeneratorTG: Turbogenerator

PT: Power turbineTC: TurbochargerSaturated

steam for heatingpurposes

Exh. Gas boiler

TC

< 37>

MAN B&W Diesel

© MAN B&W Diesel 3332167.2005.02.04 (2160/BGJ)

Main engine 6S70ME-GI = 18,660 kW at 91 r/min

ME = Main engine

PT = Power turbine

TG1 = Turbo generator, Single steam pressure7 bar abs

TG2 = Turbo generator, Dual steam pressure10.5 bar abs / 4.5 bar absWith additional feedwaterpreheating

TES1 = PT+TG1

TES2 = PT+TG2

Exhaust Gas Heat RecoveryThermo Efficiency System (TES)

7207.7

10207.8

13608.6

189010.1

kW%

Total TES2 el. productionin % of ME output

6507.0

9207.0

12407.8

17209.2

kW%

Total TES1 el. productionin % of ME output

5305.7

6304.8

7804.9

10805.8

kW%

TG2 el. productionin % of ME output

4604.9

5304.1

6604.1

9104.9

kW%

TG1 el. productionin % of ME output

1902.0

3903.0

5803.7

8104.3

kW%

PT el. productionin % of ME output

9,33050

13,06070

15,86085

18,660100

kW%

Main engine power outputMain engine load

ISO ambient conditions

< 38>

MAN B&W Diesel

© MAN B&W Diesel

TES Engine Test

TES Engine TestsNOx Emission

80

90

100

110

120

130

60.00 70.00 80.00 90.00 100.00 110.00

Engine load in %

Rela

tive

NOx

emis

sion

in %

ReferenceScav-BypassSc-by+Sc-Ex-by

< 39>

MAN B&W Diesel

© MAN B&W Diesel

Correspondence Group A– IMO Future Regulation

The following options were outlined in Nov. In Oslo :A: unchanged regulationB: global 4.5% local 1% in 2010 and 0.5% in 2015C: MDO w. 1% in 2012 and 0.5% in 2015C2: as C but using HFO w. same S% or scrubbers

Questions:Avalibility of Destillate ?What to do with remaning HFO ?Will the increased price level of DO change the transport pattern ?

< 40>

MAN B&W Diesel

© MAN B&W Diesel

Summary – orHow to Comply with the IMO C3 Regulation

• Speed reduction strongly affectsemissions

• Slide valves and Alpha lube promoted as retrofits for ‘old’engines

• Voluntary compliance with Tier 3 & Tier 4 may be possible in limited scale

• Coastal NO control area (NECA)• SCR voluntary (incentives)

Comments

• SAM (EGR, SCR)• CO2 & sfoc penalty 5+%

• 50%? NOx reduction (from Tier 1)

Tier 4

• Fuel-water emulsion• CO2 & sfoc penalty 3+%

• 30% NOx reduction (from Tier 1)From Jan. 2015

Tier 3

• Fuel nozzle & performance optimization

• Slide valves mandatory• (a few MC engine types may need

H2O addition)• CO2 & sfoc penalty 1-3%

• 10-15% NOx reduction (from Tier 1)

• HC and CO must not increase• PM & SOx by fuel Sulfur contentFrom Jan. 2010

Tier 2

• Fuel nozzle & performance optimization

• 5% sfoc tolerance

Current IMO Regulation• NOx speed limit curve• SOx – fuel Sulfur content limitFrom 1 Jan. 2000 to end Dec. 2009

Tier 1Reduction methodRegulationIMO

< 41>

MAN B&W Diesel

© MAN B&W Diesel

Slide-type fuel valves (tier 2)Alpha lubricator system (tier 2)Water-in-fuel emulsion (tier 2 or 3)SAM & EGR systems (tier 3 or 4)Scrubber systems (alternative)SCR (special areas)

(in order of increasing difficulty & cost)

Retrofit Possibilities

< 42>

MAN B&W Diesel

© MAN B&W Diesel

Strong impact from fuel nozzles on NOx, soot and smoke. (SL valves easy to retrofit)

Alpha lube-oil system saves lube oil and improves cylinder conditions. (Easy to retrofit)

The ME engine improves emission optimisation and allows different optimisation for local areas

Water emulsification possible for future NOx requirements – if required. (Possible to retrofit, but need decision on scope)

SAM (and EGR) have potentials, but further tests are needed

Summary –reduction methods

< 43>

MAN B&W Diesel

© MAN B&W Diesel

NOx Reduction Potential

5

10

15

17

Uncontrolled = Fuel optimized

IMO compliant = Fuel system adoption(additional low NOx optimization)

Lower future IMO/ EPA = ME optimization= Water in combustion (WFE,WFI)

Local regulation = EGR (under development)= SAM (under development)= Combinations of WFE, SAM & EGR

Lowest = SCR (NH3 or UREA)

NOxg/kWh