cutting sox emissions

8/13/2019 Cutting SOx Emissions

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Cutting SOxEmissionsWith the effective DryEGCSexhaust

gas cleaning system

MAN Diesel & Turbo

Department Upgrades & Retrofits

86224 Augsburg, Germany

Phone +49 821 322-3455

Fax +49 821 322-3838

[email protected]

www.mandieselturbo.com

MAN PrimeServ a service brand of MAN Diesel & Turbo

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.

D2366495EN Printed in Germany GMC-AUG-07122


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2 Cutting SOx Emissions Cutting SOxEmissions 3

MAN PrimeServ provides outstand ing technical support, drawing on our long experi-

ence as an OEM. We offer expert assistance and high-quality products, wherever

and whenever our customers need us: we operate an extensive global network of

service centres, staffed by highly-skilled professionals and equipped with the lat-

est repair technology. Our 24-hour international hotline ensures a rapid response.

MAN PrimeServs comprehensive service portfolio provides for all types of diesel,

gas and dual-fuel engines and turbo machinery. It involves much more than

repairs: we bring our customers the latest technology, enabling them to continu-

ously improve the efficiency, availability and sustainability of their products and

facilities.

One of these state-of-the-art product innovations is the DryEGCS exhaust gas

cleaning system. This technology is an effective, affordable solution for vessel

operators facing stricter emission standards. The system removes sulphur from

exhaust gas, offering significantly lower operating costs than low-sulphur fuel.

Whats more, DryEGCS is clean, based on uncomplicated proven technology,

requires little maintenance effort, is compatible with other emission-reduction

technologies and can be retrofitted on most vessels.

MAN PrimeServ

Peace of mind for life

1Diesel engine

2 DryEGCSsystem

3 SCR

4 Boiler

5 Silencer

1

3

4

5

2


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Emission regulations

In recent years, global and local regulations regarding

exhaust gas emissions from marine medium speed

diesel engines have become increasingly strict.

These particu larly target nitroge n oxide (NOx) and

sulphur oxide (SOx) e missio ns. The new thresho lds

for marine diesel exhaust gas are defined in the re-

vised IMO MARPOL 73/78 Annex VI.

Sulphur in = sulphur out

The new IMO regulat ions set NOx emission limits

depending on the vessels keel laying date. The

thresholds for sulphur, however, apply to all engines

regardless of the ships age. As engine SO x emis-

sions result entirely from the level of sulphur in the

fuel used, the IMO is introducing limits on fuel sulphur

content. While engine manufacturers can influence

NOxformation, they cannot reduce the level of SOxby changing the engine combustion process or other

similar measures. That means vessel operators have

to use low-sulphur fuel to meet SOx limits unless

they have a certified exhaust gas after-treatment me-

thod, e. g. the DryEGCS.

Vessel operators are facing stricter limitations on sulphur emissions.

MAN Diesel & Turbos DryEGCS Exhaust Gas Cleaning System offers an ideal

solution. This technology efficiently removes sulphur from exhaust gas, saving

operators from buying expensive low-sulphur fuel. DryEGCSis based on a chem-

ical process using dry granulate of hydrated lime, making it exceptionally reliable

and environmentally friendly.

DryEGCS

Exhaust gas cleaning system

Boiler

Selective catalytic

reduction SCR

(optional)

Monitoring

& control

DryEGCSreactor

Diesel engine

Hydrated lime

supply & disposal


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Existing ECA

U.S. and Canadian ECA

Discussed ECA

Sulphur limits to tighten further

In addition to general emission limits for s hips oper-

ating worldwide, the IMO has defined stricter limits

valid in specified Emission Controlled Areas (ECAs).

Since mid-2010, the permissible sulphur content in

fuel ha s been lim ited to 1.0 % in ECAs. Fr om 2015,

this threshold will be significantly lowered, allowing

fuel with just 0.1 % sulphur content. In 2020, the limitfor sulphur in fuel for all ships operating worldwide

outside of ECAs is set to decrease to 0.5 %.*

At p resent, there are ECAs in the Baltic and North

Sea. These will be joined by the coasts of the USA

and Canada in August 2012. ECAs are currently

under discussion in several other frequently used

shipping regions. Strict sulphur limits have already

been in place in EU ports (0.1 % sulphur li mit) since

early 2010, and also apply in Californian coastalwaters. Other regions are likely to impose similar local

emission regulations in future.

World map showing ECAs

Higher fuel prices on the way

It is widely believed that the introduction of tougher

SOx emission limits will have an impact on future

fuel prices: the cost of low-sulphur fuels,

especially distillates, is expected to rise signifi cantly.

To give operators a more affordabl e alternati ve,

MAN Diesel & Turbo has chosen DryEGCS , an ex-

haust gas after-treatment method suitable for all me-dium speed diesel engine installations.

DryEGCS

Lower sulphur, less cost

NOx[g/kWh]

Sulphur Content [%]

General

in ECAs

in ECAs

4,5

4,0

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0

Tier 1Tier 2

Tier 3

2008 2010 2012 2014 2016 2018 2020 2022

for vessel keel laying

Implementation schedule for SOxand NOxlimits, according to IMO MARPOL 73/78 Annex VI

* Implementation date under revision by IMO in the year 2018 and maybe delayed until 2025

MAN Diesel & Turbos DryEGCS exhaust gas clean-

ing system helps operators to avoid steep increases

in operating costs due to soaring prices for low-

sulphur fuels. DryEGCSeffectively removes sulphur

oxide (SOx) from the ex haust gas. As a resu lt, ope r-

ators can continue using high-sulphur HFO, yet still

fulfil the requirements set by the IMO and nationalauthorities.


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The Dr yEGCS technology is based on the chemical

reaction between sulphur and calcium. The exhaust

gas from the engine passes through a reactor filled

with dry granulate of hydrated lime. In the reactor, a

chemical reaction between the hydrated lime and the

SOxtakes place. These bind to form gypsum, which

accrues in the granulate, removing the SO x from

the exhaust gas. This process is completely dry anddoes not require any water at all. Th e reaction is most

efficient in the temperature range between 240 C

and 450 C.

DryEGCSessentially comprises a steel counter flow

reactor, which is thermally insulated and filled with

hydrated lime. The exhaust gas from the engines

turbocharger enters the reactor, flows through cas-

cades and is discharged after being cleaned.

Exhaust gas flow in reactor between cascades

DryEGCS

System description

Hydrated lime for the DryEGCSsystem

Fresh granulate is stored in a compartment above

the reactor and slowly moves through it from top tobottom by force of gravity. During the exhaust gas

dwell time in the reactor, the hydrated lime absorbs

the sulphur. The reactor design and the granulate

mass flow are carefully calibrated to ensure that the

degree of saturation increases towards the bottom of

the reactor. Used granulate is collected at the bottom

of the reactor. Mechanical or pneumatic conveyors

can supply fresh granulate and expel used granulate.

All ne cessar y system component s can be retrofi ttedin most cases.

Larger quantities of granulates can be stored in un-

used spaces in the hull or in special standardised

containers. The latter can be easily handled by

cranes or trucks during port stay, ensuring quick, ef-

ficient replacement.

A

A

A

Exhaust gas

duct

Shut-off

damper

Shut-off

damper

Shut-off

damperBypass

Cascade counter

flow reactor

Fresh hydrated lime

supply

Used hydrated lime

disposal

DryEGCSsystem

main compone nts


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Fuel price difference [/t]

Payback time in years

Assumptions:

Typical system investment

for one engine, excl. installation cost

Output: 10,000 kWSFOC: 190 g/kWh

Operation: 6,000 h/year

10

9

8

7

6

5

4

3

2

0

1

50 100 150 200 250 300 350

The operatin g costs of the DryEGC S system are

comparatively low and correlate with the targetedSOxreduction rate. Depending on the fuel price dif-

ferences between high-sulphur HFO and low-sulphur

alternative fuels, the system offers highly attractive

payback times. MAN Diesel & Turbo can provide you

with a specific business case based on the operating

profile of your vessel.

The figu re above illus trates a most prob able scena rio

in ECA zones from 2015 on, assuming a fuel pricedifference between HFO and MGO of 200/t. Accor-

ding to this example, the resulting payback time for

the DryEGCSsystem would be less than one year.

DryEGCS

Investment and payback time

The up-front investment involves the cost of the DryEGCSequipment and its instal-

lation on board. Both are dependent on the amount and size of the engines requiring

exhaust gas cleaning, and the ships architecture.

DryEGCS effect of fuel price difference on payback time

The DryEGC S process has no significant impact

on the exhaust gas temperature and backpressure.

Consequently, an exhaust gas boiler and additional

SCR (Selective Catalyst Reduction) to reduce nitro-

gen oxide (NOx) can be ope rated do wnstrea m from

the DryEGCSsystem.

In new-build vessels, the system can be installedclose to the engine in the bottom section of the craft,

which has the advantages of increasing stability and

reducing impact on cargo space.

DryEGCShas proven its high availability, while re-

quiring little servicing and maintenance. Another key

benefit is that DryEGCS does not simply result in

pollutants being released into the sea rather than the

atmosphere: instead, it binds them chemically.

Used granulate can be disposed of easily and at little

cost, as it can be re-used. For example, any remain-ing capacity for SOx reduction can be exploited in

large coal power plant applications or in many other

industries. Supply and disposal agreements can be

arranged worldwide with local business partners.

DryEGCS

Advantages


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The DryEGCSsystem can be retrofitted on most vessels. MAN Diesel & Turbos

retrofit experts will be pleased to assist you with further information and details

such as feasibility studies, business cases and project engineering. Please contact

us to receive a specific quotation for your application.

A successful example of retrofitting the DryEGCS system is the vessel MV

Timbus, where the system has proved its capability and reliability in marine appli-

cation.

DryEGCS

Retrofit solutions

The DryEGCSreactor during retrofit

The completed DryEGCS

system (rig ht page)


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DryEGCS

Characteristics

DryEGCScharacteristics

Exhaust gas after treatment avoiding mandatory

use of distillate fuel

SOxreduction into gypsum (CaSO4) by dry

granulate of hydrated lime

Reduction rate of SOx> 98 %, sufficient to fulfil

IMO limitations

No wash water required Short payback time

Low operating costs and easy maintenance

Attractive for retrofits and new buildings

Minor impact on exhaust gas temperature

Combination with SCR and heat recovery

possible

Improved smoke behaviour due to particle

filtration

Worldwide logistics for granulate supply and

disposal available

Operatio n temperature from 240 C to 450 C

Required operation temperature is maintained

in reactor for several days Heating up time after long non-active period

approx. 4 to 6 hours

Proven in land-based applications

cutting sox emissions

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