exhaust gas scrubbers -...

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How does it work?



Technology history

~1000 Flue gas systems sold since 1972

~3000 Combustion systems sold with scrubber section

WWW.AALBORG-INDUSTRIES.COM PRESENTATION series | © AALBORG INDUSTRIES | JAN 2011 EXHAUST GAS CLEANING4 4


One year in operation Tor Ficaria



EGC installed on Tor Ficaria

Technical data: In operation since May 2010 Height 10.5 Meters Length 8.2 Meters Diameter 4.6 Meters Weight empty 24T Weight with water 32T Exhaust gas 192,000 Kg/h Material SS alloys PM Scrubbing Jet + venturi Sea water pump 200KW/1000m3/h

Length

Diameter

Hei

gh

t


A Day in the life of a Scrubber(August 2010)

Gothenburg (SE)

Brevik (NO)

Immingham (UK)

---- Fresh Water

---- Sea Water

5

4

3

2

1

Nr. Fuel Spec. Mode NaOH kg/h50 %

solution

1. 1200l/h (2.2%) FW 115kg/h

2. 2500l/h (2.2%) SW ---

3. 1800l/h (2.2%) FW 172kg/h

4. 3900l/h (2.2%) SW ---

5. 2400l/h (2.2%) FW 229kg/h


SO2 in exhaust

SO2 measurements

– HFO 2.2% sulphur– Exhaust after scrubber– Fresh-water mode– Variation: ± 5ppm

– At MCR the exhaust will contain less than 10ppm SO2 equivalent to maximum 0.06% fuel sulphur (18,4 ppm = 0,1%)

– This easily fulfills IMO requirements for 2015


0

20

40

60

80

100

120

50%

Na

OH

co

ns

um

pti

on

[l/h

]

0,5 1 1,5 2 2,5 3 3,5

% Sulphur in HFO

50% NaOH consumption per ton HFO

NaOH consumption

NaOH – Concentration: 50%– Density 1.48 kg/l

HFO– Sulphur: 2.2%– Density: 0.98kg/l

Molar Reaction rate [NaOH/S]: 1.75


Nitrates in discharge sea water

Water may contain max 12% NOx removal from the exhaust gas according to MEPC

Actual <0.5% NOx is removed from the gas in SW mode

Therefore the nitrate formation is far beyond the limit Nitrate/nitrite increase in the SW < 0,1 mg/L has been

measured The MEPC allows 60 mg/L (at 45 tons SW /MWh) Result < 1% of MEPC requirement


SW and dilution consumption versus alkalinity (based on SW=32°C, S=3%, SOx eff = 0,1%S)

0102030405060708090

100

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

Alkalinity seawater [meq/l]

SW

co

ns

um

pti

on

[%

]SW EGC

Dilutionw ater

pH discharge water

Effect alkalinity and temperature on dilution

pH inlet depends of:– SW: alkalinity– FW: amount of NaOH

(caustic soda) pH discharge depends of:

– pH inlet water– S% HFO– Water/fuel flow ratio to the

scrubber


PAH in Sea Water discharge

Measurement in-line.

PAHphe (phenanthrene equivalent)

UV-Fluorescence analyser, 0-500 ppb used Limit in MEPC PAH * t/MWh = 2250 (ppb*ton/h)/MWh) Average measured level: 500-1000 (ppb*ton/hr/MWh)


Turbidity of discharge water

MEPC limit: 25 NTU/FNU above inlet For SW the turbidity increase measured by Eurofins

(accredited company) based on samples: 2.2 FNU Continuous measurements show 2-15 FNU increase

The picture shows fresh

water discharge before

and after cleaning.


Fresh water cleaning

Design by Alfa Laval Wet sludge

80% water / 20% solid Results are parameter depending Sludge amount in liquid form less than

2.5 liter per MWh engine output


Particular Matter (PM)

PM removal by Jet scrubber or Venturi scrubber.

Measurement acc ISO -8178

50%-80% removal measured by MAN

PM removal based on 1MW test unit of MAN at Holeby (DK)


Data Logging/Recording

Surveillance System via internet since 2010 Logging every 30 seconds Target

– Ship Owners– Authorities (EPA, Classification)– Aalborg (trouble shooting, optimizing)

Measured data: – Gas

• SO2

• CO2

– Water• PH• Turbidity• PAH


Operational issues

Scrubber performance Cleaning as expected Backpressure less than expected

Soot stains on deck Cleaning of demister Increase discharge velocity from

chimney

Corroded pipes: Exchange corroded pipes. Use resistant pipes


Operational Performance

Operation 1. June 2010 - 30 April 2011 3018 hours of operation 7711 ton of HFO has been cleaned

170 ton of SO2 has been removed

The scrubber plant is handed over to the crew

Monthly saving average with actual price gap: USD 45,000


Fuel prices



Sulpher distribution in HFO


Distillates will significantly increase in price

Residual bunker fuel has traditionally been a low value by-product and an outlet from high sulphur crudes

Removing sulphur from HFO is possible but:

Similar investment to make road diesel, which is less risky.

Low sulphur (0.5%) bunker price should be below road diesel; however well above high sulphur residual fuel

Distillates will increase worldwide CO2 levels (well to hull)

Scrubbers appear very competitive economically

Source: Purvin and Gertz


Price graph HFO versus MGO (2010+2011 YTD)

400

500

600

700

800

900

1000

1100

2010

-01-

01

2010

-02-

26

2010

-04-

23

2010

-06-

18

2010

-08-

13

2010

-10-

08

2010

-12-

03

2011

-01-

28

Date

US

D

BW380

BWDI

Fuel price development

HFOMGO

Price difference HFO-MGO

For 2020 estimated

at 400 USD/mt(Source: POTEN & PARTNERS 2010)

(Based on average value 20 ports)

USD 335 (15/3/2011)


Business Case



EGC Dimensions & Weight

Length

Diameter

Hei

gh

t

Engine Diameter Length Height Dry weight Operational weightMW m m m ton ton

4 2 3.5 5.6 11 138 2.9 4.9 7.2 15 1812 3.5 5.8 8.1 18 2216 4 6.7 9 22 2920 4.6 7.8 10 25 3524 4.9 8.3 10.4 28 4132 5.9 10.6 11.6 38 5255 7.7 13.9 14.4 62 86


Multiple inlet systems

Combinations of ME + AUX

Less space required

Less investement costs

Other configurations possible


EGC Business Case

Shiptype Typical engine Operating profile(hours/y)

ROI (years)Newbuilding

ROI (Years)Retrofit

General Cargo 5 MW 5000 1,5 2,0

Tanker 12 MW 5000 1,3 1,5

Ferry/RoRo 21 MW 4000 1,51 2,0

Based on ships sailing 100% in ECA’s Price difference HFO 380 CST with destillates 200 USD/T

ROI analysis can be made for your ships as well !


Conclusions

Proven reliability after one year in operation on Tor Ficaria with more than 3000 operational hours.

Maximum cost savings and flexibility with hybrid EGC System

Far largest EGC system in continuous operation on Tor Ficaria - 21 MW MAN B&W

Short pay back time 1-2 years

exhaust gas scrubbers -...

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