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How does it work?
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Technology history
~1000 Flue gas systems sold since 1972
~3000 Combustion systems sold with scrubber section
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One year in operation Tor Ficaria
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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
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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
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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
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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
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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
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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
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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)
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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.
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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
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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)
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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
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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
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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
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Fuel prices
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Sulpher distribution in HFO
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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
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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)
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Business Case
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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
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Multiple inlet systems
Combinations of ME + AUX
Less space required
Less investement costs
Other configurations possible
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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 !
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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