Ναυτικοί Κινητήρες και ΝΑΥΤΙΚΟΙ ΚΙΝΗΤΗΡΕΣ Friday, 19 May 2017 ΚΑΙ ΑΤΜΟΣΦΑΙΡΙΚΗ ΡΥΠΑΝΣΗ Ναυτικοί Κινητήρες και ΝΟΜΟΘΕΣΙΑ, ΤΕΧΝΟΛΟΓΙΕΣ, ΠΡΟΟΠΤΙΚΕΣ Νικόλαος Π. Κυρτάτος Καθηγητής Ε.Μ.Π. Ν. Π. Κυρτάτος Page 1
Exhaust Gas Emissions Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 2
NOx Nitrogen Oxides : Definitions Nitrogen monoxide (NO) and nitrogen dioxide (NO2) are referred as nitrogen oxides (NO x ) Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 3 Environmental Impact Acid rain acidification Over-fertilization of lakes and soil Ozone/smog formation in lower atmosphere, especially in urban areas potential damage on vegetation and human health Small size particulates formation part of NOx is forming nitrates
NOx Nitrogen Oxides : Diesel Process NOx emissions Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 4 relatively high due to high local combustion temperatures. NOx formation is thermal, main nitrogen source is combustion air. NOx formation has strong temperature influence. i.e. high temperature results in high NOx formation NOx formation process extremely complex (includes hundreds of different chemical reactions). Typical NO in NOx 95% Typical NO2 in NOx is 5%
NOx Nitrogen Oxides Tier 2 applies worldwide from 1 st Jan 2011. Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 5 Tier 3 applies only to NOx Emission Control Areas (NECAs) with a keel laying date after 1 st Jan 2016 Tier III emission limits can only be met using aftertreatment units
NOx Nitrogen Oxides Abatement Technologies Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 6 Dry low-nox Technologies Wet low-nox Technologies SCR - Selective Catalytic Reduction EGR - Exhaust Gas Recirculation
Inlet air humidification system NOx Abatement Technologies EGR System Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 7 Gas Engines (Lean Burn) 2 1 3 6 8 7 5 4 SCR System
Selective Catalytic Reduction Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 8 A reactor is placed upstream (high pressure) or downstream (low pressure) the turbine Urea is injected in the exhaust gas stream and converted to NH3 NOx in exhaust gas are catalytically reduced to N2 due to reaction with NH3 in the reactor
Low Pressure SCR HP VS LP SCR High Pressure SCR Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 9 Typical temperature 200*-300 C Pressure ~1 bara Typical temperature 250*-500 C Pressure 1-4.5 bara
SCR Reactor Size Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 10
Exhaust Gas Recirculation Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 11 30-40 % of the exhaust gasses are recirculated to the scavenge air receiver In this way, part of the oxygen is replaced by CO 2 from the combustion process. This replacement increases the heat capacity of the scavenge air, thus reducing the temperature peak of the combustion and the formation of NOx. The NOx reduction is almost linear to the ratio of recirculated exhaust gas.
Exhaust Gas Recirculation System Diagram Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 12
Exhaust Gas Recirculation Installation Aspects Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 13
Gas Engines - Otto cycle Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 14 Pre-mixed lean-burn combustion Engine operating according to the Otto Process Air and gas premixed before combustion Lean Mixture: more air available than needed for stoichiometric combustion Cold flame temperature Low NOx Lower wall heat losses No local rich combustion Low particulate matter (PM) External ignition using a pre-chamber Provides energy needed to ignite gas
SOx Sulphur Oxides : Definitions Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 15 Sulphur dioxide (SO 2 ) and sulphur trioxide (SO 3 ) referred to as Sulphur oxides (SOx) Environmental Impact Acid rain acidification Small size particulates formation part of SOx is forming SO 3 and sulphates condensing to particulates Detrimental effect on vegetation, human health and buildings
SOx Sulphur Oxides : Diesel process Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 16 All sulphur entering combustion chamber is oxidized forming Sox SOx directly proportional to fuel sulphur content and fuel consumption) SOx emissions are lowest when comparing operation for same fuel quality, due to superior fuel efficiency of diesel process among prime movers Typical SO2 in SOx is 95% Typical SO3 in SOx is 5%
SOx Sulphur Oxides: Legislation Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 17
Ναυτικοί Κινητήρες και SOx Sulphur Oxides: Emission Controll Areas Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 18
SOx Sulphur Oxides Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 19 Manmade SOx ~10% of Volcanic Ships SOx ~4% of Manmade
SOx Sulphur Oxides : Abatement Technologies Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 20 Switch to low sulphur fuel Operation on low sulphur residual fuel or distillate fuel or natural gas (LNG) Sea Water Scrubber Reduces SOx by dissolving it and neutralizing it in salt water Caustic soda scrubber (Closed Loop) Reduces SOx in a closed loop system with fresh water, to which Sodium Hydroxide (NaOH) is added for the neutralization of SOx. Hybrid Scrubber Has the flexibility to operate in both open and closed loop. Handling NaOH Onboard
Particulate Matter (PM) and Smoke : Definitions Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 21 Diesel particulate matter (PM) Complex mixture of solid carbonaceous material, unburned hydrocarbons and inorganic compounds. Strongly depends on temperature, cooling rate, residence time in sampling devices Particulate emissions (PM) are defined by the measurement method Methods are based on measuring particles various properties at different temperatures and pressures. Measurement results differ between methods Emission regulations based on different measurement methods By definition Smoke is visible (white, grey, blue, black, brown and yellow)
Particulate Matter (PM) and Smoke: Environmental Impact Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 22 Small particles considered detrimental to human health Considered to penetrate into human lung Large particles are of less concern since removed by pulmonary system Fine particulates are easily transported by air currents - detrimental effects encountered at far distance from exhaust plume Visual impact smoke
Particulate Matter (PM) and Smoke: Diesel Process Soot produced during incomplete combustion. Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 23 Ash originates from fuel and lube oil (additives, impurities), engine wear and corrosion products All liquid & gas fuel operated combustion processes generate small size particulates Majority of particulate data available from automotive engines operating on ultralow-sulphur-fuel qualities. Very few data available from marine diesel engines
Particulate Matter (PM) and Smoke - Legislation Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 24 Sulphur oxides (SOx) and particulate matter. MARPOL Anex VI Regulation 14 Outside an ECA established to limit SOx and particulate matter emissions 4.50% m/m prior to 1 January 2012 3.50% m/m on and after 1 January 2012 0.50% m/m on and after 1 January 2020* Inside an ECA established to limit SOx and particulate matter emissions 1.50% m/m prior to 1 July 2010 1.00% m/m on and after 1 July 2010 0.10% m/m on and after 1 January 2015 * depending on the outcome of a review, to be concluded by 2018
Particulate Matter (PM) and Smoke: Abatement Technologies Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 25 Primary technologies Combination of Increased fuel injection pressure and advanced fuel injection timing, Increased boost pressure, Optimized combustion chamber for swirl/squish, Split injection/multiple injection (post injection), Electronic & Common Rail FIE, Variable valve timing, Variable turbine area, Residual fuel operation. Water-in-Fuel Emulsions Scrubber Technology Particulate Traps and Oxidation Catalysts Bag Filters and Electrical Precipitators
Laboratory of Marine Engineering (LME) Marine Engine testing facility Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 26 Development of advanced measuring methods Ship-board measurements Computer simulation for marine engine performance prediction (ISO 17025-2007) Exterior view of the Laboratory Building 19 Years : 1998-2017
Engine Testing Facility Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 27 Electric Dynamometer, 500 kw, 4-quadrant operation Hydraulic Dynamometer, 1200 kw Engine Monitoring, Control and Alarm systems Data Acquisition system,16 fast, 48 slow channels Cross section of the test cell and the control room The test cell superstructure Heavy Fuel conditioning facility
1995 2015 / Research Projects in Exhaust Gas Emissions 1995-1997 Air Pollution from Marine Engines / LR, MAN B&W, WARTSILA, PIELSTICK. CCMS 1996-2000 Adaptive Control of Marine Engines / ABB, MAN B&W ACME Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 28 1997-2003 PREMTECH I & II 1998-2000 SORPTEC Emissions Reduction State of Art / FIAT, RENAULT, VW... NOx Removal Techniques / DAIMLER 2000-2003 ATECS 2000-2004 FUNIT 2000-2004 LIFETIME 2002-2005 CLEATRANS EGR Scheduling / DEUTZ, VOLVO Injection Technologies, NOx Models, EGR / VOLVO, AVL NOx Onboard Estimator / MAN B&W, HAPAG LLOYD, ABB 2002-2006 SMOKERMEN 2004-2007 HERCULES-A Emissions Control for Gas Engines / IVECO, DAIMLER Smoke Control for Marine Engines / ABB, WOODWARD, GL Ultra Low Emissions Engine / MAN, WARTSILA +40 Partners 2008-2012 HERCULES-B 2010-2015 LRET-COE 2011-2013 SEKTE Ultra Low Emissions Engine / MAN, WARTSILA + 29 Partners Centre of Excellence in Ship Tota Energy-Emissions-Economy Smoke Emissions in Fast Ferries ASL, EPE, UTH 1995 2012-2015 HERCULES-C Ultra Low Emissions Engine MAN, WARTSILA +22 Partners 2015
ENM R&D Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 29 Μετρήσεις επιδόσεων και αερίων ρύπων πειραματικού ναυτικού κινητήρα diesel μεταβλητής γεωμετρίας εξαγωγής και turbo για μείωση εκπομπών καπνού σε μεταβατική φόρτιση
Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 30 Ship-board measurements Mobile unit for exhaust species and performance measurements in marine engines: NO, NO 2, NOx, HC, CO, CO 2, SO 2 Smoke-FSN and Opacity Cylinder pressures Fuel, air, exhaust flows Torque / thrust measurements in shafts (according to IMO specs)
Hybrid testbed-hippo-1 Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 31 HIPPO-1 Hybrid Integrated Propulsion Powertrain
Hybrid testbed-hippo-2 Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 32 Diesel engine Caterpillar C9.3, 261 kw @ 2200 rpm U.S. EPA Tier 4 and EU Stage IV emissions ECU + CAN bus Common Rail Fuel System Exhaust gas recirculation system (EGR) Oxid. Catalyst + Partic. Filter + SCR Dynamometer ABB 315 kw AC motor + ABB ACS800 4 Q regenerative drive 390 kw w. Direct Torque Control (DTC) + CAN bus Electric motor/generator ABB 90 kw AC motor + ABB ACS800 drive 100 kw + CAN bus
Το Ερευνητικό Έργο HERCULES www.hercules-2.com HIGH EFFICIENCY ENGINE R&D ON COMBUSTION WITH ULTRA LOW EMISSIONS FOR SHIPS Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 33 100 M Euro Budget Duration: 2004 2018 4 Consecutive Projects MAN + Wartsila + WinGD+ ~82 Partners total Major Universities: (NTUA / AALTO / TUH / DTU / TUD/ LUND / POLIMI
Combustion process visualization development Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 34 Optical cylinder covers for 2 stroke
Advanced intelligent turbocharger Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 35 PTI / PTO T/C with variable compressor inlet guide vanes T/C with variable turbine nozzle vanes
Emission reduction Exhaust Gas Recirculation and After treatment Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 36 High Pressure Boiler installed on 4T50ME X
Full scale experimental setup for complete variability of turbochanging system combined with EGR Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 37
STRUCTURE OF THE HERCULES WORK Το Ερευνητικό Έργο HERCULES Εκπομπές αερίων ρύπων στο έργο HERCULES. Η συμβολή του ΕΝΜ/Ε.Μ.Π Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 38 54 Subprojects 18 Tasks 9 Workpackages Μοντελοποίηση φαινομένων καύσης και σχηματισμού ρύπων με μεθόδους υπολογιστικής θερμορευστοδυναμικής Μέτρηση NOx με μεθόδους υπερταχείας δειγματοληψίας <10ms
Το Ερευνητικό Έργο HERCULES www.ip-hercules.com Friday, 19 May 2017 Ναυτικοί Κινητήρες και Ν. Π. Κυρτάτος Page 39 CGR cylinder cover comprising CGR valve: Full Scale SAM System on M/V Mignon DWI system onboard Maersk Guernsey