Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
Sus ta ina ble Shipping Confe re nc e 2009 in Sa n Fra nc is c o, U.S.A.Ra lf J ürge ns , Head of R & D, Couple Sy s te ms GmbH, Hamburg, Germany
1. For the Re duc tion of Sulphur a nd Pa rtic le s
DryEGCS® ProcessDry Ex ha us t Ga s Cle a ning Sys te m
2. Combination w ith SCR e a s ily pos s ible
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
Overview• Introduction• Exhaust Gas Composition (PM, NOx, CO2, SOX)
• The DryEGCS® Process• The economical side of the DryEGCS® Process• Summary
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
1. Singapore
5. South Korea, Busan
9. Germany, Hamburg
10. China, Qingdao
6. Netherl., Rotterdam
2. China, Shanghai
8. Taiwan, Kaohsiung
7. UAE, Dubai
3. China, Hong Kong
4. China, Shenzhen
e x is ting ECAs : Baltic Sea, North Sea
pla nne d ECAs : Coasts of USA, Hawaii and Canada
Top Container Ports :
dis c us s e d ECAs : Coasts of Mexico, Coasts of Alaska and Great Lakes, Singapore, Hong Kong, Korea, Australia, Black Sea, Mediterranean Sea (2014), Tokyo Bay (in 2015)
Mos t us e d tra ding route s
Emission restricted areas by IMO – ECAs in 07/2009, Source: MAN
IntroductionIntroduction
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
What does desulphurization really mean?
• New emission values and upcoming ECAs will increase the demand of LSFO and MDO signifcantly
• The production costs for Low Sulphur Fuel are extremely high if a desulphurization plant is operated on site of the refnery compared to the blending costs if regular crude oils and sweet oils are mixed
• The desulphurization process consumes high amounts of energy in the form of temperature, steam and pressure as well as huge quantities of hydrogen (H2)
• The carbon dioxide footprint for a desulphurization plant is quite large and is estimated to increase by more than 10 % if switched to MDO
IntroductionIntroduction
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
process flow diagram for a diesel hydrotreaterprocess flow diagram for a diesel hydrotreaterprocess flow diagram for a diesel hydrotreater
Process fow diagram for a diesel hydrotreater
IntroductionIntroduction
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
The fuel oil industry claims that inves tments in excess of $ 130 Bn are required to secure the supply of LSFO
• Appreciation of fuel prices• Supply bottleneck• In Europe it is diffcult by law to fnd sites for new
refneries• Time-consuming authorization procedure• What to do with app. 10 Mill. t of sulphur?
IntroductionIntroduction
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
Price gap Oil to Gas has increased, HFO to Gas even reversed
data compiled by MAN, sources: BP, Bunker Bulleting daily, www.bloomberg.com
data compiled by MAN, sources: BP, Bunker Bulleting daily, www.bloomberg.com
IntroductionIntroduction
In June 2009 the EU has estimated the price increase for 0,1 % @ $250 - $300 per ton!
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
Conclus ion
• Simply switching to distillates as stipulated by some third parties appears to be not the single solution for lowering emissions
• Distillates are technically and economically not available to substitute app. 320 Mill. tons of HFO
• Actually a concept in which the oil industry supplies the shipping industry with a sulphur reduced fuel (1 to 1,5 % S) in combination with on board operated exhaust gas cleaning systems is discussed
IntroductionIntroduction
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
A combination of sulphur reduced fuel and the operation of an EGCS offers many benefts :
• Cost effectiveness• Emissions comply with IMO• Secured supply with fuel• Can be put into action just now!
IntroductionIntroduction
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms Exhaus t Gas Exhaus t Gas
Compos itionCompos ition Source: Germanischer Lloyd
Exhaust Gas Composition of a 4-stroke Diesel Engine (propeller curve, MCR 75 %, with 2,2 % sulphur in fuel),
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
1. Characteris tics of particles
• Consist of sulphates, water combined with sulphates, oxide ash (heavy metal), organic compounds
• Size 10 nm to 10 µm• The d50 is < 1 µm
• Visible if concentration > 0,15 g/Nm³ • Only removable by applying a ceramic/metal flter, a
wet scrubber or a dry scrubber
Exhaus t Gas Exhaus t Gas Compos itionCompos ition
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
2. Characteris tics of Nitrogen Oxides (NOx)
• NOx is a generic term for mono-nitrogen oxides (NO and NO2)
produced during combustion, especially at high temperatures
• The NOx fraction of the exhaust gas of diesel engine usually consists of 95 % NO and 5 % NO2
• Tier I + II achieved by engine modifcations (FWE, HAM, EGR a.o.)
• TIER III achievable only by SCR technology (Selective Catalytic Reduction)Exhaus t Gas Exhaus t Gas
Compos itionCompos ition
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
3. Carbon Dioxide (CO2)
• 1 ton of fuel burned equates to 3,2 tons of CO2
• From a chemical point of view Carbon dioxide is a very slowly reacting compound and thus diffcult to be treated by an exhaust gas system
• CO2 can be dissolved physically in water but an increase of temperature and pressure release it back to the atmosphere
• The design of new ships with effcient engines and the optimized operation of ships can reduce the emission of CO2
much better than any EGCS
Exhaus t Gas Exhaus t Gas Compos itionCompos ition
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
4. Characteris tics of Sulphur Oxides (SOx)
• Sulphur is a natural compound of crude oil• The sulphur is chemically bonded to the hydrocarbons of the oil• The binding energy is quite high which makes it so diffcult and
energy consuming to separate the sulphur from the hydrocarbons
• During combustion the sulphur is oxidized to SO2 (app. 95 to 98 %) and SO3 (app. 2 to 5 %).
Exhaus t Gas Exhaus t Gas Compos itionCompos ition
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
1. DryEGCS® Process
• The large-scale proven processes for the desulphurization of exhaust gases are based these days on absorptive processes
• Normally lime based materials such as calcium carbonate (CaCO3), burnt lime (CaO) or hydrated lime [Ca(OH)2] are in use
• Beside the wet desulphurization process also dry processes utilizing limestone or calcium hydroxide are established sustainably on the market
• Practically both technologies, Wet Scrubbers and Dry Scrubbers, can be operated on board of a vessel
Exhaus t Gas Exhaus t Gas Compos itionCompos ition
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
2. DryEGCS® Process
• The DryEGCS® Process is based on a technology known in land-based applications as “Chemisorption”
• Calcium hydroxide reacts with SO2 and SO3 and forms calcium sulfate = G Y P S U M
Ca (OH) 2 + SO2 → Ca SO3 + 2 H2O Ca SO3 + ½ O2 → Ca SO4
Ca (OH) 2 + SO2 + ½ O2 → Ca SO4 + H2O Ca (OH) 2 + SO3 + H2O → Ca SO4 + 2 H2O
The DryEGCSThe DryEGCS ®® Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
3. DryEGCS® - Reducing Agent
Calcium Hydroxide Granulate“Calhydgran”• The calcium hydroxide is utilized in
the form of a granulate or pellets (spherical form)
• Diameter 3 mm – 8 mm• Bulk density 800 kg/m³• BET-Surface 18 – 20 m²/g
The DryEGCSThe DryEGCS ®® Proce s sProce s s
„Calhydgran“ = Ca(OH)2
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
4. DryEGCS® Process
• A two-stage construction has been selected for the exhaust gas cleaning
• The granulate of the frst stage is a sacrifcial layer• It removes the rough sooty particles and other residues from the
exhaust gas and acts quasi as a particle flter• Within the second stage the process of chemisorption takes place
and the sulphur oxide molecules react with the calcium hydroxide
The DryEGCSThe DryEGCS ®® Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The DryEGCSThe DryEGCS ®®
Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The DryEGCSThe DryEGCS ®®
Proce s sProce s s
Ma in e ng ine2 x 8,6 Me ga w att
SCR for the re duc tion of NOx
Fix e d be d a bs orbe r For re mov a l of SOx a nd PM
18 m / 59 foot
Duc t w ork
Fa n
Exemplary design for the „Coastal Reference“, BC Ferrieswas possible!
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
5. DryEGCS® Process
• The dwell time of the exhaust gases in the granulate both stages is approximately 3,7 seconds, which guarantees an almost complete separation of sulphur oxides > 90 %
• Operation temperature from 240° C to 410° C
• In case a selective catalytic reduction (SCR) for the NOx removal of the exhaust gas is required this unit can be installed
downstream the DryEGCS® without any additional reheating
The DryEGCSThe DryEGCS ®® Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
6. DryEGCS® Process
• No temperature dropping required• Perfect solution for the combination with SCR• SCR can be designed signifcantly smaller• No formation of aerosols at the funnel• No increase of the exhaust backpressure• Heat recovery possible and recommended
The DryEGCSThe DryEGCS ®® Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms
6. DryEGCS® Process
• Dry operation for the removal of PM and SOx
• Proven technology (more than 500 installations worldwide during the last 20 years on land)
• Robust and maintenance free system• Exploitable residues => cost free disposal• Low energy consumption (ca. 0,5 %)• No operating stuff required
The DryEGCSThe DryEGCS ®® Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The DryEGCSThe DryEGCS ®®
Proce s sProce s s
DryEGCS® Pilot-Installation onMS TimbusMAK 3,6 MWat
October 26, 2009
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The DryEGCSThe DryEGCS ®®
Proce s sProce s s
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms The e conomy of the DryEGCSThe e conomy of the DryEGCS ®®
Proce s sProce s s
1. Inves tment Cos ts
• DryEGCS® Process 120 US-$ per kW• Peripheral costs (ship yard installation, pipeline, starting up, certifcation etc.) app. 100 US-$ per
kW • Calcium Hydoxide Granulate app. 24 US-$ per kW/
year Price/t 250 US-$, Exploitable residues => cost free disposal• Low energy consumption (app. 64 kWh/h) app. 0,15 US-
$/kWh• No operating stuff required app. 0,1 man
year• Maintenance maximum 2% of investment cost p.a.• Pos s ible los s of s ale s whe n cargo s pace is provide d for re ducing age nt
Dry EGCSDry EGCS ®®is a trade mark of Couple Sys te ms is a trade mark of Couple Sys te ms SummarySummary
1. Robust and maintenancefree system2. Long-term proven system3. No corrosion of donwstream installed exhaust gas components4. No aerosol formation 5. Exploitable residues6. Installation of a small sized SCR without reheating 7. Combined particle precepitation8. No examination of the sewage quality required9. Very low energy consumption
10. No tra ns mis s ion of polluta nts from the a tmos phe re into the hydros phe re but tota l re mov a l from the bios phe re !
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