European Project Semester

1. European Project Semester Team Caterpillar: Alejandro Hombravella Alican Kiliçaslan Carolin Rüss Jeremy Perales

2. Content Whatistheprojectabout? Plan toachievethegoal: • Scrubber • Catalyst • Boiler • Exhaust Gas Silencer • Funnel • Exampleexhaust gas cleaningsystem EUROPEAN PROJECT SEMESTER

3. Goal Tocreate a catalogueofoptimumconfigurationsofexhaust gas cleaningsystemsfor different typesof HFO diesel enginestofulfillthe IMO 3 criterias Other mainfocusses: • costofequipment • costofequipment in action • costofservice • repairingsituationand spare parts • place in ship EUROPEAN PROJECT SEMESTER

4. IMO 3 EUROPEAN PROJECT SEMESTER

5. EUROPEAN PROJECT SEMESTER

6. Exhaust gas cleaningsystem?I wouldsuggesttoput also anotherschema, withmoredetailedgraphics (ifexists... ) EUROPEAN PROJECT SEMESTER

7. Exhaust gas cleaningsystem EUROPEAN PROJECT SEMESTER Wet exhaust gas cleaning system Dry exhaust gas cleaning system An effective and advanced exhaust system must achieve and ensure four main objectives : 1 - To reduce noise level by between 40% and 90% through the insertion of silencers end/or silencer-separators; 2 - To cool the exhaust, and eject the engine cooling water through the exhaust without excessive back pressure; 3 - To site the outlets at the stern of the boat to minimise exhaust fumes on board; 4 - To minimize, by the insertion of an adeguate capacity silencer, the risk of water running back up the exhaust and into the engine cylinders, causing serious engine damages.

8. Time plan achieve information about system material, function, cost, dimensions suppliers of components examples for existing configurations create own configurations EUROPEAN PROJECT SEMESTER

9. Scrubber How does it work? Sulphur Oxides SOx (SO2) dissolves within water vapour forming airborne acids. What is it made of? Formed from sulphur contained in oil during combustion and refining processes. EUROPEAN PROJECT SEMESTER

10. Scrubber Water ph is elevated with alkalitysodiumhydroxide ( NaOH ) Enteringexhaust gas stream sulphur oxides are captured and neutralizedbyscrubbing waterchemicallyformingsulphates 3. Cleanedexhaust gas exits 4. Water and sulphides return to processcollectiontank EUROPEAN PROJECT SEMESTER

11. Scrubber(OPEN LOOP) EUROPEAN PROJECT SEMESTER

12. Scrubber(CLOSED LOOP) EUROPEAN PROJECT SEMESTER

13. Scrubber EUROPEAN PROJECT SEMESTER

14. Scrubber EUROPEAN PROJECT SEMESTER

15. Scrubber Summary of integrated scrubber • Avoid increased exhaust gas back pressure caused by cleaning devices. • Reduce the amount of equipment needed for SOx-cleaning of exhaust gases from all relevant combustion units onboard. • Provide a higher cleaning performance in port conditions where the total flow of exhaust gases is smaller than in normal seagoing conditions, utilising such higher performance as inherent in some exhaust gas cleaning devices when operated at reduced exhaust gas flow. Thus all combustion units can use the same fuel in all areas and all conditions. EUROPEAN PROJECT SEMESTER

16. Scrubber • Scrubbing is the cheapest way to comply • Fresh water scrubber is the only technology to: • Make zero effluent discharge possible • Be always in control of reduction efficiency • Have the smallest energy consumption • Have no creation of CO2 caused by neutralization process • Wärtsilä fresh water scrubber solutions are fit for new building and retrofit, for any engines and boilers’ brands. EUROPEAN PROJECT SEMESTER

17. Scrubber EUROPEAN PROJECT SEMESTER

18. Catalyticconverter EUROPEAN PROJECT SEMESTER

19. Catalyticconverter EUROPEAN PROJECT SEMESTER

20. Catalyticconverter A catalytic converter (colloquially, "cat" or "catcon") is a device used to reduce the toxicity of emissions from an internal combustion engine. First widely introduced on series-production automobiles in the US market for the 1975 model year to comply with tightening EPA regulations on auto exhaust, catalytic converters are still most commonly used in motor vehicle exhaust systems. Catalytic converters are also used on generator sets, forklifts, mining equipment, trucks, buses, trains, and other engine-equipped machines. A catalytic converter provides an environment for a chemical reaction wherein toxic combustion by-products are converted less-toxic substances. EUROPEAN PROJECT SEMESTER

21. Catalyticconverter Three-way catalytic converters A three-way catalytic converter has three simultaneous tasks: Reduction of nitrogen oxides to nitrogen and oxygen: 2NOx → xO2 + N2 Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2 Oxidation of unburnt hydrocarbons (HC) to carbon dioxide and water: 2CxHy + (2x+y/2)O2 → 2xCO2 + yH2O EUROPEAN PROJECT SEMESTER Functions

22. Catalyticconverter These three reactions occur most efficiently when the catalytic converter receives exhaust from an engine running slightly above the stoichiometric point. This is between 14.8 and 14.9 parts air to 1 part fuel, by weight, for gasoline (the ratio for LPG, natural gas and ethanol fuels is slightly different, requiring modified fuel system settings when using those fuels). When there is more oxygen than required, then the system is said to be running lean, and the system is in oxidizing condition.  EUROPEAN PROJECT SEMESTER

23. Catalyticconverter EUROPEAN PROJECT SEMESTER In that case, the converter's two oxidizing reactions (oxidation of CO and hydrocarbons) are favoured, at the expense of the reducing reaction. When there is excessive fuel, then the engine is running rich. The reduction of NOx is favoured, at the expense of CO and HC oxidation. If an engine could be operated with infinitesimally small about the stoichiometric point for the fuel used, it is theoretically possible to reach 100% conversion efficiencies.

24. Catalyticconverter Since 1981, three-way catalytic converters have been at the heart of vehicle emission control systems in North American roadgoing vehicles, and have been used on "large spark ignition" (LSI) engines since 2001 in California, and from 2004 in the other 49 states LSI engines are used in forklifts, aerial boom lifts, ice resurfacing machines and construction equipment. EUROPEAN PROJECT SEMESTER

25. Catalyticconverter The converters used in those types of machines are three-way types, and are designed to reduce combined NOx+HC emissions from 12 gram/BHP-hour to 3 gram/BHP-hour or less, as mandated by the United States Environmental Protection Agency's (EPA) 2004 regulations. EUROPEAN PROJECT SEMESTER

26. Catalyticconverter  A further drop to 2 gram/BHP-hour of NOx+HC emissions is mandated in  (note: NOx is the industry standard short form for nitric oxide (NO) and nitrogen dioxide (NO2) both of which are smog precursors. HC is the industry short form for hydrocarbons). The EPA intends to introduce emissions rules for stationary spark ignition engines, to take effect in January 2008. EUROPEAN PROJECT SEMESTER

27. Catalyticconverter Two-way catalytic converters Functions A two-way catalytic converter has two simultaneous tasks: Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2 Oxidation of unburnt hydrocarbons (unburnt and partially-burnt fuel) to carbon dioxide and water: 2CxHy + (2x+y/2)O2 → 2xCO2 + yH2O EUROPEAN PROJECT SEMESTER

28. Catalyticconverter This type of catalytic converter is widely used on diesel engines to reduce hydrocarbon and carbon monoxide emissions. They were also used on spark ignition (gasoline) engines in USA market automobiles up until 1981, when they were replaced by three-way converters due to regulatory changes requiring reductions on NOx emissions. Reduction of the NOx emissions requires an additional step. Platinum catalysis can be used. EUROPEAN PROJECT SEMESTER

29. Catalyticconverter EUROPEAN PROJECT SEMESTER Instead of catalysis, for diesel engines a true reactant, ammonia pyrolyzed in situ from urea, can be used to reduce the NOx into nitrogen

30. Catalyticconverter The regulations regarding hydrocarbons vary according to the engine regulated, as well as the jurisdiction. In some cases, "non-methane hydrocarbons" are regulated, while in other cases, "total hydrocarbons" are regulated. Technology for one application (to meet a non-methane hydrocarbon standard) may not be suitable for use in an application that has to meet a total hydrocarbon standard. Methane is not toxic, but is more difficult to break down in a catalytic converter, so in effect a "non-methane hydrocarbon" standard can be considered to be looser. Since methane is a greenhouse gas, interest is rising in how to eliminate emissions of it. EUROPEAN PROJECT SEMESTER

31. Catalyticconverter Attentionto global warming! EUROPEAN PROJECT SEMESTER

32. Boiler What is the purpose ? To obtain boiled water by heating water or other fluid in a closed vessel. What is it made of ? Made of steel or wrought iron, assembly by rivetting EUROPEAN PROJECT SEMESTER

33. Boiler Which fuel ? Combustion : wood, coal, oil or natural gas Electric steam boilers : resistance or immersion-type heating elements EUROPEAN PROJECT SEMESTER

34. Boiler Fire-tube boiler • Tubes of hot gases running through a sealed container of water • High-pressure • Horizontal or vertical EUROPEAN PROJECT SEMESTER

35. Boiler Water-tube boiler • Tubes of water heated externally by the fire • High-pressure • Vertical EUROPEAN PROJECT SEMESTER

36. Boiler Fire-tube boiler • Used on all steam locomotives Water-tube boiler • Used on ships (marine) EUROPEAN PROJECT SEMESTER

37. Boiler on ships For diesel engine, one or two smaller boilers are used on the ship EUROPEAN PROJECT SEMESTER

38. Boiler on ships Suppliers • Aalborg Industries • Mitsubishi Heavy Industries, LTD • Kangrim • Garioni Naval • Chromalox EUROPEAN PROJECT SEMESTER

39. Exhaust Gas Silencer EUROPEAN PROJECT SEMESTER

40. Exhaust Gas Silencer • Absorption Principle • Sound waves are directed to a blown material such as steel wool, mineral wool or fibreglass.dissipate with friction into heat. -> acustic noise resorbed exhaust gas goes through a perforated pipe in the blown material. • Good for high frequencies (500-8000Hz) force depends on geometrie of perforation, sound absorption coefficient and apparent density of material very low loss of exhaust gas pressure noise reduction loss maximum 50dB • which is a loss of sound pressure • about 300times EUROPEAN PROJECT SEMESTER

41. Exhaust Gas Silencer Features low skin temperature (LST) design extra layer of packed acustic/thermal insulation that reduces heat and noise maximum aceptable exhaust gas speed between 20-40m/sec Easy installation in any position Advanced acustical design Thick wall construction for high transmission loss Reduces noxious fumes and odors Long life service Weight from 125-1755kg EUROPEAN PROJECT SEMESTER

42. Exhaust gas silencer 2. Reflexion principle Empty case with normally 4 chambers. Different sized rooms combined with shifted arranged pipes to reflect and deflect the acustic noise. Also averaging of sound pressure amplitude and duplicating of acustic noises Pipes with different perforations and sizes. -> improving interference Hull gets very hot, because it gets in direct contact with exhaust gas I ncreasing of gas pressure Good for low frequences

43. Exhaust gas Silencer Example: Absorption exhaust gas silencer AGSD 25 Frequenz 500Hz Reduction of noise 34dB

44. Exhaust gas silencer Size of silencer Acustic velocity = frequence * wave lenght Acustic velocity in the air = 343m/s Lenght of silencer wave lenght/2 Example: 100Hz L = 1,5215m

45. Suppliers HUSS LBF Lindenberg LS Luhe-Stahl Silencer Marine Vetus Puck Taylor Universal Kaefer Maxim AGSD EUROPEAN PROJECT SEMESTER

46. Funnel EUROPEAN PROJECT SEMESTER

47. Funnel Funktions: removal of smoke and exhaus gasidentification of the ship-owner companydirect the smoke up in the air to disturb nocodybypass the friction resistance don`t foul the decks and ship structures Appendage very high funnelslittle fins to turbulate the exhaus gas and guide it to the horizontal direction How does it work Gas inside is warm and therefor have a lower weight than the cold air outside.So they have to climp up the funnel pipe. They build a room with less air pressure, in which the cold air is going. Gauge pressure is about 0,0009-0,0015 bar, depends on the resistance. EUROPEAN PROJECT SEMESTER

48. Funnel Funnel area The required funnel cross-sectional area is determined by the volume of exhaust gases produced by the propulsion plant. Often this area is too great for a single funnel. Early steam vessels needed multiple funnels had 5 when launched, but as efficiency increased new machinery needed fewer funnels. Suppliers Ditco EUROPEAN PROJECT SEMESTER

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50. Dry exhaust gas cleaningsystem EUROPEAN PROJECT SEMESTER